Juke F15 (2012 year). Service Repair Manual - part 83

 

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Juke F15 (2012 year). Service Repair Manual - part 83

 

 

DLK-320

< REMOVAL AND INSTALLATION >

[TYPE 2]

FRONT DOOR

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-315, "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:0000000006600533

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-319, "DOOR ASSEMBLY :

Adjustment"

.

DOOR HINGE

DOOR HINGE : Removal and Installation

INFOID:0000000006600534

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-315, "Removal and Installation"

.

2.

Remove front door assembly. Refer to 

DLK-317, "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-319, "DOOR ASSEMBLY : Adjust-

ment"

.

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

FRONT DOOR

DLK-321

< REMOVAL AND INSTALLATION >

[TYPE 2]

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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:0000000006600535

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

DLK-322

< REMOVAL AND INSTALLATION >

[TYPE 2]

REAR DOOR

REAR DOOR

Exploded View

INFOID:0000000006600536

DOOR ASSEMBLY

DOOR ASSEMBLY : Removal and Installation

INFOID:0000000006600537

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

REAR DOOR

DLK-323

< REMOVAL AND INSTALLATION >

[TYPE 2]

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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-324, "DOOR ASSEMBLY : Adjust-

ment"

.

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

JMKIA5881ZZ

JMKIA5882ZZ

DLK-324

< REMOVAL AND INSTALLATION >

[TYPE 2]

REAR DOOR

DOOR ASSEMBLY : Adjustment

INFOID:0000000006600538

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

REAR DOOR

DLK-325

< REMOVAL AND INSTALLATION >

[TYPE 2]

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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:0000000006600539

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-324, "DOOR ASSEMBLY :

Adjustment"

.

DOOR HINGE

DOOR HINGE : Removal and Installation

INFOID:0000000006600540

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-322, "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-324,

"DOOR ASSEMBLY : Adjustment"

.

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

DLK-326

< REMOVAL AND INSTALLATION >

[TYPE 2]

REAR 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:0000000006600541

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

BACK DOOR

DLK-327

< REMOVAL AND INSTALLATION >

[TYPE 2]

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BACK DOOR

Exploded View

INFOID:0000000006600542

REMOVAL

BACK DOOR ASSEMBLY

BACK DOOR ASSEMBLY : Removal and Installation

INFOID:0000000006600543

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

DLK-328

< REMOVAL AND INSTALLATION >

[TYPE 2]

BACK DOOR

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-333, "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

BACK DOOR

DLK-329

< REMOVAL AND INSTALLATION >

[TYPE 2]

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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-332, "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-330, "BACK DOOR ASSEMBLY :

Adjustment"

.

JMKIA5658ZZ

DLK-330

< REMOVAL AND INSTALLATION >

[TYPE 2]

BACK DOOR

BACK DOOR ASSEMBLY : Adjustment

INFOID:0000000006600544

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)

—

BACK DOOR

DLK-331

< REMOVAL AND INSTALLATION >

[TYPE 2]

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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:0000000006600545

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-330, "BACK DOOR ASSEMBLY :

Adjustment"

.

BACK DOOR HINGE

BACK DOOR HINGE : Removal and Installation

INFOID:0000000006600546

REMOVAL

1.

Remove back door assembly. Refer to 

DLK-327, "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

DLK-332

< REMOVAL AND INSTALLATION >

[TYPE 2]

BACK DOOR

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-330, "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:0000000006600547

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

BACK DOOR

DLK-333

< REMOVAL AND INSTALLATION >

[TYPE 2]

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BACK DOOR STAY : Disposal 

INFOID:0000000006600548

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:0000000006600549

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

DLK-334

< REMOVAL AND INSTALLATION >

[TYPE 2]

BACK DOOR

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

HOOD LOCK

DLK-335

< REMOVAL AND INSTALLATION >

[TYPE 2]

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HOOD LOCK

Exploded View

INFOID:0000000006600550

HOOD LOCK

HOOD LOCK : Removal and Installation

INFOID:0000000006600551

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

 

 

 

 

 

 

 

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