Juke F15 (2012 year). Service Repair Manual - part 59

CO-60

< SYMPTOM DIAGNOSIS >

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OVERHEATING CAUSE ANALYSIS

SYMPTOM DIAGNOSIS

OVERHEATING CAUSE ANALYSIS

Troubleshooting Chart

INFOID:0000000006492606

Symptom

Check items

Cooling sys-
tem parts 
malfunction

Poor heat transfer

Water pump malfunction

Worn timing belt

—

Thermostat stuck closed

—

Damaged fins

Dust contamination or pa-
per clogging

Mechanical damage

Clogged radiator cooling 
tube

Excess foreign material 
(rust, dirt, sand, etc.)

Reduced air flow

Cooling fan does not oper-
ate

Fan assembly

—

High resistance to fan rota-
tion

Damaged fan blades

Damaged radiator shroud

—

—

—

Improper coolant mixture 
ratio

—

—

—

Poor coolant quality

—

—

—

Insufficient coolant

Coolant leaks

Cooling hose

Loose clamp

Cracked hose

Water pump

Poor sealing

Reservoir tank cap

Loose

Poor sealing

Radiator

O-ring for damage, deterio-
ration or improper fitting

Cracked radiator tank

Cracked radiator core

Reservoir tank

Cracked reservoir tank

Overflowing reservoir tank

Exhaust gas leaks into cool-
ing system

Cylinder head deterioration

Cylinder head gasket deteri-
oration

OVERHEATING CAUSE ANALYSIS

CO-61

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Except cool-
ing system 
parts mal-
function

—

Overload on engine

Abusive driving

High engine rpm under no 
load

Driving in low gear for ex-
tended time

Driving at extremely high 
speed

Powertrain system malfunc-
tion

—

Installed improper size 
wheels and tires

Dragging brakes

Improper ignition timing

Blocked or restricted air 
flow

Blocked bumper

—

—

Blocked radiator grille

Installed car brassiere

Mud contamination or paper 
clogging

Blocked radiator

—

Blocked condenser

—

Installed large fog lamp

Symptom

Check items

CO-62

< PERIODIC MAINTENANCE >

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ENGINE COOLANT

PERIODIC MAINTENANCE

ENGINE COOLANT

Inspection

INFOID:0000000006492607

LEVEL 

• Check that the reservoir tank engine coolant level is within the

“MIN” to “MAX” when the engine is cool.

• Adjust the engine coolant level if necessary.

LEAKAGE

• To check for leakage, apply pressure to the cooling system with the

radiator cap tester (commercial service tool) (A) and the radiator
cap tester adapter (commercial service tool) (B).

WARNING:

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

CAUTION:

Higher test pressure than specified may cause radiator dam-
age.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.

• If anything is found, repair or replace damaged parts.

Draining

INFOID:0000000006492608

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.

Remove engine under cover.

2.

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

CAUTION:

Perform this step when engine is cold.

3.

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

CO-66,

"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-63, "Flushing"

.

5.

Remove air relief plug from water outlet. Refer to 

CO-75, "Exploded View"

.

A

:  MAX

B

:  MIN

JPBIA0102ZZ

Testing pressure: Refer to 

CO-76, "Radiator"

.

PBIC5121J

: Vehicle front

JPBIA3120ZZ

ENGINE COOLANT

CO-63

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Refilling

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• Before start working, turn off the automatic air conditioner and the blower motor.

1.

Install reservoir tank, radiator drain plug and air relief plug.

2.

Fill reservoir tank slowly with coolant until coolant spills from the air relief hole. Refer to 

CO-58, "Cooling

Circuit"

.

• Put a cloth under the air relief plug to prevent engine coolant to dampen the crankshaft position

sensor.

• Fill coolant to the MAX level line of the reservoir tank at a rate

of 2 liter (1-3/4 lmp qt)/min or lower.

3.

Close the air relief plug.

CAUTION:

If the filling rate is too fast, this could lead to air being mixed in the coolant. Be sure to fill the cool-
ant slowly according to the rate indicated above.
Use Genuine NISSAN Anti-freeze Coolant or equivalent mixed with water (distilled or demineral-
ized). Refer to 

MA-13, "Fluids and Lubricants"

.

4.

Warm up the engine for approximately five minutes without reservoir tank cap installed, and then turn off
the engine and loose air relief plug until coolant spills from air relief hole.
• If coolant overflows reservoir tank hole, install filler cap.
• Watch engine coolant temperature warning light so as not overheat the engine during all of the

operation.

WARNING:

• Be careful not be scaled with hot engine coolant or vacuum pump when operating.
• Radiator fan blade can start at any time and make personal injuries.

5.

Close the air relief plug and run the engine at 2,000 rpm until the upper hose comes hot and radiator fan
operates. Let the engine running approximately 5 minutes at idle speed and check for sound of coolant
flow while running engine from idle up to 3,000 rpm.
• Sound may be noticeable at heater water cock.

6.

If sound is heard, bleed air from cooling system by repeating steps 4 through 5 until coolant level no
longer drops.
• Check the radiator lower hose for any signs of leakage.

7.

Turn off the engine and let it cool down.
• Cool down using a fan to reduce the time.

8.

After cooling period, loose the air relief plug and check if coolant spills from the air relief hole. In other
case, remove the air relief plug until the coolant spills, and then close the relief air plug. Bleed air from
cooling system by repeating steps 5 through 8 until the coolant spills immediately.

9.

Check the engine coolant level when engine is cool and refill to MAX level line if the level is lower.
• Clean excess coolant from engine.

Flushing

INFOID:0000000006492610

1.

Fill reservoir tank with water until water spills from the air relief hole, then close air relief plug. Reinstall
reservoir tank cap.

2.

Run engine and warm it up to normal operating temperature.

SMA412B

Engine coolant capacity  Approx. 6.7  (5 - 7/8 Imp qt)

Reservoir tank capacity 0.7   (5/8 lmp qt)

CO-64

< PERIODIC MAINTENANCE >

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ENGINE COOLANT

3.

Rev engine two or three times under no-load.

4.

Stop engine and wait until it cools down.

5.

Drain water.

6.

Repeat steps 1 through 5 until clear water begins to drain from radiator.

7.

Blow compressed air into cooling circuit through the reservoir tank valve hole to drain all the water.

RESERVOIR TANK CAP

CO-65

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RESERVOIR TANK CAP

Inspection

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• Check valve seat of reservoir tank cap. 
- Check if valve seat (A) is swollen to the extent that the edge of the

metal plunger (B) cannot be seen when watching it vertically from
the top.

- Check if valve seat has no soil and damage.

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

completely when released.

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

tank cap negative-pressure valve. 

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

conditions of negative-pressure valve.

• Check reservoir tank cap relief pressure.
- When connecting reservoir tank cap to the radiator cap tester

(commercial service tool) and the radiator cap tester adapter (com-
mercial service tool) (A), apply engine coolant to the cap seal sur-
face. 

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

CAUTION:

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

JPBIA0108ZZ

SMA967B

Standard and limit

: Refer to 

CO-76, "Radiator"

.

JPBIA0109ZZ

CO-66

< REMOVAL AND INSTALLATION >

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RADIATOR

REMOVAL AND INSTALLATION

RADIATOR

Exploded View

INFOID:0000000006492612

Removal and Installation

INFOID:0000000006492613

WARNING:

Never remove the reservoir tank cap when the engine is hot. Serious burns could occur from high
pressure coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly turn it a quar-
ter turn to allow built-up pressure to escape. Carefully remove the cap by turning it all the way.    

REMOVAL

1.

Drain engine coolant. Refer to 

CO-62, "Draining"

.

CAUTION:

Perform when engine is cold.

2.

Remove cooling fan shroud assembly. Refer to 

CO-68, "Exploded View"

.

CAUTION:

Be careful not to damage or scratch the radiator core.

1.

Reservoir tank cap

2.

Reservoir tank

3.

Clamp

4.

Reservoir tank hose

5.

Mounting rubber (upper)

6.

Reservoir tank hose

7.

Radiator

8.

Mounting rubber (lower)

9.

Drain plug

10. O-ring

11. Cooling fan assembly

12. Radiator hose (upper)

13. Radiator hose (lower)

A.

To water outlet

B.

To water inlet

 : N·m (kg-m, in-lb)

JPBIA4805GB

RADIATOR

CO-67

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3.

Remove the following parts.
• Front grille assembly: Refer to 

EXT-18, "Exploded View"

.

• Front bumper: Refer to 

EXT-12, "Exploded View"

.

• Front combination lamp assembly (RH and LH): Refer to 

EXL-91, "Exploded View"

.

4.

Remove radiator core support (upper).

5.

Remove condenser fixing bolts upper.

6.

Pull up and remove the radiator assembly (1).

CAUTION:

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

INSTALLATION

• Reinstall any parts removed in reverse order of removal.
• Check for engine coolant leaks. Refer to 

CO-59, "Inspection"

.

2

: Condenser assembly

: Vehicle front

JPBIA2857ZZ

CO-68

< REMOVAL AND INSTALLATION >

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COOLING FAN

COOLING FAN

Exploded View

INFOID:0000000006492614

Removal and Installation

INFOID:0000000006492615

REMOVAL

1.

Drain engine coolant. Refer to 

CO-62, "Draining"

. 

2.

Disconnect radiator hose (lower) clip.

3.

Remove battery. Refer to 

PG-124, "Exploded View"

4.

Remove air duct (inlet). Refer to 

EM-280, "Exploded View"

.

5.

Remove fusible link and relay box bracket, and put fusible link and relay box aside.

6.

Remove reservoir tank.

7.

Disconnect fan motor connector and boost pressure control valve harness connector, and put the connec-
tors aside.

8.

Remove boost pressure control valve assembly. Refer to 

EC-825, "TURBOCHARGER BOOST CON-

TROL : Vacuum Hose Drawing"

.

9.

Remove radiator upper hose. Refer to 

CO-66, "Exploded View"

.

10. Remove radiator fan and shroud assembly.

1.

Fan motorCooling fan

2.

Fan shroud

3.

Cooling fan

A.

Reverse screw

 : Apply thread locking sealant.

: Vehicle front

 : N·m (kg-m, in-lb)

JPBIA4806GB

COOLING FAN

CO-69

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11. Remove radiator fan reverse screw.

12. Remove fan motor from fan shroud.

INSTALLATION

Install in the reverse order of removal.

PBIC1486E

CO-70

< REMOVAL AND INSTALLATION >

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WATER PUMP

WATER PUMP

Exploded View

INFOID:0000000006492616

Removal and Installation

INFOID:0000000006492617

WARNING:

Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.

REMOVAL

1.

Drain engine coolant. Refer to 

CO-62, "Draining"

.

CAUTION:

Perform when engine is cold. 

2.

Remove front wheel RH.

3.

Remove fender protector (RH). Refer to 

EXT-22, "Exploded View"

4.

Remove drive belt. Refer to 

EM-276, "Removal and Installation"

.

5.

Remove timing belt and inner cover. Refer to 

EM-302, "Exploded View"

.

6.

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

CAUTION:

• Handle the 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:0000000006492618

INSPECTION AFTER REMOVAL

MBIB1232E

1.

Water pump

2.

Gasket

3.

Cylinder block

WATER PUMP

CO-71

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• Visually make sure there is no significant dirt or rusting on the

water pump body and vane.

• Make sure there is no looseness in the vane shaft, and that it turns

smoothly when rotated by hand.

• If there are any unusualness, replace the water pump assembly.

INSPECTION AFTER INSTALLATION

• Check for engine coolant leaks using reservoir tank cap tester. Refer to 

CO-62, "Inspection"

.

MBIB0546E

CO-72

< REMOVAL AND INSTALLATION >

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THERMO PLUNGER UNIT

THERMO PLUNGER UNIT

Exploded View

INFOID:0000000006492619

Removal and Installation

INFOID:0000000006492620

REMOVAL

1.

Remove battery cable from the negative terminal. 

2.

Drain engine coolant. Refer to 

CO-62, "Draining"

.

3.

Remove the fender protector (LH). Refer to 

EXT-22, "Exploded View"

.

4.

Disconnect thermo plunger connector.

5.

Remove the earth lead nut (A).

1.

Side member LH

2.

Thermo plunger control unit

3.

Thermo plunger relay

4.

Thermo plunger connector

5.

Earth lead

6.

Thermo plunger unit

7.

Bracket stay

Vehicle front

 : N·m (kg-m, in-lb)

JPBIA3082GB

JPBIA3083ZZ

THERMO PLUNGER UNIT

CO-73

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6.

Remove the thermo plunger connection caps (4).

7.

Remove the thermo plunger connection nuts (B) using the
appropriate tool.

8.

Remove the LH and RH clamps (1) and hoses (2) and (3).

9.

Remove the fixing bolts (A) of the thermo plunger from the
bracket and remove the thermo plunger unit.

INSTALLATION

Installation is basically the reverse order of the removal.

Tightening torque of bolt

: 9.1 N.m

JPBIA3084ZZ

CO-74

< REMOVAL AND INSTALLATION >

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THERMOSTAT

THERMOSTAT

Inspection

INFOID:0000000006492621

• Place a thread so that it is caught in the valves of the thermostat.

Immerse fully in a container filled with water. Heat while stirring.
(The example in the figure shows the thermostat.) 

• The valve opening temperature is the temperature at which the

valve opens and falls from the thread.

• Continue heating. Check the full-open lift amount.
• After checking the full-open lift amount, lower the water tempera-

ture and check the valve closing temperature. 

• If the measured value is out of the standard value or unusual valve

seating condition is found, replace water inlet and thermostat
assembly.

SLC949A

Items

Temperature 

°

C (

°

F)

Start of opening

89 (192)     

End of opening

97 - 101 (207 - 214)

WATER OUTLET

CO-75

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WATER OUTLET

Exploded View

INFOID:0000000006492622

Removal and Installation

INFOID:0000000006492623

REMOVAL

1.

Remove air cleaner case. Refer to 

EM-280, "Exploded View"

.

2.

Remove vacuum hose.

3.

Remove vacuum pump. Refer to 

EM-293, "Exploded View"

.

4.

Drain engine coolant. Refer to 

CO-62, "Draining"

.

CAUTION:

Perform when engine is cold.

5.

Remove radiator upper hose. Refer to 

CO-66, "Exploded View"

.

6.

Remove water hose.

7.

Remove water outlet.

INSTALLATION

Install in the reverse order of removal.

1.

Engine coolant temperature sensor

2.

O-ring

3.

Lock plate

4.

Gasket

5.

Water outlet and thermostat assem-
bly

6.

Air relief plug

7.

Clamp

8.

Water hose

9.

Water pipe

A.

To radiator hose upper

B.

To EGR cooler hose

C.

To heater hose 

 : N·m (kg-m, ft-lb)

 : Always replace after every disassembly.

JPBIA3086GB