Juke F15 (2012 year). Service Repair Manual - part 56

CO-12

< PERIODIC MAINTENANCE >

[MR16DDT ]

ENGINE COOLANT

2.

Open radiator drain plug (A) at the bottom of radiator, and then
remove radiator cap. 

CAUTION:

Perform this step when engine is cold.
• When draining all of engine coolant in the system, open water

drain plugs on cylinder block. Refer to 

EM-63, "Setting"

.

3.

Remove reservoir tank if necessary, and drain engine coolant and clean reservoir tank before installing.
Refer to 

CO-17, "Exploded View"

.

4.

Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to 

CO-13, "Flushing"

.

Refilling

INFOID:0000000006356317

1.

IInstall reservoir tank if removed, and install radiator drain plug.

CAUTION:

Be sure to clean drain plug and install with new O-ring.

• If water drain plugs on cylinder block are removed, close and tighten them. Refer to 

EM-63, "Setting"

.

2.

Check that each hose clamp has been firmly tightened.

3.

Remove air duct (between air cleaner cover assembly and turbocharger inlet tube). Refer to 

EM-26,

"Exploded View"

.

4.

For LHD models, disconnect vacuum hose break booster side, and removal vacuum tube from clamp.
Refer to 

BR-49, "MR16DDT : Exploded View"

 (LHD models).

5.

Disconnect heater hose (1) at position (

) in the figure.

• Enhance heater hose as high as possible.

6.

 Fill radiator (1) to specified level.

CAUTION:

Never adhere the engine coolant to electronic equipments
(alternator etc.).
• Pour coolant slowly of less than 2   (2-1/8 US qt, 1-3/4

Imp qt) a minute to allow air in system to escape.

• When engine coolant overflows disconnected heater

hose, connect heater hose, and continue filling the engine
coolant. 

• Use Genuine NISSAN Engine Coolant or equivalent in its

quality mixed with water (distilled or demineralized). Refer
to 

MA-13, "Fluids and Lubricants"

.

: Vehicle front

JPBIA4452ZZ

Radiator drain plug

: Refer to 

CO-17, "Exploded View"

.

: Vehicle front

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ENGINE COOLANT

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7.

Refill reservoir tank to “MAX” level line with engine coolant.

8.

Install air duct (between air cleaner cover assembly and turbocharger inlet tube). Refer to 

EM-26,

"Exploded View"

.

9.

Install radiator cap.

10. Warm up engine until opening thermostat. Standard for warming-up time is approximately 10 minutes at

3,000 rpm.
• Check thermostat opening condition by touching radiator hose (lower) to see a flow of warm water.

CAUTION:

Watch water temperature gauge so as not to overheat engine.

11. Stop the engine and cool down to less than approximately 50

°

C (122

°

F).

• Cool down using fan to reduce the time.
• If necessary, refill radiator up to filler neck with engine coolant.

CAUTION:

Never adhere the engine coolant to electronic equipments (alternator etc.).

12. Refill reservoir tank to “MAX” level line with engine coolant.
13. Repeat steps 6 through 11 two or more times with radiator cap installed until engine coolant level no

longer drops. 

14. Check cooling system for leakage with engine running.
15. Warm up the engine, and check for sound of engine coolant flow while running engine from idle up to

3,000 rpm with heater temperature controller set at several position between “COOL” and “WARM”.
• Sound may be noticeable at heater unit.

16. Repeat step 15 three times.

17. If sound is heard, bleed air from cooling system by repeating step 6 through 11 until reservoir tank level no

longer drops. 

Flushing

INFOID:0000000006356318

1.

Install radiator drain plug.

CAUTION:

Be sure to clean drain plug and install with new O-ring.

• If water drain plugs on cylinder block are removed, close and tighten them. Refer to 

EM-63, "Setting"

.

2.

Remove air duct (between air cleaner cover assembly  and turbocharger), air cleaner cover assembly and
air cleaner body assembly. Refer to 

EM-26, "Exploded View"

.

3.

Disconnect vacuum hose break booster side, and remove vacuum tube from clamp. Refer to .

Engine coolant capacity
(With reservoir tank at “MAX” level)

 Refer to 

CO-29, "Periodical Maintenance Specifica-

tion"

.

A

:  MAX

B

:  MIN

Reservoir tank engine coolant capacity 
(At “MAX” level)

Refer to 

CO-29, "Periodical Maintenance Specification"

.

JPBIA0102ZZ

Radiator drain plug

: Refer to 

CO-17, "Exploded View"

.

CO-14

< PERIODIC MAINTENANCE >

[MR16DDT ]

ENGINE COOLANT

4.

Disconnect heater hose (1) at position (

) in the figure.

• Enhance heater as high as possible.

5.

Fill radiator and reservoir tank with water and reinstall radiator cap.
• When engine coolant over flows disconnected heater hose, connect heater hose, and continue filling the

engine coolant.

6.

Connect vacuum hose, and install vacuum tube. Refer to .

7.

Install air duct (between air cleaner cover and turbocharger), air cleaner cover assembly and air cleaner
body assembly. Refer to 

EM-26, "Exploded View"

.

8.

Run the engine and warm it up to normal operating temperature.

9.

Rev the engine two or three times under no-load.

10. Stop the engine and wait until it cools down.

11. Drain water from the system. Refer to 

CO-11, "Draining"

.

12. Repeat steps 1 through 9 until clear water begins to drain from radiator.

: Vehicle front

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RADIATOR

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RADIATOR

RADIATOR CAP

RADIATOR CAP : Inspection

INFOID:0000000006356319

• Check valve seat (A) of radiator cap. 

- Check that valve seat is swollen to the extent that the edge of the

plunger cannot be seen when watching it vertically from the top.

- Check that valve seat has no soil and damage.

• Pull negative-pressure valve to open it, and that it close completely

when released.

- Check that there is no dirt or damage on the valve seat of radiator

cap negative-pressure valve. 

- Check that there are no unusualness in the opening and closing

conditions of negative-pressure valve.

• Check radiator cap relief pressure.

- When connecting radiator cap to the radiator cap tester (commer-

cial service tool) (A) and the radiator cap tester adapter (commer-
cial service tool) (B), apply engine coolant to the cap seal surface. 

• Replace radiator cap if there is an unusualness related to the above three.

CAUTION:

When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.

RADIATOR

RADIATOR : Inspection

INFOID:0000000006356320

Check radiator for mud or clogging. If necessary, clean radiator as follows.

CAUTION:

• Be careful not to bend or damage radiator fins.
• When radiator is cleaned without removal, remove all surrounding parts such as radiator cooling fan

assembly and horns. Then tape harness and harness connectors to prevent water from entering.

1.

Apply water by hose to the back side of the radiator core vertically downward.

2.

Apply water again to all radiator core surfaces once per minute.

3.

Stop washing if any stains no longer flow out from radiator.

B : Metal plunger

JPBIA0108ZZ

SMA967B

Standard and Limit

: Refer to 

CO-29, "Radiator"

.

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CO-16

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RADIATOR

4.

Blow air into the back side of radiator core vertically downward.
• Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm

2

, 71 psi) and keep distance more than 30 cm

(11.81 in). 

5.

Blow air again into all the radiator core surfaces once per minute until no water sprays out.

RADIATOR

CO-17

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REMOVAL AND INSTALLATION

RADIATOR

Exploded View

INFOID:0000000006356321

Removal and Installation

INFOID:0000000006356322

REMOVAL

WARNING:

• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine

coolant escaping from radiator. 

• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres-

sure. Then turn it all the way.

1.

Drain engine coolant from radiator. Refer to 

CO-11, "Draining"

.

CAUTION:

1.

Cooling fan assembly

2.

Mounting rubber (upper)

3.

Radiator 

4.

Mounting rubber (lower)

5.

O-ring

6.

Drain plug

7.

Clamp

8.

Radiator hose (lower) (LH)

9.

Reservoir tank hose

10. Reservoir tank 

11.

Reservoir tank cap

12. Clamp

13. Radiator hose (upper) 

14. Water outlet adaptor

15. Radiator cap

16. Radiator hose pipe

17. Bracket

18. Radiator hose (lower) (RH)

A.

To water outlet

B.

To water inlet

 : N·m (kg-m, in-lb)

 : Always replace after every disassembly.

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< REMOVAL AND INSTALLATION >

[MR16DDT ]

RADIATOR

• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.

2.

Remove engine cover. Refer to 

EM-25, "Exploded View"

.

3.

Remove engine under cover.

4.

Remove radiator hose (upper and lower).

5.

Remove front bumper. Refer to 

EXT-12, "Exploded View"

.

6.

Remove radiator core support upper. Refer to 

DLK-149, "MR16DDT : Exploded View"

.

7.

Disconnect cooling fan harness connector.

8.

Remove reservoir tank.

9.

Remove cooling fan assembly.

CAUTION:

Be careful not to damage or scratch the radiator core.

10. Remove condenser from radiator and temporarily fasten it on vehicle with a rope.

11. Pull up and remove the radiater assembly (1).

CAUTION:

Be careful not to damage radiator core and condenser
assembly core.

INSTALLATION

Install in the reverse order of removal.

INSTALLATION

Note the following, and install in the reverse order of removal.
NOTE:
• Insert the radiator hose (1) all the way to the stopper (2) or by 33 mm (1.30 in) (hose without a stopper).

• For the orientation of the hose clamp pawl, refer to the figure.

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Unit mm (in)

A.

Radiator side

B.

Engine side

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Radiator hose

Hose end

Paint mark

Position of hose clamp*

Radiator hose (upper)

Radiator side

Upper

A

Engine side

Upper

B

Radiator hose (lower) (RH)

Radiator side

Upper

C

Engine side

Front side

D

Radiator hose (lower) (LH)

Radiator side

Rear side

E

Engine side

Rear side

F

RADIATOR

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*Refer to the illustrations for the specific position each hose clamp tab.

• The angle (b) created by the hose clamp pawl and the specified

line (A) must be within 

±

15

°

 as shown in the figure.

• To install hose clamps (1), check that the dimension (A) from the

end of the paint mark (2) on the radiator hose to the hose clamp is
within the reference value. 

Inspection

INFOID:0000000006356323

INSPECTION AFTER INSTALLATION

• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the

radiator cap tester (commercial service tool). Refer to 

CO-11, "Inspection"

.

• Start and warm up the engine. Check visually that there is no leakage of engine coolant.

G.

View G

h.

45

°

: Vehicle upper

: Vehicle front

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Dimension “A”

3 mm

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CO-20

< REMOVAL AND INSTALLATION >

[MR16DDT ]

COOLING FAN

COOLING FAN

Exploded View

INFOID:0000000006356324

Removal and Installation

INFOID:0000000006356325

REMOVAL

1.

Drain engine coolant. Refer to 

CO-11, "Draining"

.

CAUTION:

• Perform this step engine is cold.
• Never spill engine coolant on drive belt.

2.

Remove engine cover. 

3.

Remove front bumper. Refer to 

EXT-12, "Exploded View"

.

4.

Remove radiator core support upper. Refer to 

DLK-149, "MR16DDT : Exploded View"

.

5.

Disconnect cooling fan harness connector.

6.

Remove reservoir tank. Refer to 

CO-17, "Exploded View"

. 

7.

Remove radiator hose (upper). Refer to 

CO-17, "Exploded View"

.

8.

Remove cooling fan assembly.

CAUTION:

Be careful not to damage or scratch on radiator core when removing.

INSTALLATION

Note the following, and install in the reverse order of removal.

CAUTION:

Only use genuine parts for fan shroud mounting bolt and observe the specified torque (to prevent
radiator from being damaged).
NOTE:
Cooling fan is controlled by ECM. For details, Refer to 

EC-774, "Component Function Check"

.

Disassembly and Assembly

INFOID:0000000006356326

DISASSEMBLY

1.

Fan motor

2.

Fan shroud

3.

Cooling fan

A.

Apply on fan motor shaft

 : N·m (kg-m, in-lb)

 

: Apply genuine high strength thread locking sealant or equivalent.

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COOLING FAN

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1.

Remove cooling fan mounting nut, and then remove the cooling fan.

2.

Remove fan motor.

ASSEMBLY

Note the following, and assemble in the reverse order of disassembly.
• Apply genuine high strength thread locking sealant on fan motor shaft.

Inspection

INFOID:0000000006356327

INSPECTION AFTER DISASSEMBLY

Cooling Fan

Inspect cooling fan for crack or unusual bend.
• If anything is found, replace cooling fan.

CO-22

< REMOVAL AND INSTALLATION >

[MR16DDT ]

WATER PUMP

WATER PUMP

Exploded View

INFOID:0000000006356328

Removal and Installation

INFOID:0000000006356329

REMOVAL

1.

Drain engine coolant from radiator. Refer to 

CO-11, "Draining"

.

CAUTION:

• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.

2.

Steer front wheel to the right.

3.

Remove front fender protector (RH). Refer to 

EXT-22, "Exploded View"

.

4.

Remove drive belt. Refer to 

EM-155, "Removal and Installation"

.

5.

Remove water pump.
• Engine coolant will leak from cylinder block, so have a receptacle ready below.

CAUTION:

• Handle water pump vane so that it does not contact any other parts.
• Water pump cannot be disassembled and should be replaced as a unit.

INSTALLATION

Install in the reverse order of removal.

Inspection

INFOID:0000000006356330

INSPECTION AFTER REMOVAL

1.

Gasket

2.

Water pump

 : N·m (kg-m, ft-lb)

 : Always replace after every disassembly.

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WATER PUMP

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• Check visually that there is no significant dirt or rusting on water

pump body and vane (A).

• Check that there is no looseness in vane shaft, and that it turns

smoothly when rotated by hand.

• Replace water pump, if necessary.

INSPECTION AFTER INSTALLATION

• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the

radiator cap tester (commercial service tool). Refer to 

CO-11, "Inspection"

.

• Start and warm up the engine. Check visually that there is no leakage of engine coolant.

PBIC3313J

CO-24

< REMOVAL AND INSTALLATION >

[MR16DDT ]

THERMOSTAT

THERMOSTAT

Exploded View

INFOID:0000000006356331

Removal and Installation

INFOID:0000000006356332

REMOVAL

1.

Drain engine coolant from radiator. Refer to 

CO-11, "Draining"

. 

CAUTION:

Perform this step when engine is cold.

2.

Remove intake manifold. Refer to 

EM-28, "Exploded View"

.

3.

Disconnect radiator hose (lower) (RH) from water inlet. Refer to 

CO-17, "Exploded View"

.

4.

Remove water inlet and thermostat.
• Engine coolant leakage from cylinder block, so have a receptacle ready below.

Thermostat housing

1.

Drain engine coolant. Refer to 

CO-11, "Draining"

.

2.

Remove alterator. Refer to 

CHG-30, "MR16DDT : Exploded View"

.

3.

Remove water pump. Refer to 

CO-22, "Exploded View"

.

4.

Disconnect water hose, and them remove thermostat housing.

INSTALLATION

Note the following, and install in the reverse order of removal.

Thermostat 

1.

Thermostat housing

2.

Gasket

3.

Rubber ring

4.

Thermostat

5.

Water inlet

6.

Clamp

7.

Radiator hose (upper)

A.

To radiator

Engine front

 : N·m (kg-m, ft-lb)

 : Always replace after every disassembly.

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THERMOSTAT

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• Install thermostat with making rubber ring (1) groove fit to thermo-

stat flange (A) with the whole circumference. 

• Install thermostat (2) with jiggle valve (A) facing upwards. 

Thermostat housing

• Install in the reverse order of removal.

Inspection

INFOID:0000000006356333

INSPECTION AFTER REMOVAL

Thermostat

• Place a thread (A) so that it is caught in the valves of thermostat

(1). Immerse fully in a container (B) filled with water. Heat while
stirring.

• The valve opening temperature is the temperature at which the

valve opens and falls from the thread.

• Continue heating. Check the full open valve lift amount.
• After checking the maximum valve lift amount, lower the water

temperature and check the valve closing temperature. 

• If out of the standard, replace thermostat.

INSPECTION AFTER INSTALLATION

• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the

radiator cap tester (commercial service tool). Refer to 

CO-11, "Inspection"

.

• Start and warm up the engine. Check visually that there is no leakage of engine coolant.

JPBIA4456ZZ

1

: Thermostat housing

JPBIA4457ZZ

Standard: Refer to 

CO-29, "Thermostat"

.

PBIC3314J

CO-26

< REMOVAL AND INSTALLATION >

[MR16DDT ]

WATER OUTLET

WATER OUTLET

Exploded View

INFOID:0000000006356334

Removal and Installation

INFOID:0000000006356335

REMOVAL

1.

Drain engine coolant from radiator. Refer to 

CO-11, "Draining"

.

CAUTION:

• Perform this step when engine is cold.

2.

Remove engine cover. Refer to 

EM-25, "Exploded View"

.

1.

Heater pipe bracket

2.

Radiator cap

3.

Water outlet adaptor

4.

Clamp

5.

Water outlet hose

6.

Clamp

7.

Heater hose

8.

Clamp

9.

Water outlet

10. Clamp

11.

Heater hose

12.

Heater hose

13. Clamp

14.

Heater hose

15.

Clamp

16. Engine coolant temperature sensor

17.

Gasket

18.

Rubber ring

19. Water control value

20.

Gasket

Engine front

A.

For CVT models

B.

To reservoir tank

C.

To heater hose

D.

To radiator hose (upper)

E.

To CVT oil warmar

F.

To heater hose

G.

To heate hose

H.

To turbocharger inlet tube

 : N·m (kg-m, ft-lb)

 : Always replace after every disassembly.

JPBIA4340GB

WATER OUTLET

CO-27

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3.

Remove battery. 

PG-124, "Exploded View"

.

4.

Remove air duct (duct side) and air cleaner cover assembly and air cleaner body assembly.

5.

Disconnect radiator hose (upper). Refer to 

CO-17, "Exploded View"

.

6.

Remove water outlet adaptor.

7.

Disconnect connectors of engine harness around the battery.

8.

Remove bracket (2), and disconnect engine harness clip.(trans-
mission side and water outlet side)

9.

Disconnect crankshaft position sensor harness connector.

10. Move engine (1) harness, and keep a service area.
11. Remove water hose and heater hose.

12. Remove water outlet.

13. Remove engine coolant temperature sensor from water outlet, if

necessary.

INSTALLATION

Note the following, and install in the reverse order of removal.

Water Control valve

• Install water control valve with making rubber ring (1) groove fit to

water control valve flange (A) with the whole circumference.

• Install water control valve (2) with the arrow (A) facing up and the

frame center part (B) facing upwards.

Inspection

INFOID:0000000006356336

INSPECTION AFTER REMOVAL

Water Control Valve

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: Water control valve

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