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Juke F15 (2012 year). Service Repair Manual - part 201

EX-4

< PERIODIC MAINTENANCE >

[MR16DDT ]

EXHAUST SYSTEM

PERIODIC MAINTENANCE

EXHAUST SYSTEM

Inspection

INFOID:0000000006356455

Check exhaust pipes, muffler, and mounting for improper attach-
ment, leakage, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.

SMA211A

EXHAUST SYSTEM

EX-5

< REMOVAL AND INSTALLATION >

[MR16DDT ]

REMOVAL AND INSTALLATION

EXHAUST SYSTEM

Exploded View

INFOID:0000000006356456

2WD

JPBIA4322GB

Center muffler

Mounting rubber

Spring

Seal bearing

Stud bolt

Three way catalyst

Heated oxygen sensor 2

Seal bearing

Ring gasket

10. Main muffler

To catalyst convertor

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

EX-6

< REMOVAL AND INSTALLATION >

[MR16DDT ]

EXHAUST SYSTEM

4WD

Removal and Installation

INFOID:0000000006356457

REMOVAL

• Disconnect each joint and mounting.
• Remove heated oxygen sensor 2 with following procedure:
- Using heated oxygen sensor wrench [SST: KV10114400] (A),

removal heated oxygen sensor 2 (1).

CAUTION:

Be careful not to damage heated oxygen sensor 2.

INSTALLATION

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

CAUTION:

• Always replace seal bearings with new ones when reassembling.

JPBIA4323GB

Center pipe

Mounting rubber

Spring

Seal bearing

Stud bolt

Three way catalyst

Seal bearing

Ring gasket

Main muffler

To catalyst convertor

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

: Exhaust front tube

PBIC4498J

EXHAUST SYSTEM

EX-7

< REMOVAL AND INSTALLATION >

[MR16DDT ]

• Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a con-

crete floor. Use a new one.

• Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxy-

gen sensor thread cleaner [commercial service tool: J-43897-18 or J-43897-12] and apply anti-seize
lubricant (commercial service tool).

• Never over torque heated oxygen sensor 2. Doing so may cause damage to the heated oxygen sen-

sor 2, resulting in the “MIL” coming on.

• If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heat

insulator, remove them.

• When installing heat insulator avoid large gaps or interference between heat insulator and each

exhaust pipe.

• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas

leakage.

• When installing each mounting rubber, use silicon oil to avoid twisting.
• Temporarily tighten mounting nuts and bolts. Check each part for unusual interference and mount-

ing rubber interference, and then tighten them to the specified torque.

• When installing each mounting rubber, avoid twisting or unusual extension in up/down, front/rear

and right/left directions.

Catalyst convertor to Exhaust Front Tube

Securely insert seal bearing (2) into catalyst convertor (1).

CAUTION:

Be careful not to damage seal bearing surface when install-
ing.

With spring, tighten nut.

CAUTION:

• Fasten stud bolts to the flange of exhaust manifold side to

the specified torque before fastening mounting nuts.

• Ensure springs are seated correctly on the flange and not sitting on (A).
• Be careful that stud bolt does not interfere with mounting hole of exhaust front tube (

After installing, check that stud bolt does not interfere with mounting hole of exhaust front tube.

Exhaust Front Tube to Center Muffler

Securely insert seal bearing (2) into exhaust front tube (1) side
in the direction shown in the figure.

CAUTION:

Be careful not to damage seal bearing surface when install-
ing.

With spring, tighten bolt.

CAUTION:

• Ensure springs are seated correctly on the flange and not sitting on (A).
• Be careful that bolt does not interfere with mounting hole of center muffler (

After installing, check that bolt does not interfere with mounting hole of center muffler.

Inspection

INFOID:0000000006356458

INSPECTION AFTER INSTALLATION

• Check clearance between tail tube and rear bumper is even.
• With engine running, check exhaust tube joints for gas leakage and unusual noises.

: Spring

: Nut

: Exhaust front tube

JPBIA4440ZZ

: Spring

: Bolt

: Center muffler

JPBIA2174ZZ

EX-8

< REMOVAL AND INSTALLATION >

[MR16DDT ]

EXHAUST SYSTEM

• Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue

stress. Improper installation could result in excessive noise and vibration.

PRECAUTIONS

EX-9

< PRECAUTION >

[HR16DE]

PRECAUTION

PRECAUTIONS

Removal and Installation

INFOID:0000000006502093

CAUTION:

• Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat

resistance, corrosion resistance, and shape.

• Perform the operation with the exhaust system fully cooled down because the system will be hot

just after engine stops.

• Be careful not to cut your hand on the heat insulator edge.

EX-10

< PREPARATION >

[HR16DE]

PREPARATION

PREPARATION

Special Service Tools

INFOID:0000000006502094

Commercial Service Tools

INFOID:0000000006502095

Tool number
Tool name

Description

KV10114400
Heated oxygen sensor wrench

Loosening or tightening heated oxygen sen-
sor 2
a: For 22 mm (0.87 in) width hexagon nut

S-NT636

Tool name

Description

Power tool

Loosening nuts and bolts

Heated oxygen sensor thread cleaner

Reconditioning the exhaust system threads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
A: J-43897-18 [18 mm (0.71 in) dia.] for zir-
conia heated oxygen sensor
B: J-43897-12 [12 mm (0.47 in) dia.] for tita-
nia heated oxygen sensor
C: Mating surface shave cylinder
D: Flutes

Anti-seize lubricant (Permatex 133AR
or equivalent meeting MIL specifica-
tion MIL-A-907)

Lubricating heated oxygen sensor thread
cleaner when reconditioning exhaust system
threads

PBIC0190E

JPBIA0238ZZ

AEM489

EXHAUST SYSTEM

EX-11

< PERIODIC MAINTENANCE >

[HR16DE]

PERIODIC MAINTENANCE

EXHAUST SYSTEM

Inspection

INFOID:0000000006502096

Check exhaust pipes, muffler, and mounting for improper attach-
ment, leakage, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.

SMA211A

EX-12

< REMOVAL AND INSTALLATION >

[HR16DE]

EXHAUST SYSTEM

REMOVAL AND INSTALLATION

EXHAUST SYSTEM

Exploded View

INFOID:0000000006502097

Removal and Installation

INFOID:0000000006502098

REMOVAL

• Disconnect each joint and mounting.
• Remove heated oxygen sensor 2 with following procedure:

Mounting rubber

Main muffler

Seal bearing

Spring

Mounting rubber

Seal bearing

Exhaust front tube

Heated oxygen sensor 2

Sub muffler

10. Gasket

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

JPBIA4113GB

EXHAUST SYSTEM

EX-13

< REMOVAL AND INSTALLATION >

[HR16DE]

- Using heated oxygen sensor wrench [SST: KV10114400] (A),

removal heated oxygen sensor 2 (1).

CAUTION:

Be careful not to damage heated oxygen sensor 2.

INSTALLATION

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

CAUTION:

• Always replace seal bearings with new ones when reassembling.
• Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a con-

crete floor. Use a new one.

• Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxy-

gen sensor thread cleaner [commercial service tool: J-43897-18 or J-43897-12] and apply anti-seize
lubricant (commercial service tool).

• Never over torque heated oxygen sensor 2. Doing so may cause damage to the heated oxygen sen-

sor 2, resulting in the “MIL” coming on.

• If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heat

insulator, remove them.

• When installing heat insulator avoid large gaps or interference between heat insulator and each

exhaust pipe.

• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas

leakage.

• When installing each mounting rubber, use silicon oil to avoid twisting.
• Temporarily tighten mounting nuts and bolts. Check each part for unusual interference and mount-

ing rubber interference, and then tighten them to the specified torque.

• When installing each mounting rubber, avoid twisting or unusual extension in up/down, front/rear

and right/left directions.

Exhaust Manifold to Exhaust Front Tube

Securely insert seal bearing (2) into exhaust manifold (1) side in
the direction shown in the figure.

CAUTION:

Be careful not to damage seal bearing surface when install-
ing.

With spring, tighten nut.

CAUTION:

• Fasten stud bolts to the flange of exhaust manifold side to the specified torque before fastening

mounting nuts.

• Ensure springs are seated correctly on the flange and not sitting on (A).
• Be careful that stud bolt does not interfere with mounting hole of exhaust front tube (

After installing, check that stud bolt does not interfere with mounting hole of exhaust front tube.

Exhaust Front Tube to Center Muffler

JPBIA4222ZZ

: Spring

: Nut

: Stud bolt

: Exhaust front tube

JPBIA2372ZZ

EX-14

< REMOVAL AND INSTALLATION >

[HR16DE]

EXHAUST SYSTEM

Securely insert seal bearing (2) into exhaust front tube (1) side
in the direction shown in the figure.

CAUTION:

Be careful not to damage seal bearing surface when install-
ing.

With spring, tighten bolt.

CAUTION:

• Ensure springs are seated correctly on the flange and not sitting on (A).
• Be careful that bolt does not interfere with mounting hole of center muffler (

After installing, check that bolt does not interfere with mounting hole of center muffler.

Inspection

INFOID:0000000006502099

INSPECTION AFTER INSTALLATION

• Check clearance between tail tube and rear bumper is even.
• With engine running, check exhaust tube joints for gas leakage and unusual noises.
• Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue

stress. Improper installation could result in excessive noise and vibration.

: Spring

: Bolt

: Center muffler

JPBIA2174ZZ

PRECAUTIONS

EX-15

< PRECAUTION >

[K9K]

PRECAUTION

PRECAUTIONS

Removal and Installation

INFOID:0000000006502100

CAUTION:

• Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat

resistance, corrosion resistance, and shape.

• Perform the operation with the exhaust system fully cooled down because the system will be hot

just after engine stops.

• Be careful not to cut your hand on the heat insulator edge.

EX-16

< PERIODIC MAINTENANCE >

[K9K]

EXHAUST SYSTEM

PERIODIC MAINTENANCE

EXHAUST SYSTEM

Inspection

INFOID:0000000006502101

Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.

SMA211A

EXHAUST SYSTEM

EX-17

< REMOVAL AND INSTALLATION >

[K9K]

REMOVAL AND INSTALLATION

EXHAUST SYSTEM

Exploded View

INFOID:0000000006502102

Removal and Installation

INFOID:0000000006502103

CAUTION:

• Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat

resistance, corrosion resistance and shape.

• Perform the operation with the exhaust system fully cooled down because the system is still hot just

after the engine stops.

• Be careful not to cut your hand on the insulator edge.

REMOVAL

Remove Diesel particulate filter assembly.

Remove exhaust center tube and muffler from rubber mounting.

Remove exhaust center tube.

Remove main muffler.

Exhaust Pressure Sensor

REMOVAL

Main muffler

Mounting rubber

Ring gasket

Center tube

Exhaust gas temperature sensor 2

Diesel particulate filter assembly

Gasket

Stud bolt

Diesel particulate filter inlet tube

10. Gasket

To exhaust manifold

To pressure hose

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

JPBIA4804GB

EX-18

< REMOVAL AND INSTALLATION >

[K9K]

EXHAUST SYSTEM

WARNING:

• Any intervention on system during product life cycle is prohibited. If an intervention is required, the

system will need to be entirely replaced.

• The pressure measurement circuit must never be opened except at the adapters on the exhaust

pipe.

• Any intervention (excluding assembly) on system and more specifically, on the connection between

stainless steel preformed tube and rubber hose is prohibited (sealing of the system would no longer
be guaranteed). For example, intervention on screw, clamp, sensor, etc..

Remove engine under cover.

Disconnect exhaust pressure sensor harness connector.

Remove exhaust pressure sensor fixing bolt.

Remove exhaust pressure hose.

INSTALLATION

• Install in the reverse order of removal.

CAUTION:

• Always replace exhaust gaskets with new ones when reassembling.
• If the insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the insula-

tor, remove them.

• When installing the insulator avoid large gaps or interference between the insulator and each

exhaust pipe.

• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas

leakage.

• Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicle

side. Check each part for unusual interference, and then tighten them to the specified torque.

• When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left

directions.

Exhaust Pressure sensor

CAUTION:

• In case clamp has been damaged or broken, it is necessary to charge the differential assembly itself,

in order to avoid any leakage. it is not possible to replace just the clamp.

• In case it would be necessary to change the washer of the coupling nut, then the coupling nut must

be replaced itself as these two parts are an assembly part.

• Any contact of the hose with products likely to damage them should be avoided.
• The screw of the stainless steel preformed tube can only be tightened once (re-use is prohibited)
• During any handling operation of the Diesel Particulate Filter pressure measurement hoses (han-

dling, storage, assembly, etc.), the parts should never be folded or submitted to tension.

Installation is basically the reverse order of the removal.

Inspection

INFOID:0000000006502104

INSPECTION AFTER INSTALLATION

• With the engine running, check exhaust tube joints for gas leakage and unusual noises.
• Check to ensure that mounting brackets and mounting insulators are installed properly and free from undue

stress. Improper installation could result in excessive noise and vibration.

EXL-1

DRIVER CONTROLS

SECTION

EXL

EXL

CONTENTS

EXTERIOR LIGHTING SYSTEM

HALOGEN TYPE

PRECAUTION ...............................................

PRECAUTIONS ...................................................

Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................