Juke F15 (2012 year). Service Repair Manual — part 91

DLK-448

< REMOVAL AND INSTALLATION >

[TYPE 3]

RADIATOR CORE SUPPORT

7.

Remove upper fixing clips (2) of air guide (LH and RH) (1).

8.

Remove hood support rod. Refer to

DLK-444, "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

RADIATOR CORE SUPPORT

DLK-449

< REMOVAL AND INSTALLATION >

[TYPE 3]

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Install in the reverse order of removal.

DLK-450

< REMOVAL AND INSTALLATION >

[TYPE 3]

FRONT FENDER

FRONT FENDER

Exploded View

INFOID:0000000006600583

Removal and Installation

INFOID:0000000006600584

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

EXT-20, "Exploded View"

.

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

FRONT FENDER

DLK-451

< REMOVAL AND INSTALLATION >

[TYPE 3]

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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-440, "HOOD ASSEMBLY : Adjustment"

.

- Front door: Refer to

DLK-454, "DOOR ASSEMBLY : Adjustment"

.

DLK-452

< REMOVAL AND INSTALLATION >

[TYPE 3]

FRONT DOOR

FRONT DOOR

Exploded View

INFOID:0000000006600585

DOOR ASSEMBLY

DOOR ASSEMBLY : Removal and Installation

INFOID:0000000006600586

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.

Door hinge (upper)

4.

Door hinge (lower)

5.

Door check link

6.

Bumper rubber

7.

Door pad

8.

Door striker

9.

TORX bolt

10. Grommet

: Do not reuse

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Body grease

JMKIA5637GB

FRONT DOOR

DLK-453

< REMOVAL AND INSTALLATION >

[TYPE 3]

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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-454, "DOOR ASSEMBLY : Adjust-

ment"

.

• After installation, apply touch-up paint (the body color) onto the head of door hinge mounting nuts.

JMKIA5639ZZ

DLK-454

< REMOVAL AND INSTALLATION >

[TYPE 3]

FRONT DOOR

DOOR ASSEMBLY : Adjustment

INFOID:0000000006600587

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-450, "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

FRONT DOOR

DLK-455

< REMOVAL AND INSTALLATION >

[TYPE 3]

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3.

Adjust the surface height of front door according to the fitting standard dimension.

4.

Temporarily tighten door hinge mounting nuts on door side.

5.

Loosen door hinge mounting bolts on body side.

6.

Raise front door at rear end to adjust clearance of the front door according to the fitting standard dimen-
sion.

7.

After adjustment tighten bolts and nuts to the specified torque.

CAUTION:

• After installation, apply touch-up paint (the body color) onto the head of hinge mounting bolts

and nuts.

• Check door hinge rotating part for poor lubrication. If necessary, apply body grease.

8.

Install front fender. Refer to refer to

DLK-450, "Removal and Installation"

.

DOOR STRIKER ADJUSTMENT

Adjust door striker so that it becomes parallel with door lock insertion direction.

DOOR STRIKER

DOOR STRIKER : Removal and Installation

INFOID:0000000006600588

REMOVAL

Remove TORX bolts, and then remove door striker.

INSTALLATION

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

CAUTION:

• Check front door open/close, lock/unlock operation after installation.
• After installation, be sure to perform the fitting adjustment. Refer to

DLK-454, "DOOR ASSEMBLY :

Adjustment"

.

DOOR HINGE

DOOR HINGE : Removal and Installation

INFOID:0000000006600589

REMOVAL

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.

1.

Remove front fender. Refer to

DLK-450, "Removal and Installation"

.

2.

Remove front door assembly. Refer to

DLK-452, "DOOR ASSEMBLY : Removal and Installation"

.

3.

Remove front door hinge mounting bolts (body side), and then remove front door hinge.

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.
• After installation, perform the fitting adjustment. Refer to

DLK-454, "DOOR ASSEMBLY : Adjust-

ment"

.

• After installation, apply touch-up paint (the body color) onto the head of door hinge mounting nuts.

DLK-456

< REMOVAL AND INSTALLATION >

[TYPE 3]

FRONT DOOR

• Check door hinge rotating part for poor lubrication. If neces-

sary, apply body grease.

DOOR CHECK LINK

DOOR CHECK LINK : Removal and Installation

INFOID:0000000006600590

REMOVAL

1.

Fully close the front door window.

2.

Remove front door finisher. Refer to

INT-13, "Removal and Installation"

.

3.

Disconnect harness connector of front door speaker.

4.

Remove mounting bolts of front door speaker, and then remove front door speaker.

5.

Remove mounting bolt of door check link on the vehicle.

6.

Remove mounting bolts of door check link on door panel.

7.

Take door check link (1) out from the hole of door panel (2).

INSTALLATION

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

CAUTION:

• Check front door open/close operation after installation.
• Check door check link rotating part for poor lubrication. If

necessary, apply grease.

: Grease up point

JMKIA5641ZZ

JMKIA5640ZZ

: Grease up point

JMKIA5642ZZ

REAR DOOR

DLK-457

< REMOVAL AND INSTALLATION >

[TYPE 3]

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REAR DOOR

Exploded View

INFOID:0000000006600591

DOOR ASSEMBLY

DOOR ASSEMBLY : Removal and Installation

INFOID:0000000006600592

CAUTION:

• Perform work with 2 workers, because of it’s heavy weight.
• When removing and installing rear door assembly, support door with a jack and shop cloth to pro-

tect door and body.

REMOVAL

1.

Rear door panel

2.

Door hinge (upper)

3.

Door hinge (lower)

4.

Door check link

5.

Door striker

6.

TORX bolt

: Do not reuse

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Body grease

JMKIA5644GB

DLK-458

< REMOVAL AND INSTALLATION >

[TYPE 3]

REAR DOOR

1.

Remove rear door harness grommet (2) from body side outer
(1), and then pull out rear door harness.

2.

Disconnect rear door harness connector.

3.

Remove mounting bolt of door check link on the vehicle.

4.

Remove door hinge mounting bolts (door side), and then remove rear door assembly.

INSTALLATION

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

CAUTION:

• Apply anticorrosive agent onto the mounting surface.
• Check rear 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-459, "DOOR ASSEMBLY : Adjust-

ment"

.

• After installation, apply touch-up paint (the body color) onto the head of door hinge mounting nuts.

JMKIA5645ZZ

JMKIA5646ZZ

REAR DOOR

DLK-459

< REMOVAL AND INSTALLATION >

[TYPE 3]

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DOOR ASSEMBLY : Adjustment

INFOID:0000000006600593

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 center pillar lower garnish. Refer to

INT-20, "CENTER PILLAR LOWER GARNISH : Removal

and Installation"

.

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 door – Rear door

B – B

3.3 – 5.3 (0.130 – 0.209)

(-1.0) – (+1.0) [(-0.039) – (+0.039)]

Rear door – Body side outer

C – C

2.6 – 4.6 (0.102 – 0.181)

(-1.0) – (+1.0) [(-0.039) – (+0.039)]

JMKIA5638GB

DLK-460

< REMOVAL AND INSTALLATION >

[TYPE 3]

REAR DOOR

2.

Loosen door hinge mounting nuts on door side.

3.

Adjust the surface height of rear door according to the fitting standard dimension.

4.

Temporarily tighten door hinge mounting nuts on door side.

5.

Loosen door hinge mounting nuts and bolts on body side.

6.

Raise rear door at rear end to adjust clearance of rear door according to the fitting standard dimension.

7.

After adjustment tighten bolts and nuts to the specified torque.

CAUTION:

• After installation, apply touch-up paint (the body color) onto the head of hinge mounting bolts

and nuts.

• Check door hinge rotating part for poor lubrication. If necessary, apply body grease.

8.

Install center pillar lower garnish. Refer to

INT-20, "CENTER PILLAR LOWER GARNISH : Removal and

Installation"

.

DOOR STRIKER ADJUSTMENT

Adjust door striker so that it becomes parallel with door lock insertion direction.

DOOR STRIKER

DOOR STRIKER : Removal and Installation

INFOID:0000000006600594

REMOVAL

Remove TORX bolts, and then remove door striker.

INSTALLATION

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

CAUTION:

• Check rear door open/close, lock/unlock operation after installation.
• After installation, be sure to perform the fitting adjustment. Refer to

DLK-459, "DOOR ASSEMBLY :

Adjustment"

.

DOOR HINGE

DOOR HINGE : Removal and Installation

INFOID:0000000006600595

CAUTION:

• Perform work with 2 workers, because of it’s heavy weight.
• When removing and installing rear door assembly, support door with a jack and shop cloth to pro-

tect door and body.

REMOVAL

1.

Remove rear door assembly. Refer to

DLK-457, "DOOR ASSEMBLY : Removal and Installation"

.

2.

Remove center pillar lower garnish. Refer to

INT-20, "CENTER PILLAR LOWER GARNISH : Removal

and Installation"

.

3.

Remove rear door hinge mounting bolts and nuts (body side), and then remove door hinge.

INSTALLATION

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

CAUTION:

• Apply anticorrosive agent onto the mounting surface.
• Check rear door open/close operation after installation.
• When removing and installing rear door assembly, perform the fitting adjustment. Refer to

DLK-459,

"DOOR ASSEMBLY : Adjustment"

.

• After installing, apply the touch-up paint (the body color) onto the head of door hinge mounting nuts.

REAR DOOR

DLK-461

< REMOVAL AND INSTALLATION >

[TYPE 3]

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• Check door hinge rotating part for poor lubrication. If neces-

sary, apply body grease.

DOOR CHECK LINK

DOOR CHECK LINK : Removal and Installation

INFOID:0000000006600596

REMOVAL

1.

Fully close the rear door window.

2.

Remove rear door finisher. Refer to

INT-16, "Removal and Installation"

.

3.

Remove mounting bolts of rear door speaker, and then remove rear door speaker.

4.

Disconnect harness connector of rear door speaker.

5.

Remove mounting bolt of the check link on the vehicle.

6.

Remove mounting bolts of the check link on door panel.

7.

Take door check link (1) out from the hole of door panel (2).

INSTALLATION

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

CAUTION:

• Check rear door open/close operation after installation.
• Check door check link rotating part for poor lubrication. If

necessary, apply grease.

: Grease up point

JMKIA5641ZZ

JMKIA5640ZZ

: Grease up point

JMKIA5642ZZ

DLK-462

< REMOVAL AND INSTALLATION >

[TYPE 3]

BACK DOOR

BACK DOOR

Exploded View

INFOID:0000000006600597

REMOVAL

BACK DOOR ASSEMBLY

BACK DOOR ASSEMBLY : Removal and Installation

INFOID:0000000006600598

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.

Remove luggage side upper finisher (LH and RH). Refer to

INT-32, "LUGGAGE SIDE UPPER FINISHER

: Removal and Installation"

.

1.

Back door weather-strip

2.

Back door stay

3.

Back door stay lower bracket

4.

Bumper rubber

5.

Back door striker

6.

Back door panel

7.

Back door hinge

8.

Hole cover

A

: Center mark

B

: Seam

: Do not reuse

: Body grease

JMKIA5652ZZ

BACK DOOR

DLK-463

< REMOVAL AND INSTALLATION >

[TYPE 3]

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2.

Disconnect harness connector.

3.

Remove rear washer hose (1) from hose mounting clip (A), and
then disengage hose.

4.

Remove center pillar upper garnish. Refer to

INT-21, "CENTER PILLAR UPPER GARNISH : Removal

and Installation"

.

5.

Remove upper side of back door weather-strip. Refer to

DLK-468, "BACK DOOR WEATHER-STRIP :

Removal and Installation"

.

6.

Remove rear assist grip (LH and RH) and mounting clips for rear portion of headlining, and then remove
rear portion of headlining. Refer to

INT-26, "Exploded View"

.

7.

Remove ground harness mounting bolt (A) and harness fixing
clip (B).

8.

Remove grommet (1), and then pull out harness from roof panel
(2).

: Vehicle front

JMKIA5653ZZ

: Vehicle front

JMKIA5654ZZ

: Vehicle front

JMKIA5655ZZ

JMKIA5657ZZ