Juke F15 (2012 year). Service Repair Manual — part 72

Remove front combination lamp (LH and RH). Refer to

Remove front fender assembly (LH and RH). Refer to

Loosen hood hinge mounting bolts.

Temporarily install front fender assembly (LH and RH), front combination lamp (LH and RH) and front
bumper fascia.

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).

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

13. Install front combination lamp (LH and RH). Refer to

14. Install front bumper fascia. Refer to

EXT-18, "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

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

Clearance

2.0 – 6.0 (0.079 – 0.236)

< 2.5 (0.098)

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

Clearance

2.5 – 4.5 (0.098 – 0.177)

< 1.5 (0.059)

Surface height

(-2.0) – (0.0) [(-0.079) – (0.000)]

< 1.5 (0.059)

DLK-146

< REMOVAL AND INSTALLATION >

[TYPE 1]

HOOD

HOOD SUPPORT ROD : Removal and Installation

INFOID:0000000006521142

REMOVAL

CAUTION:

Two workers are required to support the hood.

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.

Pull hood support rod from grommet and remove.

INSTALLATION

Install in the reverse order of removal.

RADIATOR CORE SUPPORT

DLK-147

< REMOVAL AND INSTALLATION >

[TYPE 1]

DLK

RADIATOR CORE SUPPORT

HR16DE

HR16DE : Exploded View

INFOID:0000000006521143

HR16DE : Removal and Installation

INFOID:0000000006521144

RADIATOR CORE SUPPORT UPPER

Removal

Remove front bumper fascia. Refer to

Remove front combination lamp (LH and RH). Refer to

EXL-89, "Removal and Installation"

Remove headlamp (LH and RH). Refer to

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.

Remove hood lock and hood lock cable fixing clip. Refer to

DLK-172, "HOOD LOCK : Removal and Instal-

lation"

Remove horn bracket. Refer to

HRN-4, "Removal and Installation"

Remove air guide (upper) fixing clips, and then remove air guide (upper).

Radiator core support upper

Air guide RH (MT models)

Radiator core support lower

Air guide LH

Air guide (upper)

Air guide LH (CVT models)

Air guide RH (CVT models)

: N·m (kg-m, ft-lb)

JMKIA6021GB

DLK-148

< REMOVAL AND INSTALLATION >

[TYPE 1]

RADIATOR CORE SUPPORT

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

Remove hood support rod. Refer to

DLK-146, "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

Remove front bumper fascia. Refer to

Remove lower fixing clips (2) of radiator side seal (LH and RH)
(1).

Use belts (A) to suspend radiator and condenser to prevent
them from falling.

CAUTION:

Never damage radiator and condenser.

Remove mounting bolts, and then remove radiator core support lower.

Installation

Install in the reverse order of removal.

MR16DDT

JMKIA5628ZZ

JMKIA5629ZZ

JMKIA5630ZZ

RADIATOR CORE SUPPORT

DLK-149

< REMOVAL AND INSTALLATION >

[TYPE 1]

DLK

MR16DDT : Exploded View

INFOID:0000000006521145

MR16DDT : Removal and Installation

INFOID:0000000006521146

RADIATOR CORE SUPPORT UPPER

Removal

Remove front bumper fascia. Refer to

Remove front combination lamp (LH and RH). Refer to

EXL-89, "Removal and Installation"

Remove headlamp (LH and RH). Refer to

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.

Remove hood lock and hood lock cable fixing clip. Refer to

DLK-172, "HOOD LOCK : Removal and Instal-

lation"

Remove horn bracket. Refer to

HRN-4, "Removal and Installation"

Radiator core support upper

Air guide RH

Radiator core support lower

Air guide LH

: 2WD models

: 4WD models

: N·m (kg-m, ft-lb)

JMKIA6022GB

DLK-150

< REMOVAL AND INSTALLATION >

[TYPE 1]

RADIATOR CORE SUPPORT

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

Remove hood support rod. Refer to

DLK-146, "HOOD SUPPORT ROD : Removal and Installation"

Remove mounting bolts, and then remove radiator core support upper.

Installation

Install in the reverse order of removal.

RADIATOR CORE SUPPORT LOWER

Removal

Remove front bumper fascia. Refer to

EXT-26, "FRONT FILLET MOLDING : Removal and Installation"

Remove lower fixing clips (2) of radiator side seal (LH and RH)
(1).

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.

Support lower side radiator using wooden blocks (B) and a floor
jack (A).

CAUTION:

Never damage radiator.

Remove mounting bolts, and then remove radiator core support lower.

Installation

JMKIA6023ZZ

JMKIA6024ZZ

JMKIA6025ZZ

JMKIA6026ZZ

RADIATOR CORE SUPPORT

DLK-151

< REMOVAL AND INSTALLATION >

[TYPE 1]

DLK

Install in the reverse order of removal.

DLK-152

< REMOVAL AND INSTALLATION >

[TYPE 1]

FRONT FENDER

FRONT FENDER

Exploded View

INFOID:0000000006521147

Removal and Installation

INFOID:0000000006521148

REMOVAL

Remove front fillet molding. Refer to

Remove front bumper fascia assembly. Refer to

EXT-23, "Removal and Installation"

Remove sill cover. Refer to

Remove fender protector. Refer to

EXT-22, "Removal and Installation"

Remove front fender cover. Refer to

EXT-20, "Exploded View"

Remove front combination lamp. Refer to

EXL-98, "Removal and Installation"

Remove side turn signal lamp. Refer to

Remove mounting bolts of front fender assembly.

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.

Front fender assembly

Front fender stiffener

: Vehicle front

JMKIA5632ZZ

: Vehicle front

JMKIA5633ZZ

FRONT FENDER

DLK-153

< REMOVAL AND INSTALLATION >

[TYPE 1]

DLK

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-142, "HOOD ASSEMBLY : Adjustment"

- Front door: Refer to

DLK-156, "DOOR ASSEMBLY : Adjustment"

DLK-154

< REMOVAL AND INSTALLATION >

[TYPE 1]

FRONT DOOR

FRONT DOOR

Exploded View

INFOID:0000000006521149

DOOR ASSEMBLY

DOOR ASSEMBLY : Removal and Installation

INFOID:0000000006521150

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

Front door panel

Grommet

Door hinge (upper)

Door hinge (lower)

Door check link

Bumper rubber

Door pad

Door striker

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-155

< REMOVAL AND INSTALLATION >

[TYPE 1]

DLK

Disconnect front door harness connector.

Remove mounting bolt of door check link on the vehicle.

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-156, "DOOR ASSEMBLY : Adjust-

ment"

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

JMKIA5639ZZ

DLK-156

< REMOVAL AND INSTALLATION >

[TYPE 1]

FRONT DOOR

DOOR ASSEMBLY : Adjustment

INFOID:0000000006521151

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

Remove front fender. Refer to

Loosen door hinge mounting nuts on door side.

Front fender

Front door

Rear door

Body side outer

Door striker

TORX bolt

Front door hinge

Rear door hinge (upper)

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-157

< REMOVAL AND INSTALLATION >

[TYPE 1]

DLK

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

Temporarily tighten door hinge mounting nuts on door side.

Loosen door hinge mounting bolts on body side.

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

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.

Install front fender. Refer to refer to

DLK-156, "DOOR ASSEMBLY :

DOOR STRIKER ADJUSTMENT

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

DOOR STRIKER

DOOR STRIKER : Removal and Installation

INFOID:0000000006521152

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

Adjustment"

DOOR HINGE

DOOR HINGE : Removal and Installation

INFOID:0000000006521153

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.

Remove front fender. Refer to