Juke F15 (2012 year). Service Repair Manual - part 98

DLK-560

< REMOVAL AND INSTALLATION >

[TYPE 4]

HOOD

HOOD SUPPORT ROD : Removal and Installation

INFOID:0000000006600643

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.

RADIATOR CORE SUPPORT

DLK-561

< REMOVAL AND INSTALLATION >

[TYPE 4]

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RADIATOR CORE SUPPORT

HR16DE

HR16DE : Exploded View

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HR16DE : Removal and Installation

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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-587, "HOOD LOCK CONTROL CABLE :

Removal and Installation"

.

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

DLK-562

< REMOVAL AND INSTALLATION >

[TYPE 4]

RADIATOR CORE SUPPORT

8.

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

9.

Remove hood support rod. Refer to 

DLK-560, "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

RADIATOR CORE SUPPORT

DLK-563

< REMOVAL AND INSTALLATION >

[TYPE 4]

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MR16DDT : Exploded View

INFOID:0000000006600646

MR16DDT : Removal and Installation

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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-587, "HOOD LOCK CONTROL CABLE :

Removal and Installation"

.

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

DLK-564

< REMOVAL AND INSTALLATION >

[TYPE 4]

RADIATOR CORE SUPPORT

7.

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

8.

Remove hood support rod. Refer to 

DLK-560, "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-565

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[TYPE 4]

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Install in the reverse order of removal.

DLK-566

< REMOVAL AND INSTALLATION >

[TYPE 4]

FRONT FENDER

FRONT FENDER

Exploded View

INFOID:0000000006600648

Removal and Installation

INFOID:0000000006600649

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-567

< REMOVAL AND INSTALLATION >

[TYPE 4]

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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-556, "HOOD ASSEMBLY : Adjustment"

.

- Front door: Refer to 

DLK-570, "DOOR ASSEMBLY : Adjustment"

.

DLK-568

< REMOVAL AND INSTALLATION >

[TYPE 4]

FRONT DOOR

FRONT DOOR

Exploded View

INFOID:0000000006628062

DOOR ASSEMBLY

DOOR ASSEMBLY : Removal and Installation

INFOID:0000000006628063

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

FRONT DOOR

DLK-569

< REMOVAL AND INSTALLATION >

[TYPE 4]

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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-570, "DOOR ASSEMBLY : Adjust-

ment"

.

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

JMKIA5878ZZ

DLK-570

< REMOVAL AND INSTALLATION >

[TYPE 4]

FRONT DOOR

DOOR ASSEMBLY : Adjustment

INFOID:0000000006600652

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-566, "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-571

< REMOVAL AND INSTALLATION >

[TYPE 4]

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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-566, "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:0000000006600653

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-570, "DOOR ASSEMBLY :

Adjustment"

.

DOOR HINGE

DOOR HINGE : Removal and Installation

INFOID:0000000006600654

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-566, "Removal and Installation"

.

2.

Remove front door assembly. Refer to 

DLK-568, "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-570, "DOOR ASSEMBLY : Adjust-

ment"

.

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

DLK-572

< REMOVAL AND INSTALLATION >

[TYPE 4]

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:0000000006628064

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

JMKIA5879ZZ

: Grease up point

JMKIA5642ZZ

REAR DOOR

DLK-573

< REMOVAL AND INSTALLATION >

[TYPE 4]

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REAR DOOR

Exploded View

INFOID:0000000006628065

DOOR ASSEMBLY

DOOR ASSEMBLY : Removal and Installation

INFOID:0000000006628066

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.

TORX bolt

3.

Door striker

4.

Door check link

5.

Door hinge (lower)

6.

Door hinge (upper)

: Do not reuse

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Body grease

JMKIA5880GB

DLK-574

< REMOVAL AND INSTALLATION >

[TYPE 4]

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-575, "DOOR ASSEMBLY : Adjust-

ment"

.

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

JMKIA5881ZZ

JMKIA5882ZZ

REAR DOOR

DLK-575

< REMOVAL AND INSTALLATION >

[TYPE 4]

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DOOR ASSEMBLY : Adjustment

INFOID:0000000006600658

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