Juke F15 (2012 year). Service Repair Manual — part 82
DLK-304
< REMOVAL AND INSTALLATION >
[TYPE 2]
HOOD
REMOVAL AND INSTALLATION
HOOD
Exploded View
INFOID:0000000006600518
HOOD ASSEMBLY
HOOD ASSEMBLY : Removal and Installation
INFOID:0000000006600519
CAUTION:
• Operate with two workers, because of its heavy weight.
• Use protective tape or shop cloth to protect from damage during removal and installation.
REMOVAL
1.
Support hood assembly with the proper material to prevent it from falling.
WARNING:
Injury may occur if hood assembly is not supported by the proper material when removing hood
assembly.
2.
Remove hood hinge mounting nuts on the hood to remove the hood assembly.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
1.
Hood assembly
2.
Hood bumper rubber
3.
Radiator core seal
4.
Hood bumper rubber
5.
Clamp
6.
Hood hinge
7.
Grommet
8.
Hood support rod
: Clip
: Pawl
: Body grease
JMKIA5625ZZ
HOOD
DLK-305
< REMOVAL AND INSTALLATION >
[TYPE 2]
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• After installation, apply touch-up paint (the body color) onto the heads of hood hinge mounting bolts
and nuts.
• After installing, perform hood fitting adjustment. Refer to
DLK-305, "HOOD ASSEMBLY : Adjust-
HOOD ASSEMBLY : Adjustment
INFOID:0000000006600520
Check the clearance and the surface height between hood and each part by visually and touching.
If the clearance and the surface height are out of specification, adjust them according to the procedures
shown below.
1.
Hood assembly
2.
Hood bumper rubber
3.
Hood hinge
4.
Hood lock assembly
5.
Front bumper fascia
6.
Front combination lamp
7.
Front fender
: N·m (kg-m, ft-lb)
: Body grease
JMKIA5626GB
DLK-306
< REMOVAL AND INSTALLATION >
[TYPE 2]
HOOD
Unit: mm (in)
FITTING ADJUSTMENT PROCEDURE
1.
Remove front center grille. Refer to
EXT-18, "Removal and Installation"
2.
Remove hood lock assembly, and then adjust the surface height of hood assembly, front fender assembly,
and front combination lamp according to the specified value, by rotating hood bumper rubber.
3.
Position hood lock assembly and engage hood striker. Check hood lock assembly and hood striker for
looseness.
4.
Move hood lock assembly laterally until the center of hood striker and hood lock assembly are vertical
when viewed from the front.
5.
After adjustment, tighten lock bolts to the specified torque.
6.
Open hood. Rotate bumper rubber counterclockwise between half a turn and three-quarters of a turn.
7.
Check that secondary latch is securely engaged with secondary hood striker from the dead load of the
hood assembly.
8.
Check that primary latch is securely engaged with primary hood striker when hood assembly is closed
[free-fall from approximately 200 mm (7.874 in) height].
CAUTION:
Never free-fall hood assembly from a height of 300 (11.811 in) mm or more.
9.
Install front center grille. Refer to
EXT-18, "Removal and Installation"
HOOD HINGE
HOOD HINGE : Removal and Installation
INFOID:0000000006600521
REMOVAL
1.
Remove hood assembly. Refer to
DLK-304, "HOOD ASSEMBLY : Removal and Installation"
2.
Remove front fender. Refer to
DLK-315, "Removal and Installation"
3.
Remove hood hinge mounting bolts, and then remove hood hinge.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• After installation, perform hood hinge fitting adjustment. Refer to
DLK-307, "HOOD HINGE : Adjust-
• After installation, apply touch-up paint (the body color) onto the head of the hinge mounting bolts
and nuts.
Portion
Standard
Difference
(RH/LH,
MAX)
Hood – Front
bumper fascia
A – A
E
Clearance
2.0 – 6.0 (0.079 – 0.236)
< 2.5 (0.098)
F
Surface height
(-2.0) – (+2.0) [(-0.079) – (+0.079)]
< 2.5 (0.098)
Hood – Front combi-
nation lamp
B – B G
Clearance
2.0 – 6.0 (0.079 – 0.236)
< 2.5 (0.098)
Hood – Front combi-
nation lamp
C – C H
Clearance
2.0 – 6.0 (0.079 – 0.236)
< 2.5 (0.098)
Hood – Front fender
D – D
I
Clearance
2.5 – 4.5 (0.098 – 0.177)
< 1.5 (0.059)
J
Surface height
(-2.0) – (0.0) [(-0.079) – (0.000)]
< 1.5 (0.059)
HOOD
DLK-307
< REMOVAL AND INSTALLATION >
[TYPE 2]
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• Check hood hinge rotating part for poor lubrication. If neces-
sary, apply grease.
HOOD HINGE : Adjustment
INFOID:0000000006600522
Check the clearance and the surface height between hood and each part by visually and touching.
JMKIA5721ZZ
1.
Hood assembly
2.
Hood bumper rubber
3.
Hood hinge
4.
Hood lock assembly
5.
Front bumper fascia
6.
Front combination lamp
7.
Front fender
: N·m (kg-m, ft-lb)
: Body grease
JMKIA5626GB
DLK-308
< REMOVAL AND INSTALLATION >
[TYPE 2]
HOOD
If the clearance and the surface height are out of specification, adjust them according to the procedures
shown below.
Unit: mm (in)
1.
Remove front center grille. Refer to
EXT-18, "Removal and Installation"
2.
Remove hood lock assembly.
3.
Remove front bumper fascia. Refer to
EXT-13, "Removal and Installation"
.
4.
Remove front combination lamp (LH and RH). Refer to
EXL-91, "Removal and Installation"
.
5.
Remove front fender assembly (LH and RH). Refer to
DLK-315, "Removal and Installation"
6.
Loosen hood hinge mounting bolts.
7.
Temporarily install front fender assembly (LH and RH), front combination lamp (LH and RH) and front
bumper fascia.
8.
Adjust the clearance of hood assembly, front fender assembly (LH and RH), front combination lamp (LH
and RH) and front bumper fascia according to the specified value, by moving hood hinge (body side).
9.
Temporarily tighten hood hinge (LH and RH).
10. Remove front bumper fascia, front combination lamp (LH and RH) and front fender assembly (LH and
RH).
11. Tighten hood hinge (LH and RH) to the specified torque.
12. Install front fender assembly (LH and RH). Refer to
DLK-315, "Removal and Installation"
.
13. Install front combination lamp (LH and RH). Refer to
EXL-91, "Removal and Installation"
.
14. Install front bumper fascia. Refer to
EXT-13, "Removal and Installation"
.
15. Adjust the surface height of hood assembly, front fender assembly, and front combination lamp according
to the specified value, by rotating hood bumper rubber.
16. Position hood lock assembly and engage hood striker. Check hood lock assembly and hood striker for
looseness.
17. Move hood lock assembly laterally until the center of hood striker and hood lock assembly are vertical
when viewed from the front.
18. After adjustment, tighten lock bolts to the specified torque.
19. Open hood. Rotate bumper rubber counterclockwise between half a turn and three-quarters of a turn.
20. Check that secondary latch is securely engaged with secondary hood striker from the dead load of the
hood assembly.
21. Check that primary latch is securely engaged with primary hood striker when hood assembly is closed
[free-fall from approximately 200 mm (7.874 in) height].
CAUTION:
Never free-fall hood assembly from a height of 300 (11.811 in) mm or more.
22. Install front center grille. Refer to
EXT-18, "Removal and Installation"
CAUTION:
After installation, apply touch-up paint (the body color) onto the heads of hood hinge mounting
bolts and nuts.
HOOD SUPPORT ROD
Portion
Standard
Difference
(RH/LH,
MAX)
Hood – Front
bumper fascia
A – A
E
Clearance
2.0 – 6.0 (0.079 – 0.236)
< 2.5 (0.098)
F
Surface height
(-2.0) – (+2.0) [(-0.079) – (+0.079)]
< 2.5 (0.098)
Hood – Front combi-
nation lamp
B – B G
Clearance
2.0 – 6.0 (0.079 – 0.236)
< 2.5 (0.098)
Hood – Front combi-
nation lamp
C – C H
Clearance
2.0 – 6.0 (0.079 – 0.236)
< 2.5 (0.098)
Hood – Front fender
D – D
I
Clearance
2.5 – 4.5 (0.098 – 0.177)
< 1.5 (0.059)
J
Surface height
(-2.0) – (0.0) [(-0.079) – (0.000)]
< 1.5 (0.059)
HOOD
DLK-309
< REMOVAL AND INSTALLATION >
[TYPE 2]
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HOOD SUPPORT ROD : Removal and Installation
INFOID:0000000006600523
REMOVAL
CAUTION:
Two workers are required to support the hood.
1.
Support hood assembly with a suitable material to prevent it from falling.
WARNING:
Injury may occur if hood assembly is not supported by the proper material when removing hood
assembly.
2.
Pull hood support rod from grommet and remove.
INSTALLATION
Install in the reverse order of removal.
DLK-310
< REMOVAL AND INSTALLATION >
[TYPE 2]
RADIATOR CORE SUPPORT
RADIATOR CORE SUPPORT
HR16DE
HR16DE : Exploded View
INFOID:0000000006600524
HR16DE : Removal and Installation
INFOID:0000000006600525
RADIATOR CORE SUPPORT UPPER
Removal
1.
Remove front bumper fascia. Refer to
EXT-13, "Removal and Installation"
.
2.
Remove front combination lamp (LH and RH). Refer to
EXL-91, "Removal and Installation"
.
3.
Remove headlamp (LH and RH). Refer to
EXL-89, "Removal and Installation"
.
4.
Disconnect crash zone sensor harness connector. Refer to
SR-26, "Removal and Installation"
CAUTION:
Turn ignition switch OFF, disconnect battery negative terminal and then wait for at least 3 minutes.
5.
Remove hood lock and hood lock cable fixing clip. Refer to
DLK-335, "HOOD LOCK : Removal and Instal-
.
6.
Remove horn bracket. Refer to
HRN-4, "Removal and Installation"
7.
Remove air guide (upper) fixing clips, and then remove air guide (upper).
1.
Radiator core support upper
2.
Air guide RH (MT models)
3.
Radiator core support lower
4.
Air guide LH
5.
Air guide (upper)
6.
Air guide LH (CVT models)
7.
Air guide RH (CVT models)
: N·m (kg-m, ft-lb)
JMKIA6021GB
RADIATOR CORE SUPPORT
DLK-311
< REMOVAL AND INSTALLATION >
[TYPE 2]
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8.
Remove upper fixing clips (2) of air guide (LH and RH) (1).
9.
Remove hood support rod. Refer to
DLK-309, "HOOD SUPPORT ROD : Removal and Installation"
.
10. Remove mounting bolts, and then remove radiator core support upper.
Installation
Install in the reverse order of removal.
RADIATOR CORE SUPPORT LOWER
Removal
1.
Remove front bumper fascia. Refer to
EXT-13, "Removal and Installation"
.
2.
Remove lower fixing clips (2) of radiator side seal (LH and RH)
(1).
3.
Use belts (A) to suspend radiator and condenser to prevent
them from falling.
CAUTION:
Never damage radiator and condenser.
4.
Remove mounting bolts, and then remove radiator core support lower.
Installation
Install in the reverse order of removal.
MR16DDT
JMKIA5628ZZ
JMKIA5629ZZ
JMKIA5630ZZ
DLK-312
< REMOVAL AND INSTALLATION >
[TYPE 2]
RADIATOR CORE SUPPORT
MR16DDT : Exploded View
INFOID:0000000006600526
MR16DDT : Removal and Installation
INFOID:0000000006600527
RADIATOR CORE SUPPORT UPPER
Removal
1.
Remove front bumper fascia. Refer to
EXT-13, "Removal and Installation"
.
2.
Remove front combination lamp (LH and RH). Refer to
EXL-91, "Removal and Installation"
.
3.
Remove headlamp (LH and RH). Refer to
EXL-89, "Removal and Installation"
.
4.
Disconnect crash zone sensor harness connector. Refer to
SR-26, "Removal and Installation"
CAUTION:
Turn ignition switch OFF, disconnect battery negative terminal and then wait for at least 3 minutes.
5.
Remove hood lock and hood lock cable fixing clip. Refer to
DLK-335, "HOOD LOCK : Removal and Instal-
.
6.
Remove horn bracket. Refer to
HRN-4, "Removal and Installation"
1.
Radiator core support upper
2.
Air guide RH
3.
Radiator core support lower
4.
Air guide LH
A
: 2WD models
B
: 4WD models
: N·m (kg-m, ft-lb)
JMKIA6022GB
RADIATOR CORE SUPPORT
DLK-313
< REMOVAL AND INSTALLATION >
[TYPE 2]
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D
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7.
Remove upper fixing clips (2) of air guide (LH and RH) (1).
8.
Remove hood support rod. Refer to
DLK-309, "HOOD SUPPORT ROD : Removal and Installation"
.
9.
Remove mounting bolts, and then remove radiator core support upper.
Installation
Install in the reverse order of removal.
RADIATOR CORE SUPPORT LOWER
Removal
1.
Remove front bumper fascia. Refer to
EXT-13, "Removal and Installation"
.
2.
Remove lower fixing clips (2) of radiator side seal (LH and RH)
(1).
3.
Using strings (A), hang inlet hose (1) and inlet hose (2) together
with charge air cooler.
CAUTION:
Never damage inlet hoses with charge air cooler.
4.
Support lower side radiator using wooden blocks (B) and a floor
jack (A).
CAUTION:
Never damage radiator.
5.
Remove mounting bolts, and then remove radiator core support lower.
Installation
JMKIA6023ZZ
JMKIA6024ZZ
JMKIA6025ZZ
JMKIA6026ZZ
DLK-314
< REMOVAL AND INSTALLATION >
[TYPE 2]
RADIATOR CORE SUPPORT
Install in the reverse order of removal.
FRONT FENDER
DLK-315
< REMOVAL AND INSTALLATION >
[TYPE 2]
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FRONT FENDER
Exploded View
INFOID:0000000006600528
Removal and Installation
INFOID:0000000006600529
REMOVAL
1.
Remove front fillet molding. Refer to
EXT-26, "FRONT FILLET MOLDING : Removal and Installation"
.
2.
Remove front bumper fascia assembly. Refer to
EXT-13, "Removal and Installation"
.
3.
Remove sill cover. Refer to
EXT-23, "Removal and Installation"
4.
Remove fender protector. Refer to
EXT-22, "Removal and Installation"
5.
Remove front fender cover. Refer to
6.
Remove front combination lamp. Refer to
EXL-91, "Removal and Installation"
.
7.
Remove side turn signal lamp. Refer to
EXL-98, "Removal and Installation"
8.
Remove mounting bolts of front fender assembly.
9.
Remove front fender stiffener (2) from the vehicle body while
carefully pulling upper portion of front fender (1) toward vehicle
outside.
10. Remove front fender assembly.
CAUTION:
An viscous urethane foam is installed on the back surface of front fender. When removing the
front fender, be careful to not deform the front fender while performing the procedure and remov-
ing the viscous urethane foam a little at a time.
INSTALLATION
Note the following items, and install in the reverse order of removal.
1.
Front fender assembly
2.
Front fender stiffener
: Vehicle front
JMKIA5632ZZ
: Vehicle front
JMKIA5633ZZ
DLK-316
< REMOVAL AND INSTALLATION >
[TYPE 2]
FRONT FENDER
CAUTION:
• After installation, apply the touch-up paint (the body color) onto the head of front fender mounting
bolts.
• After installation, adjust the following part.
- Hood assembly: Refer to
DLK-305, "HOOD ASSEMBLY : Adjustment"
.
- Front door: Refer to
FRONT DOOR
DLK-317
< REMOVAL AND INSTALLATION >
[TYPE 2]
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FRONT DOOR
Exploded View
INFOID:0000000006600530
DOOR ASSEMBLY
DOOR ASSEMBLY : Removal and Installation
INFOID:0000000006600531
CAUTION:
• Perform work with 2 workers, because of its heavy weight.
• When removing and installing front door assembly, support door with a jack and shop cloth to pro-
tect door and body.
REMOVAL
1.
Front door panel
2.
Grommet
3.
TORX bolt
4.
Door striker
5.
Door pad
6.
Bumper rubber
7.
Door check link
8.
Door hinge (lower)
9.
Door hinge (upper)
10. Grommet
: Do not reuse
: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
: Body grease
JMKIA5877GB
DLK-318
< REMOVAL AND INSTALLATION >
[TYPE 2]
FRONT DOOR
1.
Disconnect front door harness connector.
2.
Remove mounting bolt of door check link on the vehicle.
3.
Remove door hinge mounting bolts (door side), and then remove door assembly.
INSTALLATION
Note the following items, and install in the reverse order of removal.
CAUTION:
• Apply anticorrosive agent onto the mounting surface.
• Check front door open/close, lock/unlock operation after installation.
• Check door hinge rotating part for poor lubrication. If necessary, apply body grease.
• After installation, perform the fitting adjustment. Refer to
DLK-319, "DOOR ASSEMBLY : Adjust-
• After installation, apply touch-up paint (the body color) onto the head of door hinge mounting nuts.
JMKIA5878ZZ
FRONT DOOR
DLK-319
< REMOVAL AND INSTALLATION >
[TYPE 2]
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DOOR ASSEMBLY : Adjustment
INFOID:0000000006600532
Check the clearance and surface height between front door and each part by visually and touching.
If the clearance and the surface height are out of specification, adjust them according to the procedures
shown below.
Unit: mm (in)
FITTING ADJUSTMENT PROCEDURE
1.
Remove front fender. Refer to
DLK-315, "Removal and Installation"
.
2.
Loosen door hinge mounting nuts on door side.
1.
Front fender
2.
Front door
3.
Rear door
4.
Body side outer
5.
Door striker
6.
TORX bolt
7.
Front door hinge
8.
Rear door hinge (upper)
9.
Rear door hinge (lower)
: Do not reuse
: N·m (kg-m, ft-lb)
: Body grease
Portion
Clearance
Surface height
Front fender – Front door
A – A
3.0 – 5.0 (0.118 – 0.197)
(-1.0) – (+1.0) [(-0.039) – (+0.039)]
Front door – Rear door
B – B
3.3 – 5.3 (0.130 – 0.209)
(-1.0) – (+1.0) [(-0.039) – (+0.039)]
JMKIA5638GB
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