Nissan Juke (2012 year). Service Repair Manual - part 40

CLUTCH MASTER CYLINDER

CL-13

< REMOVAL AND INSTALLATION >

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CLUTCH MASTER CYLINDER

Exploded View

INFOID:0000000007576615

Removal and Installation

INFOID:0000000007576616

REMOVAL

CAUTION:

• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately

and wash the affected area with water.

• Never disassemble clutch master cylinder.
1.

Drain clutch fluid. Refer to 

CL-8, "Draining"

.

2.

Remove air cleaner case. Refer to 

EM-25, "Removal and Installation"

.

3.

Remove reservoir hose from reservoir tank and master cylinder.

4.

Remove master cylinder rod end (

) from clutch pedal.

5.

Pull up the lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3).

6.

Rotate master cylinder clockwise by 45 degrees, and then
remove master cylinder from the vehicle.

1.

Reservoir hose

2.

Reservoir tank

3.

Master cylinder

JPDIB0162ZZ

PCIB1491E

JPDIB0167ZZ

Revision: 2011 October

2012 JUKE

CL-14

< REMOVAL AND INSTALLATION >

CLUTCH MASTER CYLINDER

INSTALLATION

CAUTION:

Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.

1.

Tilt master cylinder clockwise by 45 degrees (A) and insert it to
the mounting hole. Rotate counterclockwise and secure it. At
this time, nipple (1) is upward of the vehicle.

2.

Install master cylinder rod end to clutch pedal.

CAUTION:

Press master cylinder rod end into clutch pedal until it
stops.

3.

Install reservoir hose to reservoir tank and master cylinder.

CAUTION:

Set reservoir hose with painted mark facing upward.

4.

Press down the lock pin into connector of master cylinder until it stops.

5.

Install clutch tube into connector of master cylinder until it stops.

6.

For the next step and after, install in the reverse order of removal.

Inspection and Adjustment

INFOID:0000000007576617

INSPECTION AFTER INSTALLATION

• Check the fluid leakage and the fluid level. Refer to 

CL-8, "Inspection"

.

• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to

CL-6, "Inspection and Adjustment"

.

• Check the clutch interlock switch position. Refer to 

CL-6, "Inspection and Adjustment"

.

• Check the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)

Refer to 

CL-6, "Inspection and Adjustment"

.

ADJUSTMENT AFTER INSTALLATION

• Adjust the clutch interlock switch position. Refer to 

CL-6, "Inspection and Adjustment"

.

• Adjust the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)

Refer to 

CL-6, "Inspection and Adjustment"

.

• Perform the air bleeding. Refer to 

CL-10, "Air Bleeding"

.

B

: Mounting condition

JPDIB0114ZZ

Revision: 2011 October

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CLUTCH PIPING

CL-15

< REMOVAL AND INSTALLATION >

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CLUTCH PIPING

Exploded View

INFOID:0000000007576618

Hydraulic Layout

INFOID:0000000007576619

Removal and Installation

INFOID:0000000007576620

CAUTION:

Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.

REMOVAL 

Note the following, and refer to 

CL-15, "Exploded View"

 for removal procedure.

• Drain clutch fluid. Refer to 

CL-8, "Draining"

.

1.

CSC (Concentric Slave Cylinder)

2.

Clutch tube

3.

Clutch damper

4.

Bracket

5.

Master cylinder

JPDIB0184ZZ

1.

Clutch tube

2.

Lock pin

3.

CSC (Concentric Slave Cylinder)

4.

Clutch damper

5.

Master cylinder

6.

Clutch pedal

PCIB1499E

Revision: 2011 October

2012 JUKE

CL-16

< REMOVAL AND INSTALLATION >

CLUTCH PIPING

• Press the lock pin into the bleeding connector of the CSC, and then remove clutch tube from CSC.
• Pull the lock pins from the connectors of the clutch damper until the pins stop, and then remove clutch tubes

from clutch damper.

• Pull the lock pin from the connector of the clutch master cylinder until the pin stop, and then remove clutch

tube from clutch master cylinder.

INSTALLATION

Note the following, and refer to 

CL-15, "Exploded View"

 for installation procedure.

CAUTION:

Never damage clutch tube.
• Insert each clutch tube into the CSC bleeding connector, the clutch damper connector, and the clutch master

cylinder connector until it contacts the end of each connector.

• Install each lock pin into the clutch damper connector and the clutch master cylinder connector until it con-

tacts the end of each connector.

Inspection and Adjustment

INFOID:0000000007576621

INSPECTION AFTER REMOVAL

• Check the clutch tube for cracks and damage. If the clutch tube has cracks or damage, replace it with a new

one.

• Check the O-ring of the clutch tube for cracks and damage. If the O-ring of the clutch tube has cracks or

damage, replace clutch tube with a new one.

• Check the clutch damper for cracks and damage. If the clutch damper has cracks or damage, replace it with

a new one.

INSPECTION AFTER INSTALLATION

• Check the fluid leakage and the fluid level. Refer to 

CL-8, "Inspection"

.

• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to

CL-6, "Inspection and Adjustment"

.

ADJUSTMENT AFTER INSTALLATION

Perform the air bleeding. Refer to 

CL-10, "Air Bleeding"

.

Revision: 2011 October

2012 JUKE

CSC (CONCENTRIC SLAVE CYLINDER)

CL-17

< UNIT REMOVAL AND INSTALLATION >

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UNIT REMOVAL AND INSTALLATION

CSC (CONCENTRIC SLAVE CYLINDER)

Exploded View

INFOID:0000000007576622

Removal and Installation

INFOID:0000000007576623

CAUTION:

• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position

every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage.

• Never disassemble CSC.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately

and wash the affected area with water.

REMOVAL

1.

Remove transaxle assembly. Refer to 

TM-25, "Removal and Installation"

.

2.

Remove CSC from clutch housing.

INSTALLATION

1.

Install CSC to clutch housing, and then tighten CSC mounting bolts to the specified torque.

CAUTION:

• Never reuse CSC.
• Never insert and operate CSC because piston and stopper of CSC components may fall off.

2.

For the next step and after, install in the reverse order of removal.

Inspection and Adjustment

INFOID:0000000007576624

INSPECTION AFTER INSTALLATION

Check the fluid leakage and the fluid level. Refer to 

CL-8, "Inspection"

.

ADJUSTMENT AFTER INSTALLATION

Perform the air bleeding. Refer to 

CL-10, "Air Bleeding"

.

1.

Transaxle assembly

2.

CSC (Concentric Slave Cylinder)

 : Always replace after every disassembly.

 : N·m (kg-m, ft-lb)

JPDIB0040GB

Revision: 2011 October

2012 JUKE

CL-18

< UNIT REMOVAL AND INSTALLATION >

CLUTCH DISC AND CLUTCH COVER

CLUTCH DISC AND CLUTCH COVER

Exploded View

INFOID:0000000007576625

Removal and Installation

INFOID:0000000007576626

CAUTION:

• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position

every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage. Refer to 

CL-17, "Removal and Installation"

.

• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• Never clean clutch disc using solvent.

REMOVAL

1.

Remove transaxle assembly. Refer to 

TM-25, "Removal and Installation"

.

2.

Remove clutch cover mounting bolts while holding clutch cover.

CAUTION:

Never drop clutch disc.

3.

Remove clutch cover and clutch disc.

CAUTION:

Never drop clutch disc.

INSTALLATION

1.

Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.

1.

Flywheel

2.

Clutch disc

3.

Clutch cover

4.

Input shaft

A.

First step

B.

Final step

 : N·m (kg-m, ft-lb)

 : Apply lithium-based grease including molybdenum disulphide.

JPDIB0049GB

Revision: 2011 October

2012 JUKE

CLUTCH DISC AND CLUTCH COVER

CL-19

< UNIT REMOVAL AND INSTALLATION >

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2.

Apply recommended grease to clutch disc (1) and input shaft (2)
splines (A).

CAUTION:

Be sure to apply grease to the points specified. Otherwise,
noise, poor disengagement, or damage to the clutch may
result. Excessive grease may cause slip or judder. And if it
adheres to seal of CSC, it cause clutch fluid leakage. Wipe
out excess grease. Wipe out any grease oozing from the
parts.

3.

Install clutch disc, using a clutch aligner (A) [Commercial service
tool].

4.

Install clutch cover, and then temporarily tighten clutch cover
mounting bolts.

5.

Tighten clutch cover mounting bolts to the specified torque
evenly in two steps in the numerical order as shown in the fig-
ure.

6.

For the next step and after, install in the reverse order of
removal.

Inspection

INFOID:0000000007576627

INSPECTION AFTER REMOVAL

Clutch Disc

• Measure circumferential runout relative to clutch disc center spline.

If it is outside the specification, replace clutch disc.

• Measure backlash to clutch disc spline and main drive gear spline

at the circumference of clutch disc. If it is outside the specification,
replace clutch disc.

• Measure the depth “A” to clutch disc facing rivet heads, using a

calipers. If it exceeds the allowable wear limit, replace clutch disc.

Clutch Cover

• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover.

NOTE:
• Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.
• Broken thrust ring will make a clinking sound when cover is shaken up and down.

• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,

repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.

JPDIB0239ZZ

PCIB1503E

Runout limit/diameter of the area 
to be measured

: Refer to 

CL-21, 

"Clutch Disc"

.

Maximum allowable spline back-
lash (at outer edge of disc)

: Refer to 

CL-21, 

"Clutch Disc"

.

Facing wear limit (depth to the 
rivet head) “A”

: Refer to 

CL-21, 

"Clutch Disc"

.

SCL221

JPDIB0026ZZ

Revision: 2011 October

2012 JUKE

CL-20

< UNIT REMOVAL AND INSTALLATION >

CLUTCH DISC AND CLUTCH COVER

INSPECTION AFTER INSTALLATION

Clutch Cover

Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height,
using the diaphragm adjusting wrench (A) [SST: ST20050240 ( - )].

Tolerance for diaphragm spring 
lever unevenness

: Refer to 

CL-21, 

"Clutch Cover"

.

JPDIB0160ZZ

Revision: 2011 October

2012 JUKE

SERVICE DATA AND SPECIFICATIONS (SDS)

CL-21

< SERVICE DATA AND SPECIFICATIONS (SDS) 

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SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

INFOID:0000000007576628

Unit: mm (in)

Clutch Pedal

INFOID:0000000007576629

Unit: mm (in)

*: With ASCD or with push-button ignition switch system

Clutch Disc

INFOID:0000000007576630

Unit: mm (in)

Clutch Cover

INFOID:0000000007576631

Unit: mm (in)

Engine type

MR16DDT

Transaxle type

RS6F94R

Type of clutch control

Hydraulic

Clutch disc

Facing size (Outer dia. 

×

 Inner dia. 

×

 Thickness)

230 

×

 155 

×

 3.2

(9.06 

×

 6.10 

×

 0.126)

Recommended clutch fluid

Refer to 

MA-10, "Fluids and Lubricants"

.

Engine type

MR16DDT

Transaxle type

RS6F94R

Clutch pedal height

169.7 – 179.7 (6.68 – 7.07)

Clutch pedal height at clutch disengagement

80 (3.15) or more

Clutch pedal play
[Looseness at clutch pedal pin]

2 – 8 (0.08 – 0.31)

[0 – 1.3 (0 – 0.051)]

Clearance between stopper rubber and clutch interlock switch threaded 
end while clutch pedal is fully depressed.

0.74 – 1.96 (0.0291 – 0.0772)

Clearance between clutch pedal and clutch pedal position switch thread-

ed end while clutch pedal is fully released.

*

0.74 – 1.96 (0.0291 – 0.0772)

Engine type

MR16DDT

Transaxle type

RS6F94R

Runout limit/diameter of the area to be measured

1.0 (0.039) / 220 (8.66) dia.

Maximum allowable spline backlash (at outer edge of disc)

0.9 (0.035)

Facing wear limit (depth to the rivet head)

0.35 (0.0138)

Engine type

MR16DDT

Transaxle type

RS6F94R

Tolerance for diaphragm spring lever unevenness

0.7 (0.028) or less

Revision: 2011 October

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CO-1

ENGINE

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SECTION 

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CONTENTS

ENGINE COOLING SYSTEM

MR16DDT 

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

2

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

2

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

2

PREPARATION ............................................

3

PREPARATION ...................................................

3

Commercial Service Tools .......................................

3

SYSTEM DESCRIPTION  ..............................

4

DESCRIPTION ....................................................

4

Engine Cooling System .............................................

4

Engine Cooling System Schematic  ...........................

5

SYMPTOM DIAGNOSIS  ...............................

6

OVERHEATING CAUSE ANALYSIS  ..................

6

Troubleshooting Chart ...............................................

6

PERIODIC MAINTENANCE ..........................

8

ENGINE COOLANT  ............................................

8

Inspection ..................................................................

8

Draining .....................................................................

8

Refilling .....................................................................

9

Flushing ...................................................................

10

RADIATOR .........................................................

12

RADIATOR CAP ........................................................

12

RADIATOR CAP : Inspection ..................................

12

RADIATOR ................................................................

12

RADIATOR : Inspection  ..........................................

12

REMOVAL AND INSTALLATION  ...............

14

RADIATOR ........................................................

14

Exploded View .........................................................

14

Removal and Installation  .........................................

14

Inspection ................................................................

16

COOLING FAN ..................................................

17

Exploded View .........................................................

17

Removal and Installation  .........................................

17

Disassembly and Assembly .....................................

18

Inspection ................................................................

18

WATER PUMP  ..................................................

19

Exploded View .........................................................

19

Removal and Installation  .........................................

19

Inspection ................................................................

19

THERMOSTAT ..................................................

21

Exploded View .........................................................

21

Removal and Installation  .........................................

21

Inspection ................................................................

22

WATER OUTLET  ..............................................

23

Exploded View .........................................................

23

Removal and Installation  .........................................

23

Inspection ................................................................

24

SERVICE DATA AND SPECIFICATIONS 
(SDS) ............................................................

26

SERVICE DATA AND SPECIFICATIONS 
(SDS) .................................................................

26

Periodical Maintenance Specification ......................

26

Radiator ...................................................................

26

Thermostat ..............................................................

26

Water Control Valve  ................................................

26

Revision: 2011 October

2012 JUKE

CO-2

< PRECAUTION >

[MR16DDT ]

PRECAUTIONS

PRECAUTION

PRECAUTIONS

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

INFOID:0000000007579986

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this
Service Manual.

WARNING:

Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in

the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.

• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal

injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”.

• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-

vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the

ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.

• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the

battery, and wait at least 3 minutes before performing any service.

Revision: 2011 October

2012 JUKE

PREPARATION

CO-3

< PREPARATION >

[MR16DDT ]

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PREPARATION

PREPARATION

Commercial Service Tools

INFOID:0000000007579987

Tool name

Description

Radiator cap tester

Checking radiator and radiator cap

Radiator cap tester adapter

Adapting radiator cap tester to radiator cap 
and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

PBIC1982E

S-NT564

Revision: 2011 October

2012 JUKE

CO-4

< SYSTEM DESCRIPTION >

[MR16DDT ]

DESCRIPTION

SYSTEM DESCRIPTION

DESCRIPTION

Engine Cooling System

INFOID:0000000007579988

M/T models

CVT models

JPBIA4333GB

JPBIA4372GB

Revision: 2011 October

2012 JUKE

DESCRIPTION

CO-5

< SYSTEM DESCRIPTION >

[MR16DDT ]

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Engine Cooling System Schematic

INFOID:0000000007579989

M/T models

CVT models

JPBIA4335GB

JPBIA4334GB

Revision: 2011 October

2012 JUKE

CO-6

< SYMPTOM DIAGNOSIS >

[MR16DDT ]

OVERHEATING CAUSE ANALYSIS

SYMPTOM DIAGNOSIS

OVERHEATING CAUSE ANALYSIS

Troubleshooting Chart

INFOID:0000000007579990

Symptom

Check items

Cooling sys-
tem parts 
malfunction

Poor heat transfer

Water pump malfunction

Worn or loose drive belt

—

Thermostat and water con-
trol valve stuck closed

—

Damaged fins

Dust contamination or pa-
per clogging

Physical 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 engine coolant 
mixture ratio

—

—

—

Poor engine coolant quality

—

Engine coolant viscosity

—

Insufficient engine coolant

Engine coolant leakage

Cooling hose

Loose clamp

Cracked hose

Water pump

Poor sealing

Radiator 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 leakage into 
cooling system

Cylinder head deterioration

Cylinder head gasket deteri-
oration

Revision: 2011 October

2012 JUKE

OVERHEATING CAUSE ANALYSIS

CO-7

< SYMPTOM DIAGNOSIS >

[MR16DDT ]

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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

Power train system mal-
function

—

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

Blocked air flow

Installed large fog lamp

Symptom

Check items

Revision: 2011 October

2012 JUKE