Engine Cooling System: Section

ENGINE
ENGINE COOLING SYSTEM

SECTION CO CO
E
CONTENTS
MR16DDT REMOVAL AND INSTALLATION ............... 14 F
PRECAUTION ............................................... 2 RADIATOR ........................................................ 14

Exploded View .........................................................14 G
PRECAUTIONS ................................................... 2 Removal and Installation .........................................14
Precaution for Supplemental Restraint System Inspection ................................................................16
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 2 COOLING FAN .................................................. 17 H
Exploded View .........................................................17
PREPARATION ............................................ 3 Removal and Installation .........................................17
Disassembly and Assembly .....................................18 I
PREPARATION ................................................... 3 Inspection ................................................................18
Commercial Service Tools ....................................... 3
WATER PUMP .................................................. 19
SYSTEM DESCRIPTION .............................. 4 Exploded View .........................................................19 J
Removal and Installation .........................................19
DESCRIPTION .................................................... 4
Inspection ................................................................19
Engine Cooling System ............................................. 4
K
Engine Cooling System Schematic ........................... 5 THERMOSTAT .................................................. 21
Exploded View .........................................................21
SYMPTOM DIAGNOSIS ............................... 6 Removal and Installation .........................................21
L
OVERHEATING CAUSE ANALYSIS .................. 6 Inspection ................................................................22
Troubleshooting Chart ............................................... 6 WATER OUTLET .............................................. 23
PERIODIC MAINTENANCE .......................... 8 Exploded View .........................................................23 M
Removal and Installation .........................................23
ENGINE COOLANT ............................................ 8 Inspection ................................................................24
Inspection .................................................................. 8 N
Draining ..................................................................... 8 SERVICE DATA AND SPECIFICATIONS
Refilling ..................................................................... 9 (SDS) ............................................................ 26
Flushing ................................................................... 10
SERVICE DATA AND SPECIFICATIONS O
RADIATOR .........................................................12 (SDS) ................................................................. 26
Periodical Maintenance Specification ......................26
RADIATOR CAP ........................................................ 12 Radiator ...................................................................26 P
RADIATOR CAP : Inspection .................................. 12 Thermostat ..............................................................26
Water Control Valve ................................................26
RADIATOR ................................................................ 12
RADIATOR : Inspection .......................................... 12
Revision: 2011 October CO-1 2012 JUKE

PRECAUTIONS
< PRECAUTION > [MR16DDT ]
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.

PREPARATION
< PREPARATION > [MR16DDT ]
PREPARATION A
PREPARATION
Commercial Service Tools INFOID:0000000007579987
CO
Tool name Description

C
Radiator cap tester Checking radiator and radiator cap
E
PBIC1982E
Radiator cap tester adapter Adapting radiator cap tester to radiator cap
and radiator filler neck
a: 28 (1.10) dia. F
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
G
S-NT564

DESCRIPTION
< SYSTEM DESCRIPTION > [MR16DDT ]
SYSTEM DESCRIPTION
DESCRIPTION
Engine Cooling System INFOID:0000000007579988
M/T models
JPBIA4333GB
CVT models
JPBIA4372GB

DESCRIPTION
< SYSTEM DESCRIPTION > [MR16DDT ]
Engine Cooling System Schematic INFOID:0000000007579989
A
M/T models
CO
JPBIA4335GB
I
CVT models
JPBIA4334GB

OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [MR16DDT ]
SYMPTOM DIAGNOSIS
Troubleshooting Chart INFOID:0000000007579990
Symptom Check items

Water pump malfunction Worn or loose drive belt
Thermostat and water con-
—
trol valve stuck closed
Dust contamination or pa-
Poor heat transfer —
Damaged fins per clogging
Physical damage
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Cooling fan does not oper-
ate
Reduced air flow High resistance to fan rota- Fan assembly —
tion
Damaged fan blades
Damaged radiator shroud — — —
Cooling sys- Improper engine coolant

— — —
tem parts mixture ratio
malfunction Poor engine coolant quality — Engine coolant viscosity —
Loose clamp
Cooling hose
Cracked hose
Water pump Poor sealing
Loose
Radiator cap
Poor sealing
Engine coolant leakage
O-ring for damage, deterio-
Insufficient engine coolant ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leakage into
Overflowing reservoir tank Cylinder head gasket deteri-
cooling system
oration

< SYMPTOM DIAGNOSIS > [MR16DDT ]
Symptom Check items
A
High engine rpm under no
load
Driving in low gear for ex-
Abusive driving CO
tended time
Driving at extremely high
speed
— Overload on engine C
Power train system mal-
function
Installed improper size
Except cool- —
wheels and tires D
ing system
parts mal- Dragging brakes
function
Improper ignition timing
E
Blocked bumper —
Installed car brassiere
Blocked radiator grille Mud contamination or paper F
Blocked or restricted air clogging —
flow
Blocked radiator —
Blocked condenser G
Blocked air flow
Installed large fog lamp

ENGINE COOLANT
< PERIODIC MAINTENANCE > [MR16DDT ]
PERIODIC MAINTENANCE
ENGINE COOLANT
Inspection INFOID:0000000007579991
LEVEL
• Check that the reservoir tank engine coolant level is within the
“MIN” to “MAX” when the engine is cool.
A : MAX
B : MIN
• Adjust the engine coolant level if necessary.
CAUTION:
Refill Genuine NISSAN Long Life Antifreeze/Coolant (blue) or
equivalent in its quality mixed with water (distilled or deminer-
alized). Refer to MA-10, "Fluids and Lubricants".
JPBIA0102ZZ
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).
Testing pressure: Refer to CO-26, "Radiator".

WARNING:
Never remove radiator cap when engine is hot. Serious burns
may occur from high-pressure engine coolant escaping from
engine cooling system.
CAUTION:
Higher test pressure than specified may cause radiator dam- PBIC5121J
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:0000000007579992
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. Connect drain hose.
• Use a genera-purpose hose with the dimensions show in the
figure.
A : φ 8 mm (0.31 in)
B : 300 mm (11.81 in)
JPBIA4770ZZ

ENGINE COOLANT
2. Open radiator drain plug (A) at the bottom of radiator, and then
remove radiator cap. A
: Vehicle front
CAUTION: CO
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-68, "Setting". C
JPBIA4452ZZ
D
3. Remove reservoir tank if necessary, and drain engine coolant and clean reservoir tank before installing.
Refer to CO-14, "Exploded View".
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated, E
flush the engine cooling system. Refer to CO-10, "Flushing".
5. Disconnect drain hose.
Refilling INFOID:0000000007579993 F
CAUTION:
• Do not reuse O-rings. G
• Do not put additive such as waterleak preventive, since it may cause cooling waterway clogging.
• When refilling use Genuine NISSAN Long Life Antifreeze/Coolant (blue) or equivalent in its quality
mixed with water (distilled or demineralized). Refer to MA-10, "Fluids and Lubricants".
H
1. Install reservoir tank if removed, and install radiator drain plug.
CAUTION:
Be sure to clean drain plug and install with new O-ring.
I
Radiator drain plug : Refer to CO-14, "Exploded View".
• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-68, "Setting".
J
2. Check that each hose clamp has been firmly tightened.
3. Remove air duct (suction side). Refer to EM-25, "Exploded View".
4. Disconnect vacuum hose break booster side, and removal vacuum tube from clamp. Refer to BR-37, K
"Exploded View".
5. Disconnect heater hose (1) at position ( ) in the figure.
L
: Vehicle front
• Enhance heater hose as high as possible.

M
JPBIA4453ZZ
O
6. Fill radiator (1) to specified level.
CAUTION:
Never adhere the engine coolant to electronic equipments
(alternator etc.). P
• 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.
JPBIA0819ZZ

ENGINE COOLANT
Engine coolant capacity

(With reservoir tank at “MAX” level)
Refer to CO-26, "Periodical Maintenance Specifica-
tion".
7. Refill reservoir tank to “MAX” level line with engine coolant.
A : MAX
B : MIN
Reservoir tank engine coolant capacity

(At “MAX” level)
Refer to CO-26, "Periodical Maintenance Specification".
JPBIA0102ZZ
8. Install air duct (suction side). Refer to EM-25, "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:0000000007579994
1. Install radiator drain plug.

CAUTION:
Be sure to clean drain plug and install with new O-ring.
Radiator drain plug : Refer to CO-14, "Exploded View".

• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-68, "Setting".
2. Remove air duct (suction side), air cleaner cover assembly and air cleaner body assembly. Refer to EM-
25, "Exploded View".
3. Disconnect vacuum hose break booster side, and remove vacuum tube from clamp. Refer to .

ENGINE COOLANT
4. Disconnect heater hose (1) at position ( ) in the figure.
A
: Vehicle front
• Enhance heater as high as possible.

CO
JPBIA4453ZZ
D
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.
E
6. Connect vacuum hose, and install vacuum tube.
7. Install air duct (suction side), air cleaner cover assembly and air cleaner body assembly. Refer to EM-25,
"Exploded View".
F
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. G
11. Drain water from the system. Refer to CO-8, "Draining".
12. Repeat steps 1 through 9 until clear water begins to drain from radiator.
H

RADIATOR
RADIATOR
RADIATOR CAP
RADIATOR CAP : Inspection INFOID:0000000007579995
• Check valve seat (A) of radiator cap.
B : Metal plunger
- 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.
JPBIA0108ZZ
• 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.
SMA967B
• Check radiator cap relief pressure.
Standard and Limit : Refer to CO-26, "Radiator".

- 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.
PBIC5122J
• 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:0000000007579996
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.

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/cm2, 71 psi) and keep distance more than 30 cm A
(11.81 in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
CO

RADIATOR
< REMOVAL AND INSTALLATION > [MR16DDT ]
REMOVAL AND INSTALLATION

RADIATOR
Exploded View INFOID:0000000007579997
JPBIA4336GB
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.
: Indicates that the parts is connected at points with symbols in actual vehicle.
Removal and Installation INFOID:0000000007579998
REMOVAL
WARNING:
• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine
coolant escaping from engine cooling system.
• 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-8, "Draining".

RADIATOR
CAUTION:
• Perform this step when the engine is cold. A
• Never spill engine coolant on drive belt.
2. Remove engine cover. Refer to EM-24, "Exploded View".
3. Remove engine under cover. CO
4. Remove radiator hose (upper and lower).
5. Remove front bumper. Refer to EXT-11, "Exploded View".
6. Remove radiator core support upper. Refer to DLK-123, "Removal and Installation" (With Intelligent Key) C
or DLK-238, "Removal and Installation" (Without Intelligent Key).
7. Disconnect cooling fan harness connector.
8. Remove reservoir tank. D
9. Remove cooling fan assembly.
CAUTION:
Never damage or scratch the radiator core. E
10. Remove condenser from radiator and temporarily fasten it on vehicle with a rope.
11. Pull up and remove the radiater assembly (1).
CAUTION: F
Never damage radiator core and condenser assembly core.
JPBIA4455ZZ
I
INSTALLATION
CAUTION:
Do not reuse O-rings. J
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).
K
JPBIA4294GB N
Unit mm (in)
A. Radiator side B. Engine side O
• For the orientation of the hose clamp pawl, refer to the figure.
Radiator hose Hose end Paint mark Position of hose clamp* P

Radiator side Upper A
Radiator hose (upper)
Engine side Upper B
Radiator side Upper C
Radiator hose (lower) (RH)
Engine side Front side D

RADIATOR
Radiator hose Hose end Paint mark Position of hose clamp*
Radiator side Rear side E
Radiator hose (lower) (LH)
Engine side Rear side F
*Refer to the illustrations for the specific position each hose clamp tab.
JPBIA4375ZZ
G. View G h. 45°
: Vehicle upper
• The angle (b) created by the hose clamp pawl and the specified
line (A) must be within ±15° as shown in the figure.
JPBIA4295ZZ
• 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.
Dimension “A” 3 mm (0.12 in)
JPBIA4374ZZ
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-8, "Inspection".
• Start and warm up the engine. Check visually that there is no leakage of engine coolant.

COOLING FAN
COOLING FAN
A
CO
G
JPBIA4337GB
1. Fan motor 2. Fan shroud 3. Cooling fan

A. Apply on fan motor shaft
H
: N·m (kg-m, in-lb)

: Apply genuine high strength thread locking sealant or equivalent. I
J
REMOVAL
1. Drain engine coolant. Refer to CO-8, "Draining".
CAUTION: K
• Perform this step engine is cold.
2. Remove engine cover. L
3. Remove front bumper. Refer to EXT-11, "Exploded View".
4. Remove radiator core support upper. Refer to DLK-123, "Removal and Installation" (With Intelligent Key)
or DLK-238, "Removal and Installation" (Without Intelligent Key). M
5. Disconnect cooling fan harness connector.
6. Remove reservoir tank. Refer to CO-14, "Exploded View".
7. Remove radiator hose (upper). Refer to CO-14, "Exploded View". N
8. Remove cooling fan assembly.
CAUTION:
Be careful not to damage or scratch on radiator core when removing. O
INSTALLATION
CAUTION: P
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-504, "Component Function Check".

COOLING FAN
Disassembly and Assembly INFOID:0000000007580002
DISASSEMBLY
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 AFTER DISASSEMBLY

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

WATER PUMP
WATER PUMP
A
CO
G
JPBIA4338GB
1. Gasket 2. Water pump

H
: N·m (kg-m, ft-lb)
I
REMOVAL J
CAUTION:
• Perform this step when the engine is cold. K
2. Steer front wheel to the right.
3. Remove front fender protector (RH). Refer to EXT-21, "Exploded View". L
4. Remove drive belt. Refer to EM-18, "Exploded View".
5. Remove water pump.
• Engine coolant will leak from cylinder block, so have a receptacle ready below. M
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.
N
INSTALLATION
Install in the reverse order of removal.
Inspection INFOID:0000000007580006 O
INSPECTION AFTER REMOVAL

P

WATER PUMP
• 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.
PBIC3313J


THERMOSTAT
THERMOSTAT
A
CO
G
JPBIA4339GB
1. Thermostat housing 2. Gasket 3. Rubber ring

4. Thermostat 5. Water inlet 6. Clamp
H
7. Radiator hose (upper)
A. To radiator
Engine front
I
: N·m (kg-m, ft-lb)

: Always replace after every disassembly. J
K
REMOVAL
CAUTION: L
Perform this step when engine is cold.
2. Remove intake manifold. Refer to EM-27, "Exploded View".
3. Disconnect radiator hose (lower) (RH) from water inlet. Refer to CO-14, "Exploded View". M
4. Remove water inlet and thermostat.
• Engine coolant leakage from cylinder block, so have a receptacle ready below.
Thermostat housing N
1. Drain engine coolant. Refer to CO-8, "Draining".

2. Remove alterator. Refer to CHG-22, "Exploded View".
O
3. Remove water pump. Refer to CO-19, "Exploded View".
4. Disconnect water hose, and them remove thermostat housing.
INSTALLATION P
Thermostat

THERMOSTAT
• Install thermostat with making rubber ring (1) groove fit to thermo-
stat flange (A) with the whole circumference.
JPBIA4456ZZ
• Install thermostat (2) with jiggle valve (A) facing upwards.
1 : Thermostat housing
JPBIA4457ZZ
Thermostat housing
• Install in the reverse order of 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.
Standard: Refer to CO-26, "Thermostat".

• If out of the standard, replace thermostat. PBIC3314J


WATER OUTLET
WATER OUTLET
A
CO
J
JPBIA4340GB
1. Heater pipe bracket 2. Radiator cap 3. Water outlet adaptor K

4. Clamp 5. Water outlet hose 6. Clamp
7. Hose 8. Clamp 9. Water outlet
10. Clamp 11. Heater hose 12. Clamp L
13. Heater hose 14. Hose 15. Clamp
16. Engine coolant temperature sensor 17. Gasket 18. Rubber ring
19. Water control value 20. Gasket M
Engine front
A. For CVT models B. To reservoir tank C. To electric throttle control actuator
N
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) O

Removal and Installation INFOID:0000000007580011 P
REMOVAL
CAUTION:
• Perform this step when engine is cold.
2. Remove engine cover. Refer to EM-24, "Exploded View".

WATER OUTLET
3. Remove battery. PG-95, "Exploded View".
4. Remove air duct (upper) and air cleaner cover assembly and air cleaner body assembly.
5. Disconnect radiator hose (upper). Refer to CO-14, "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)
1 : Engine harness
JPBIA4454ZZ
9. Disconnect crankshaft position sensor harness connector.

10. Move engine harness, and keep a service area.
11. Remove water hose of each water outlet connection and heater hose.
12. Remove water outlet.
13. Remove engine coolant temperature sensor from water outlet, if necessary.
INSTALLATION
Water Control valve
• Install water control valve with making rubber ring (1) groove fit to
water control valve flange (A) with the whole circumference.
JPBIA4458ZZ
• Install water control valve (2) with the arrow (A) facing up and the
frame center part (B) facing upwards.
1 : Water outlet
JPBIA4373ZZ

Water Control Valve

WATER OUTLET
• Place a thread (A) so that it is caught in the valves of water control
valve (1). Immerse fully in a container (B) filled with water. Heat A
while stirring.
• The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
CO
• Continue heating. Check the continuous valve lifting toward maxi-
mum valve lift.
NOTE:
The maximum valve lift amount standard temperature for water C
control valve is the reference value.
• After checking the maximum valve lift amount, lower the water
PBIC3314J
temperature and check the valve closing temperature. D
Standard: Refer to CO-26, "Water Control Valve".
• If out of the standard, replace water control valve. E
radiator cap tester (commercial service tool). Refer to CO-8, "Inspection". F

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [MR16DDT ]

Periodical Maintenance Specification INFOID:0000000007580013
ENGINE COOLANT CAPACITY (APPROXIMATE)

Unit: (US qt, Imp qt)
M/T models 7.9 (8- 3/8, 7)
Engine coolant capacity (With reservoir tank at “MAX” level)
CVT models 8.1 (8- 1/2, 7-1/8)
Reservoir tank engine coolant capacity (At “MAX” level) 0.6 (5/8, 1/2)
Radiator INFOID:0000000007580014
Unit: kPa (kg/cm2, psi)
Standard 78 - 98 (0.8 - 1.0, 11 - 14)

Cap relief pressure
Limit 59 (0.6, 9)
Leakage testing pressure 98 (1.0, 14)
Thermostat INFOID:0000000007580015
Standard
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)

Maximum valve lift 8.0 mm/95°C (0.315 in/203°F)
Valve closing temperature 77°C (171°F)
Water Control Valve INFOID:0000000007580016
Standard
Valve opening temperature 93.5 - 96.5°C (200 - 206°F)

Maximum valve lift 8.0 mm/108°C (0.315 in/226°F)
Valve closing temperature 90°C (194°F)

Engine Cooling System: Section

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Engine Cooling System: Section

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ENGINE

ENGINE COOLING SYSTEM

PRECAUTION ............................................... 2 RADIATOR ........................................................ 14

Revision: 2011 October CO-1 2012 JUKE

Revision: 2011 October CO-2 2012 JUKE

Tool name Description

Revision: 2011 October CO-3 2012 JUKE

Revision: 2011 October CO-4 2012 JUKE

Revision: 2011 October CO-5 2012 JUKE

Symptom Check items

Cooling sys- Improper engine coolant

Revision: 2011 October CO-6 2012 JUKE

Revision: 2011 October CO-7 2012 JUKE

Testing pressure: Refer to CO-26, "Radiator".

Revision: 2011 October CO-8 2012 JUKE

• Enhance heater hose as high as possible.

Revision: 2011 October CO-9 2012 JUKE

Engine coolant capacity

Reservoir tank engine coolant capacity

8. Install air duct (suction side). Refer to EM-25, "Exploded View".

1. Install radiator drain plug.

Radiator drain plug : Refer to CO-14, "Exploded View".

Revision: 2011 October CO-10 2012 JUKE

• Enhance heater as high as possible.

Revision: 2011 October CO-11 2012 JUKE

• Check valve seat (A) of radiator cap.

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

• Check radiator cap relief pressure.

Standard and Limit : Refer to CO-26, "Radiator".

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

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

Revision: 2011 October CO-12 2012 JUKE

Revision: 2011 October CO-13 2012 JUKE

REMOVAL AND INSTALLATION

1. Cooling fan assembly 2. Mounting rubber (upper) 3. Radiator

: N·m (kg-m, in-lb)

Removal and Installation INFOID:0000000007579998

Revision: 2011 October CO-14 2012 JUKE

Radiator hose Hose end Paint mark Position of hose clamp* P

Revision: 2011 October CO-15 2012 JUKE

Dimension “A” 3 mm (0.12 in)

INSPECTION AFTER INSTALLATION

Revision: 2011 October CO-16 2012 JUKE

1. Fan motor 2. Fan shroud 3. Cooling fan

: N·m (kg-m, in-lb)

Removal and Installation INFOID:0000000007580001

Revision: 2011 October CO-17 2012 JUKE

INSPECTION AFTER DISASSEMBLY

Revision: 2011 October CO-18 2012 JUKE

1. Gasket 2. Water pump

INSPECTION AFTER REMOVAL

Revision: 2011 October CO-19 2012 JUKE

INSPECTION AFTER INSTALLATION

Revision: 2011 October CO-20 2012 JUKE

1. Thermostat housing 2. Gasket 3. Rubber ring

: N·m (kg-m, ft-lb)

Removal and Installation INFOID:0000000007580008

1. Drain engine coolant. Refer to CO-8, "Draining".

Revision: 2011 October CO-21 2012 JUKE