Juke F15 (2012 year). Service Repair Manual — part 99

DLK-576

< REMOVAL AND INSTALLATION >

[TYPE 4]

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:0000000006600659

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-575, "DOOR ASSEMBLY :

Adjustment"

.

DOOR HINGE

DOOR HINGE : Removal and Installation

INFOID:0000000006600660

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-573, "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-575,

"DOOR ASSEMBLY : Adjustment"

.

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

REAR DOOR

DLK-577

< REMOVAL AND INSTALLATION >

[TYPE 4]

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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:0000000006628067

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

JMKIA5879ZZ

: Grease up point

JMKIA5642ZZ

DLK-578

< REMOVAL AND INSTALLATION >

[TYPE 4]

BACK DOOR

BACK DOOR

Exploded View

INFOID:0000000006600662

REMOVAL

BACK DOOR ASSEMBLY

BACK DOOR ASSEMBLY : Removal and Installation

INFOID:0000000006600663

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-579

< REMOVAL AND INSTALLATION >

[TYPE 4]

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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-584, "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

DLK-580

< REMOVAL AND INSTALLATION >

[TYPE 4]

BACK DOOR

9.

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

10. Support back door with the proper material to prevent it from falling.

WARNING:

Bodily injury may occur if no supporting rod is holding the back door open when removing the
back door stay.

11. Remove back door stay (back door side). Refer to

DLK-583, "BACK DOOR STAY : Removal and Installa-

tion"

.

12. Remove back door hinge mounting nuts on back door and remove back door assembly.

INSTALLATION

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

CAUTION:

• Check back door hinge rotating part for poor lubrication. If necessary, apply body grease.
• After installation, check back door open/close, lock/unlock operation.
• After installation, perform the fitting adjustment. Refer to

DLK-581, "BACK DOOR ASSEMBLY :

Adjustment"

.

JMKIA5658ZZ

BACK DOOR

DLK-581

< REMOVAL AND INSTALLATION >

[TYPE 4]

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BACK DOOR ASSEMBLY : Adjustment

INFOID:0000000006600664

Check the clearance and the surface height between back door and each part by seeing and touching.
If the clearance and the surface height are out of specification, adjust them according to the procedures
shown below.

Unit: mm (in)

1.

Back door assembly

2.

Bumper rubber (upper)

3.

Bumper rubber (lower)

4.

Back door hinge

5.

Back door striker

6.

TORX bolt

7.

Roof panel

8.

Rear combination lamp

9.

Back door glass

10. Rear bumper fascia

: Do not reuse

: N·m (kg-m, ft-lb)

: Body grease

JMKIA5660GB

Portion

Standard

Difference

(LH/RH, MAX)

Roof panel – Back
door

A – A

D

Clearance

5.0 – 7.0 (0.197 – 0.276)

—

E

Surface height

0.9 – 2.9 (0.035 – 0.114)

—

DLK-582

< REMOVAL AND INSTALLATION >

[TYPE 4]

BACK DOOR

FITTING ADJUSTMENT PROCEDURE

1.

Loosen back door striker mounting bolts.

2.

Loosen back door hinge mounting nuts (back door side).

3.

Adjust back door using back door striker and back door hinge to the specified value, as shown in the fol-
lowing table.

4.

After adjustment tighten back door striker mounting bolts and back door hinge mounting nuts (back door
side) to the specified torque.

5.

Screw bumper rubber (upper) into the stopper position (A), and
then loosen by a half turn.

6.

Screw bumper rubber (lower) into the end position of threads.

CAUTION:

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

BACK DOOR STRIKER ADJUSTMENT

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

BACK DOOR STRIKER

BACK DOOR STRIKER : Removal and Installation

INFOID:0000000006600665

REMOVAL

1.

Remove luggage rear plate. Refer to

INT-30, "LUGGAGE REAR PLATE : Removal and Installation"

.

2.

Remove TORX bolts, and then remove back door striker.

INSTALLATION

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

CAUTION:

• After installation, check back door open/close, lock/unlock operation.
• After installation, perform the fitting adjustment. Refer to

DLK-581, "BACK DOOR ASSEMBLY :

Adjustment"

.

BACK DOOR HINGE

BACK DOOR HINGE : Removal and Installation

INFOID:0000000006600666

REMOVAL

1.

Remove back door assembly. Refer to

DLK-578, "BACK DOOR ASSEMBLY : Removal and Installation"

.

2.

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

INSTALLATION

Rear combination
lamp – Back door
glass

B – B

F

Clearance

2.8 – 7.2 (0.110 – 0.283)

<2.0 (0.079)

Rear bumper fas-
cia – Back door

C – C

G

Clearance

6.0 – 10.0 (0.236 – 0.394)

—

H

Surface height

(-2.5) – (+1.0) [(-0.098) – (+0.039)]

—

Portion

Standard

Difference

(LH/RH, MAX)

JMKIA5843ZZ

BACK DOOR

DLK-583

< REMOVAL AND INSTALLATION >

[TYPE 4]

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

CAUTION:

• After installation, check back door open/close, lock/unlock operation.
• After installation, perform the fitting adjustment. Refer to

DLK-581, "BACK DOOR ASSEMBLY :

Adjustment"

.

• Check back door hinge rotating part for poor lubrication. If

necessary, apply body grease.

BACK DOOR STAY

BACK DOOR STAY : Removal and Installation

INFOID:0000000006600667

REMOVAL

1.

Remove luggage side upper finisher and rear pillar cap. Refer to

INT-32, "LUGGAGE SIDE UPPER FIN-

ISHER : Removal and Installation"

.

2.

Support the back door with the suitable material to prevent it from falling.

WARNING:

Bodily injury may occur if no supporting rod is holding the back door open when removing the
back door stay.

3.

Remove back door stay mounting bolts (body side).

4.

Remove the metal clip (3) located on the connection between
the back door stay (1) and the stud ball (2) (back door side) by
using a flat-bladed screwdriver (A).

CAUTION:

Be careful not to damage painted surface.

5.

Remove back door stay (back door side).

6.

Remove mounting bolts, and then remove back door stay lower bracket.

INSTALLATION

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

CAUTION:

• Apply anticorrosive agent onto the mounting surface.
• After installation, check back door open/close, lock/unlock operation.

: Grease up point

JMKIA5659ZZ

JMKIA2255ZZ

DLK-584

< REMOVAL AND INSTALLATION >

[TYPE 4]

BACK DOOR

BACK DOOR STAY : Disposal

INFOID:0000000006600668

1.

Fix back door stay (1) using a vise (C).

2.

Using hacksaw (A) slowly make 2 holes in the back door stay, in
numerical order as shown in the figure.

CAUTION:

• When cutting a hole on back door stay, always cover a

hacksaw using a shop cloth (B) to avoid scattering metal
fragments or oil.

• Wear eye protection (safety glasses).
• Wear gloves.

BACK DOOR WEATHER-STRIP

BACK DOOR WEATHER-STRIP : Removal and Installation

INFOID:0000000006600669

REMOVAL

Pull up and remove engagement with body from weather-strip joint.

CAUTION:

Never pull strongly on weather-strip.

INSTALLATION

1.

Working from the upper section, align weather-strip center mark with vehicle center position mark and
install weather-strip onto the vehicle.

2.

For the lower section, insert pad (A) into weather-strip (1), and
then fix the connection point.

JMKIA3336ZZ

A:

20 mm (0.787 in)

B:

Cut at the groove.

JMKIA3609ZZ

JMKIA5661ZZ

BACK DOOR

DLK-585

< REMOVAL AND INSTALLATION >

[TYPE 4]

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3.

Align the connecting point (B) of weather-strip (2) to the center
(A) of striker (1), and then install as shown in the figure.

4.

Pull weather-strip gently to ensure that there is no loose section.
NOTE:
Check that weather-strip fits tightly in each corner and luggage rear plate.

JMKIA5662ZZ

DLK-586

< REMOVAL AND INSTALLATION >

[TYPE 4]

HOOD LOCK

HOOD LOCK

Exploded View

INFOID:0000000006628068

HOOD LOCK

HOOD LOCK : Removal and Installation

INFOID:0000000006628069

REMOVAL

1.

Remove front center grille. Refer to

EXT-18, "Removal and Installation"

.

2.

Remove crash zone sensor. Refer to

SR-26, "Removal and Installation"

.

3.

Remove hood lock assembly mounting bolts, and then remove hood lock assembly.

4.

Disconnect hood lock control cable assembly (2) from hood lock
assembly (1).

INSTALLATION

1.

Hood lock control cable assembly

2.

Hood lock assembly

: Clip

: N·m (kg-m, ft-lb)

: Body grease

JMKIA5899GB

JMKIA5900ZZ

HOOD LOCK

DLK-587

< REMOVAL AND INSTALLATION >

[TYPE 4]

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

CAUTION:

• Check that hood lock control cable is properly engaged with hood lock.
• After installation, perform hood fitting adjustment. Refer to

DLK-556, "HOOD ASSEMBLY : Adjust-

ment"

.

• After installation, perform hood lock control inspection. Refer to

DLK-587, "Inspection"

.

HOOD LOCK CONTROL CABLE

HOOD LOCK CONTROL CABLE : Removal and Installation

INFOID:0000000006628070

REMOVAL

1.

Disconnect hood lock control cable assembly from hood lock assembly.

2.

Remove fender protector (LH). Refer to

EXT-22, "Removal and Installation"

.

3.

Remove hood lock cable clip.

4.

Remove hood lock control cable assembly of instrument lower
panel (LH), and then remove fuel filler lid opener cable (2) from
fuel filler lid opener lever (1).

5.

Remove grommet on the lower dash, and pull the hood lock control cable toward the passenger compart-
ment.

CAUTION:

While pulling, never to damage (peeling) the outside of hood lock control cable.

INSTALLATION

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

CAUTION:

• Never to bend cable too much, keeping the radius 100 mm (3.937 in) or more.
• Check that cable is not offset from the positioning grommet,

and apply the sealant to the grommet (at * mark) properly.

• Check that hood lock control cable is properly engaged with hood lock.
• After installation, perform hood fitting adjustment. Refer to

DLK-556, "HOOD ASSEMBLY : Adjust-

ment"

.

• After installation, perform hood lock control inspection. Refer to

DLK-587, "Inspection"

.

Inspection

INFOID:0000000006600673

NOTE:
If the hood lock cable is bent or deformed, replace it.

1.

Check that secondary latch is securely engaged with securely striker from the dead load of the hood
assembly.

JMKIA5901ZZ

PIIB5801E

DLK-588

< REMOVAL AND INSTALLATION >

[TYPE 4]

HOOD LOCK

2.

Check that primary latch is securely engaged with primary 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.

3.

While operating the hood opener carefully, check that the front end of the hood is lifted by approximately
20 mm (0.787 in) (A). Also, check that the hood opener returns to the original position.

4.

Check that secondary latch is properly engaged with secondary striker [6.8 mm (0.268 in)] (B).

5.

Check the hood lock lubrication condition. If necessary, apply
body grease to hood lock.

1.

Primary striker

2.

Primary latch

3.

Secondary latch

4.

Secondary striker

: Grease up point

JMKIA5673ZZ

JMKIA5674ZZ

FRONT DOOR LOCK

DLK-589

< REMOVAL AND INSTALLATION >

[TYPE 4]

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FRONT DOOR LOCK

Exploded View

INFOID:0000000006628071

DOOR LOCK

DOOR LOCK : Removal and Installation

INFOID:0000000006628072

REMOVAL

1.

Remove front door glass and front door lower sash (rear). Refer to

GW-17, "Removal and Installation"

.

2.

Remove inside handle. Refer to

DLK-590, "INSIDE HANDLE : Removal and Installation"

.

3.

Disengage inside handle cable and lock knob cable from cable clip.

4.

Remove outside handle bracket. Refer to

DLK-590, "OUTSIDE HANDLE : Removal and Installation"

.

5.

Remove door lock assembly TORX bolts.

6.

Disconnect door lock actuator connector, and then remove door lock assembly.

1.

Door key cylinder assembly (driver
side)
Outside handle escutcheon (passen-
ger side)

2.

Rear gasket

3.

Outside handle bracket

4.

TORX bolt

5.

Key rod (driver side)

6.

Door lock assembly

7.

Inside handle

8.

Outside handle

9.

Front gasket

10. Cable clip

: Pawl

: Vehicle front

: Do not reuse

: N·m (kg-m, in-lb)

: Body grease

JMKIA5883GB

DLK-590

< REMOVAL AND INSTALLATION >

[TYPE 4]

FRONT DOOR LOCK

INSTALLATION

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

CAUTION:

• Never reuse TORX bolt. Always replace it with a new one when it is removed.
• Check door open/close, lock/unlock operation after installation.
• Check door lock cable is properly engaged with outside handle bracket.
• Check door lock assembly for poor lubrication. Apply body

grease to door lock if necessary.

INSIDE HANDLE

INSIDE HANDLE : Removal and Installation

INFOID:0000000006628073

REMOVAL

1.

Remove front door finisher. Refer to

INT-13, "Removal and Installation"

.

2.

Remove inside handle mounting bolt (A).

3.

Disengage inside handle (1) from door panel (2) while sliding
inside handle toward vehicle rear, and then separate inside han-
dle.

4.

Disengage inside handle cable (3) and lock knob cable (2), and
then remove inside handle (1).

INSTALLATION

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

CAUTION:

Check door open/close, lock/unlock operation after installation.

OUTSIDE HANDLE

OUTSIDE HANDLE : Removal and Installation

INFOID:0000000006628074

REMOVAL

1.

Fully close the front door glass.

2.

Remove front door finisher. Refer to

INT-13, "Removal and Installation"

.

: Grease up point

JMKIA5892ZZ

: Vehicle front

JMKIA5884ZZ

JMKIA5885ZZ

FRONT DOOR LOCK

DLK-591

< REMOVAL AND INSTALLATION >

[TYPE 4]

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3.

Remove sealing screen.
NOTE:
Cut the butyl-tape so that some parts of the butyl-tape do not remain on the sealing screen, if the sealing
screen is reused.

4.

Disengage lock holder (1), and then separate key rod (3) from
door lock assembly (2).(Driver side)

5.

Remove grommet (1) of door side. Loosen, through grommet
hole, TORX bolt (2) that fixes door lock cylinder. (For passenger
side, TORX bolt fixes outside handle escutcheon.)

6.

While pulling outside handle, remove door key cylinder assem-
bly (diver side) or outside handle escutcheon (passenger side).

7.

While pulling outside handle (1), slide toward rear of vehicle to
remove outside handle.

JMKIA5886ZZ

JMKIA5888ZZ

JMKIA0560ZZ

JMKIA0524ZZ