BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

SECTION BRM BODY REPAIR

B

E
CONTENTS
VEHICLE INFORMATION ............................. 2 Hoodledge ...............................................................35 F
Hoodledge (Partial Replacement) ...........................36
BODY EXTERIOR PAINT COLOR ..................... 2 Front Side Member ..................................................38
Body Exterior Paint Color .......................................... 2 Front Side Member (Partial Replacement) ..............40 G
Front Pillar ...............................................................42
PRECAUTION ............................................... 4 Center Pillar (Standard Roof Models) ......................45
Center Pillar (With Sunroof Models) ........................47
REPAIRING HIGH STRENGTH STEEL .............. 4 H
Outer Sill (Partial Replacement) ..............................50
High Strength Steel (HSS) ...................................... 4
Outer Sill ..................................................................51
Handling of Ultra High Strength Steel Plate Parts...... 6
Rear Fender (2WD Models) ....................................54
Rear Fender (AWD Models) ....................................57 I
PREPARATION ............................................ 7
Rear Fender Extension (2WD Models) ....................60
REPAIRING MATERIAL ..................................... 7 Rear Fender Extension (AWD Models) ...................61
Foam Repair ............................................................. 7 Rear Panel (2WD Models) .......................................62 J
Rear Panel (AWD Models) ......................................63
BODY COMPONENT PARTS ............................. 9 Rear Floor Rear (2WD Models) ...............................63
Underbody Component Parts (2WD Models) ............ 9 Rear Floor Rear (AWD Models) ..............................64
BRM
Underbody Component Parts (AWD Models) ......... 11 Rear Side Member (AWD Models Partial Replace-
Body Component Parts (2WD Models) ................... 13 ment) .......................................................................65
Body Component Parts (AWD Models) ................... 15 Rear Side Member Extension (2WD Models) ..........66
Rear Side Member Extension (AWD Models) .........67 L
REMOVAL AND INSTALLATION ............... 18
SERVICE DATA AND SPECIFICATIONS
CORROSION PROTECTION .............................18
Description .............................................................. 18
(SDS) ............................................................ 69 M
Anti-corrosive Wax .................................................. 18 BODY ALIGNMENT .......................................... 69
Undercoating (2WD Models) ................................... 19 Body Center Marks ..................................................69
Undercoating (AWD Models) .................................. 20 Description ...............................................................70 N
Body Sealing (2WD Models) ................................... 21 Engine Compartment ...............................................70
Body Sealing (AWD Models) ................................... 25 Underbody (2WD Models) .......................................73
Underbody (AWD Models) .......................................75 O
BODY CONSTRUCTION ....................................28
Passenger Compartment .........................................78
Body Construction (Standard roof Models) ............. 28
Rear Body ...............................................................80
Body Construction (With sunroof Models) ............... 30
Rear Fender Hemming Process .............................. 31 P
LOCATION OF PLASTIC PARTS .................... 82
REPLACEMENT OPERATIONS ........................33 Precautions for Plastics ...........................................82
Location of Plastic Parts ..........................................83
Description .............................................................. 33
Radiator Core Support ............................................ 35

Revision: 2011 October BRM-1 2012 JUKE

 BODY EXTERIOR PAINT COLOR
< VEHICLE INFORMATION >
VEHICLE INFORMATION
BODY EXTERIOR PAINT COLOR
Body Exterior Paint Color INFOID:0000000007578104

JSKIA2126ZZ

Color code BB20 BB51 BKAD BKAX BKY0 BNAH BQX1 BRAQ
Bluish Dark Dark
Description Blue Gray Silver Red White
Black Gray Blue
Component
Paint type Note P PM M PM M PM 3P M
Hard clear
× − − × − × − ×
coat
Grille Material color − − − − − − − −
Front
1 Chromium
grille Molding Cr Cr Cr Cr Cr Cr Cr Cr
plate
2 Front bumper fascia Body color BB20 BB51 BKAD BKAX BKY0 BNAH BQX1 BRAQ
3 Front fillet molding Material color − − − − − − − −
Body color BB20 BB51 BKAD BKAX BKY0 BNAH BQX1 BRAQ
4 Door outside mirror
Material color − − − − − − − −
5 Back door finisher Body color BB20 BB51 BKAD BKAX BKY0 BNAH BQX1 BRAQ
6 Rear bumper fascia Body color BB20 BB51 BKAD BKAX BKY0 BNAH BQX1 BRAQ
7 Rear fillet molding Material color − − − − − − − −
8 Center mudguard Material color − − − − − − − −

Front door outside Body color BB20 BB51 BKAD BKAX BKY0 BNAH BQX1 BRAQ
9
handle Material color − − − − − − − −
Rear door outside
10 Material color − − − − − − − −
handle
NOTE:
• S: Solid
• 2S: Solid + Clear
• CS: Color clear solid
• M: Metallic
• P: 2-Coat pearl
• 3P: 3-Coat pearl
• FPM: Iron oxide pearl
• RPM: Multi flex color

Revision: 2011 October BRM-2 2012 JUKE

 BODY EXTERIOR PAINT COLOR
< VEHICLE INFORMATION >
• TM: Micro titanium metallic
• PM: Pearl metallic A

BRM

Revision: 2011 October BRM-3 2012 JUKE

 REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
PRECAUTION
REPAIRING HIGH STRENGTH STEEL
High Strength Steel (HSS) INFOID:0000000007578105

High strength steel is used for body panels in order to reduce vehicle weight.
Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:

Tensile strength Major applicable parts

• Trans control reinforcement
(Center front floor component part)
• 2nd crossmember
(Front floor component part)
• Inner sill
• Side dash
• Lower dash crossmember (Lower)
• Front strut housing
• Front side member assembly
• Front side member closing plate assembly
• Front suspension mounting bracket (Front)
• Rear seat crossmember
• Rear seat crossmember reinforcement
(Rear crossmember center assembly component part)
• Rear side member
440 - 780 MPa
• Rear side member extension
• Upper rear seat crossmember
• Front side member front assembly
• Inner side roof rail
• Upper inner front pillar
• Inner center pillar
• Outer side roof rail reinforcement
• Lower center pillar brace
• Outer front pillar reinforcement
(Front pillar brace component part)
• Lower front pillar hinge brace
• Outer sill reinforcement
• Inner rear pillar reinforcement
• Front roof rail
• Rear bumper stay assembly
• Front side member rear extension
(Front floor component part)
• Inner sill reinforcement
(Inner sill component part)
980 - 1310 MPa
• Lower dash crossmember (Upper)
(Lower dash component part)
• Inner center front bumper reinforcement
• Inner center rear bumper reinforcement

Read the following precautions when repairing HSS:

1. Additional points to consider
• The repair of reinforcements (such as side members) by heat-
ing is not recommended, because it may weaken the compo-
nent. When heating is unavoidable, never heat HSS parts
above 550°C (1,022°F).
Verify heating temperature with a thermometer.
(Crayon-type and other similar type thermometer are appropri-
ate.)

PIIA0115E

Revision: 2011 October BRM-4 2012 JUKE

 REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >

• When straightening body panels, use caution in pulling any A

HSS panel. Because HSS is very strong, pulling may cause
deformation in adjacent sections of the body. In this case,
increase the number of measuring points, and carefully pull
the HSS panel. B

PIIA0116E
D

• When cutting HSS panels, avoid gas (torch) cutting if possible.

Instead, use a saw to avoid weakening surrounding areas due E
to heat. If gas (torch) cutting is unavoidable, allow a minimum
margin of 50 mm (1.97in).

PIIA0117E

H
• When welding HSS panels, use spot welding whenever possi-
ble in order to minimize weakening surrounding areas due to
heat. I
If spot welding is impossible, use MIG. welding. Do not use
gas (torch) for welding because it is inferior in welding
strength.
J

BRM
JSKIA0082GB

• Spot welding on HSS panels is harder than that of an ordinary L

steel panel.
Therefore, when cutting spot welds on a HSS panel, use a low
speed high torque drill (1,000 to 1,200 rpm) to increase drill bit M
durability and facilitate the operation.

PIIA0145E O

Revision: 2011 October BRM-5 2012 JUKE

 REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
2. Precautions in spot welding HSS
This work should be performed under standard working condi-
tions. Always note the following when spot welding HSS:
• The electrode tip diameter must be sized properly according to
the metal thickness.

PIIA0146E

• The panel surfaces must fit flush to each other, leaving no

gaps.

PIIA0147E

• Follow the specifications for the proper welding pitch.

Unit: mm (in)
Thickness (T) Minimum pitch (L)
0.6 (0.024) 10 (0.39) or more
0.8 (0.031) 12 (0.47) or more
1.0 (0.039) 18 (0.71) or more
1.2 (0.047) 20 (0.79) or more
1.6 (0.063) 27 (1.06) or more
1.8 (0.071) 31 (1.22) or more
JSKIA0781ZZ

Handling of Ultra High Strength Steel Plate Parts INFOID:0000000007578106

PROHIBITION OF CUT AND CONNECTION

Never cut and Joint the stiffener front side member (front floor inside frame parts) because its material is high
strength steel plate (ultra high strength steel plate).
The front floor assembly must be replaced if this part is damaged.

Revision: 2011 October BRM-6 2012 JUKE

 REPAIRING MATERIAL
< PREPARATION >
PREPARATION A
REPAIRING MATERIAL
Foam Repair INFOID:0000000007578107
B
During factory body assembly, foam insulators are installed in certain body panels and locations around the
vehicle. Use the following procedure(s) to replace any factory-installed foam insulators.
C
URETHANE FOAM APPLICATIONS
Use commercially available Urethane foam for sealant (foam material) repair of material used on vehicle.
D
<Urethane foam for foaming agent> 3M™ Automix™ Flexible Foam 08463 or equiva-
lent
Read instructions on product for fill procedures. E
Example of foaming agent filling operation procedure
1. Fill procedures after installation of service part.
a. Eliminate foam material remaining on vehicle side. F
b. Clean area after eliminating form insulator and foam material.
c. Install service part.
G
d. Insert nozzle into hole near fill area and fill foam material or fill enough to close gap with the service part.

BRM

L
JSKIA0129GB

1. Urethane foam
A. Nozzle insert hole
M
: Vehicle front

2. Fill procedures before installation of service part. N

a. Eliminate foam material remaining on vehicle side.
b. Clean area after eliminating foam insulator and foam material.
c. Fill foam material on wheelhouse outer side. O

Revision: 2011 October BRM-7 2012 JUKE

 REPAIRING MATERIAL
< PREPARATION >

1. Urethane foam
A. Fill while avoiding flange area
: Vehicle front
NOTE:
Fill enough to close gap with service part while avoiding flange
area.
d. Install service part.
NOTE: JSKIA0130GB
Refer to label for information on working times.

Revision: 2011 October BRM-8 2012 JUKE

 BODY COMPONENT PARTS
< PREPARATION >
BODY COMPONENT PARTS
A
Underbody Component Parts (2WD Models) INFOID:0000000007578108

BRM

JSKIA2193ZZ

: Both sided anti-corrosive precoated steel sections

: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections

Revision: 2011 October BRM-9 2012 JUKE

 BODY COMPONENT PARTS
< PREPARATION >

Tensile strength Both sided anti-corrosive

No. Parts name
(MPa) precoated steel sections
1. Center front floor 590 ×
T=1.8 mm
2. Front floor (RH & LH) a. 980caution ×
(0.071 in)
T=1.4 mm
3. Inner sill (RH & LH) b. 980caution ×
(0.055 in)
4. Inner cowl top Under 440 ×
5. Upper dash Under 440 ×
6. Side dash (RH & LH) 590 ×
T=1.4 mm
7. Lower dash c. 980caution ×
(0.055 in)
8. Lower dash crossmember 780 ×
9. Front strut housing (RH & LH) 590 ×
10. Lower front hoodledge (RH & LH) Under 440 ×
11. Upper hoodledge (RH & LH) Under 440 ×
12. Hoodledge reinforcement (RH & LH) Under 440 ×
13. Hoodledge connector (RH & LH) Under 440 ×
14. Side radiator core support (RH & LH Upper) Under 440 ×
15. Side radiator core support (RH & LH Lower) Under 440 ×
16. Front side member closing plate assembly (RH & LH) 590 ×
17. Add on frame bracket (RH & LH) Under 440 ×
18. Front side member assembly (RH & LH) 590 ×
19. Front suspension mounting bracket (RH & LH Front) 440 ×
20. Front suspension mounting bracket (RH & LH Rear) Under 440 ×
21. Rear crossmember center assembly 780 ×
22. Rear seat crossmember 440 ×
23. Rear floor front Under 440 ×
24. Rear floor rear cover Under 440 ×
25. Rear side member (RH & LH) 780 ×
26. Rear side member extension (RH & LH) 440 ×
27. Upper rear seat crossmember 440 —
28. Muffler mounting bracket Under 440 ×
29. Canister mounting bracket Under 440 ×
30. Spare wheel clamp reinforcement Under 440 ×
31. Canister bracket (Front) Under 440 ×
32. Rear floor rear side (RH & LH) 440 ×
33. Rear floor rear Under 440 ×
34. Rear towing hook bracket 440 ×
35. Canister bracket (Rear) Under 440 —
36. Spare tire clamp bracket Under 440 —
NOTE:
• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part.
CAUTION:
If the high strength steel (ultra high strength steel) of this is broken, replace by assembly for the supply part.

Revision: 2011 October BRM-10 2012 JUKE

 BODY COMPONENT PARTS
< PREPARATION >
Underbody Component Parts (AWD Models) INFOID:0000000007578109

BRM

P
JSKIA2194ZZ

: Both sided anti-corrosive precoated steel sections

: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections

Revision: 2011 October BRM-11 2012 JUKE

 BODY COMPONENT PARTS
< PREPARATION >

Tensile strength Both sided anti-corrosive

No. Parts name
(MPa) precoated steel sections
1. Center front floor 590 ×
T=1.8 mm
2. Front floor (RH & LH) a. 980caution ×
(0.071 in)
T=1.4 mm
3. Inner sill (RH & LH) b. 980caution ×
(0.055 in)
4. Inner cowl top Under 440 ×
5. Upper dash Under 440 ×
6. Side dash (RH & LH) 590 ×
T=1.4 mm
7. Lower dash c. 980caution ×
(0.055 in)
8. Lower dash crossmember 780 ×
9. Front strut housing (RH & LH) 590 ×
10. Lower front hoodledge (RH & LH) Under 440 ×
11. Upper hoodledge (RH & LH) Under 440 ×
12. Hoodledge reinforcement (RH & LH) Under 440 ×
13. Hoodledge connector (RH & LH) Under 440 ×
14. Side radiator core support (RH & LH Upper) Under 440 ×
15. Side radiator core support (RH & LH Lower) Under 440 ×
16. Front side member closing plate assembly (RH & LH) 590 ×
17. Add on frame bracket (RH & LH) Under 440 ×
18. Front side member assembly (RH & LH) 590 ×
19. Front suspension mounting bracket (RH & LH Front) 440 ×
20. Front suspension mounting bracket (RH & LH Rear) Under 440 ×
21. Rear seat crossmember 440 ×
22. Rear crossmember center assembly 590 ×
23. 7th crossmember Under 440 ×
24. Rear side member (RH & LH) 780 ×
25. Rear side member extension (RH & LH) 590 ×
26. Rear floor front extension Under 440 ×
27. Rear floor front Under 440 ×
28. Rear floor belt anchor reinforcement 590 ×
29. Upper rear seat crossmember 440 —
30. Spare wheel clamp reinforcement Under 440 ×
31. Canister bracket (Front) Under 440 ×
32. Rear floor rear Under 440 ×
33. Rear floor rear side (RH & LH) Under 440 ×
34. Spare tire clamp bracket Under 440 —
35. Canister bracket (Rear) Under 440 —
36. Jack mounting bracket Under 440 —
NOTE:
• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part.
CAUTION:
If the high strength steel (ultra high strength steel) of this is broken, replace by assembly for the supply part.

Revision: 2011 October BRM-12 2012 JUKE

 BODY COMPONENT PARTS
< PREPARATION >
Body Component Parts (2WD Models) INFOID:0000000007578110

BRM

P
JSKIA2195ZZ

A. Right side B. With sunroof models C. Standard roof models

: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections

Revision: 2011 October BRM-13 2012 JUKE

 BODY COMPONENT PARTS
< PREPARATION >

Tensile strength Both sided anti-corrosive

No. Parts name
(MPa) precoated steel sections
1. Hood Under 440 ×
T=1.2 mm
2. Inner center front bumper reinforcement
(0.047 in) 1310caution —

3. Front side member front assembly (RH & LH) 590 ×

4. Front fender (RH & LH) Under 440 ×
5. Inner side roof rail (RH & LH) 590 —
6. Upper inner front pillar (RH & LH) 780 —
7. Inner center pillar (RH & LH) 590 ×
8. Side body assembly (RH & LH) Refer to No.9−15
9. Outer side roof rail reinforcement (RH & LH) 590 —
10. Lower center pillar brace (RH & LH) 590 —
11. Front pillar brace (RH & LH) 590 —
12. Lower front pillar hinge brace (RH & LH) 590 —
13. Outer front side body (RH & LH) Under 440 ×
14. Front fender bracket assembly (RH & LH) Under 440 ×
15. Outer sill reinforcement (RH & LH) 780 ×
16. Outer sill (RH & LH) Under 440 ×
17. Front door (RH & LH) Under 440 ×
18. Outer front door panel (RH & LH) Under 440 ×
19. Rear door (RH & LH) Under 440 ×
20. Outer rear door panel (RH & LH) Under 440 ×
21. Inner rear pillar reinforcement (RH & LH) 440 —
22. Rear pillar reinforcement (RH & LH) Under 440 —
23. Inner rear pillar (RH & LH) Under 440 —
24. Inner rear wheelhouse (RH & LH) 440 ×
25. Outer rear wheelhouse (RH & LH) Under 440 ×
26. Outer rear wheelhouse extension (RH & LH) Under 440 ×
27. Roof Under 440 —
28. Front roof rail 780 —
29. Roof bow No.1 Under 440 —
30. Roof bow No.2 590 —
31. Roof bow No.3 Under 440 —
32. Rear roof rail Under 440 —
33. Rear fender (RH & LH) Under 440 ×
34. Rear fender extension (RH & LH) Under 440 —
35. Rear fender corner (RH & LH) Under 440 ×
36. Fuel filler lid Under 440 ×
37. Back door Under 440 ×
38. Upper rear panel Under 440 ×
39. Upper rear bumper retainer Under 440 ×
40. Rear side bumper bracket Under 440 ×
41. Rear bumper stay (RH & LH) 590 ×
T=1.2 mm
42. Inner center rear bumper reinforcement
(0.047 in) 1310caution —

Revision: 2011 October BRM-14 2012 JUKE

 BODY COMPONENT PARTS
< PREPARATION >
NOTE:
• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with. A
• Tensile strength column shows the largest strength value of a part in the component part.
CAUTION:
If the high strength steel (ultra high strength steel) of this is broken, replace by assembly for the supply part. B
Body Component Parts (AWD Models) INFOID:0000000007578111

BRM

JSKIA2196ZZ

Revision: 2011 October BRM-15 2012 JUKE

 BODY COMPONENT PARTS
< PREPARATION >

A. Right side B. With sunroof models C. Standard roof models

: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections

Tensile strength Both sided anti-corrosive

No. Parts name
(MPa) precoated steel sections
1. Hood Under 440 ×
T=1.2 mm
2. Inner center front bumper reinforcement
(0.047 in) 1310caution —

3. Front side member front assembly (RH & LH) 590 ×

4. Front fender (RH & LH) Under 440 ×
5. Inner side roof rail (RH & LH) 590 —
6. Upper inner front pillar (RH & LH) 780 —
7. Inner center pillar (RH & LH) 590 ×
8. Side body assembly (RH & LH) Refer to No.9−15
9. Outer side roof rail reinforcement (RH & LH) 590 —
10. Lower center pillar brace (RH & LH) 590 —
11. Front pillar brace (RH & LH) 590 —
12. Lower front pillar hinge brace (RH & LH) 590 —
13. Outer front side body (RH & LH) Under 440 ×
14. Front fender bracket assembly (RH & LH) Under 440 ×
15. Outer sill reinforcement (RH & LH) 780 ×
16. Outer sill (RH & LH) Under 440 ×
17. Front door (RH & LH) Under 440 ×
18. Outer front door panel (RH & LH) Under 440 ×
19. Rear door (RH & LH) Under 440 ×
20. Outer rear door panel (RH & LH) Under 440 ×
21. Inner rear pillar reinforcement (RH & LH) 440 —
22. Rear pillar reinforcement (RH & LH) Under 440 —
23. Inner rear pillar (RH & LH) Under 440 —
24. Inner rear wheelhouse (RH & LH) 440 ×
25. Outer rear wheelhouse (RH & LH) Under 440 ×
26. Outer rear wheelhouse extension (RH & LH) Under 440 ×
27. Roof Under 440 —
28. Front roof rail 780 —
29. Roof bow No.1 Under 440 —
30. Roof bow No.2 590 —
31. Roof bow No.3 Under 440 —
32. Rear roof rail Under 440 —
33. Rear fender (RH & LH) Under 440 ×
34. Rear fender extension (RH & LH) Under 440 —
35. Rear fender corner (RH & LH) Under 440 ×
36. Fuel filler lid Under 440 ×
37. Back door Under 440 ×
38. Upper rear panel Under 440 ×

Revision: 2011 October BRM-16 2012 JUKE

 BODY COMPONENT PARTS
< PREPARATION >
Tensile strength Both sided anti-corrosive
No. Parts name
(MPa) precoated steel sections A
39. Upper rear bumper retainer Under 440 ×
40. Rear side bumper bracket Under 440 ×
B
41. Rear bumper stay (RH & LH) 440 ×
T=1.2 mm
42. Inner center rear bumper reinforcement
(0.047 in) 1310caution —
C
NOTE:
• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part. D
CAUTION:
If the high strength steel (ultra high strength steel) of this is broken, replace by assembly for the supply part.

BRM

Revision: 2011 October BRM-17 2012 JUKE

 CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
CORROSION PROTECTION
Description INFOID:0000000007578112

To provide improved corrosion prevention, the following anti-corrosive measures have been implemented in
NISSAN production plants. When repairing or replacing body panels, it is necessary to use the same anti-cor-
rosive measures.
ANTI-CORROSIVE PRECOATED STEEL (GALVANNEALED STEEL)
To improve repairability and corrosion resistance, a new type of anti-
corrosive precoated steel sheet has been adopted replacing conven-
tional zinc-coated steel sheet.
Galvannealed steel is electroplated and heated to form Zinc-iron
alloy, which provides excellent and long term corrosion resistance
with cationic electrodeposition primer.

SIIA2294E

Nissan Genuine Service Parts are fabricated from galvannealed steel. Therefore, it is recommended that
GENUINE NISSAN PARTS or equivalent be used for panel replacement to maintain the anti-corrosive perfor-
mance built into the vehicle at the factory.
PHOSPHATE COATING TREATMENT AND CATIONIC ELECTRODEPOSITION PRIMER
A phosphate coating treatment and a cationic electrodeposition
primer, which provide excellent corrosion protection, are employed
on all body components.
CAUTION:
Confine paint removal during welding operations to an absolute
minimum.

PIIA0095E

Nissan Genuine Service Parts are also treated in the same manner. Therefore, it is recommended that GENU-
INE NISSAN PARTS or an equivalent be used for panel replacement to maintain anti-corrosive performance
built into the vehicle at the factory.
Anti-corrosive Wax INFOID:0000000007578113

To improve corrosion resistance, anti-corrosive wax is applied inside the body sill and inside other closed sec-
tions. Accordingly, when replacing these parts, be sure to apply anti-corrosive wax to the appropriate areas of
the new parts. Select an excellent anti-corrosive wax which will penetrate after application and has a long shelf
life.
DOOR

Revision: 2011 October BRM-18 2012 JUKE

 CORROSION PROTECTION
< REMOVAL AND INSTALLATION >

JSKIA2131ZZ
BRM

B. Nozzle insert hole

Unit: mm (in) L
: Anti-corrosive wax coated portions

Undercoating (2WD Models) INFOID:0000000007578114 M

The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chip-
ping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoat-
N
ing which is rust resistant, soundproof, vibration-proof, shock-resistant, adhesive, and durable.
PRECAUTIONS IN UNDERCOATING
1. Never apply undercoating to any place unless specified (such as the areas above the muffler and three- O
way catalyst that are subjected to heat).
2. Never undercoat the exhaust pipe or other parts that become hot.
3. Never undercoat rotating parts. P
4. Apply bitumen wax after applying undercoating.
5. After putting seal on the vehicle, put undercoating on it.

Revision: 2011 October BRM-19 2012 JUKE

 CORROSION PROTECTION
< REMOVAL AND INSTALLATION >

JSKIA2197ZZ

: Undercoated areas
: Sealed portions

Undercoating (AWD Models) INFOID:0000000007578115

The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chip-
ping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoat-
ing which is rust resistant, soundproof, vibration-proof, shock-resistant, adhesive, and durable.
PRECAUTIONS IN UNDERCOATING
1. Never apply undercoating to any place unless specified (such as the areas above the muffler and three-
way catalyst that are subjected to heat).
2. Never undercoat the exhaust pipe or other parts that become hot.
3. Never undercoat rotating parts.
4. Apply bitumen wax after applying undercoating.
5. After putting seal on the vehicle, put undercoating on it.

Revision: 2011 October BRM-20 2012 JUKE

 CORROSION PROTECTION
< REMOVAL AND INSTALLATION >

H
JSKIA2198ZZ

: Undercoated areas
: Sealed portions
I

Body Sealing (2WD Models) INFOID:0000000007578116

J
The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas
should be smooth and free from cuts or gaps. Care should be taken not to apply an excess amount of sealant
and not to allow other unaffected parts to come into contact with the sealant.
BRM

Revision: 2011 October BRM-21 2012 JUKE

 CORROSION PROTECTION
< REMOVAL AND INSTALLATION >

JSKIA2199ZZ

T. Standard roof models U. With sunroof models

: Vehicle front
: Sealed portions

Revision: 2011 October BRM-22 2012 JUKE

 CORROSION PROTECTION
< REMOVAL AND INSTALLATION >

BRM

JSKIA2610ZZ

P
: Vehicle front
: Sealed portions

Revision: 2011 October BRM-23 2012 JUKE

 CORROSION PROTECTION
< REMOVAL AND INSTALLATION >

JSKIA2135ZZ

: Vehicle front
: Sealed portions

Revision: 2011 October BRM-24 2012 JUKE

 CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
Body Sealing (AWD Models) INFOID:0000000007578117

A
The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas
should be smooth and free from cuts or gaps. Care should be taken not to apply an excess amount of sealant
and not to allow other unaffected parts to come into contact with the sealant. B

BRM

JSKIA2199ZZ
P
T. Standard roof models U. With sunroof models
: Vehicle front
: Sealed portions

Revision: 2011 October BRM-25 2012 JUKE

 CORROSION PROTECTION
< REMOVAL AND INSTALLATION >

JSKIA2611ZZ

: Vehicle front
: Sealed portions

Revision: 2011 October BRM-26 2012 JUKE

 CORROSION PROTECTION
< REMOVAL AND INSTALLATION >

BRM

JSKIA2202ZZ

P
: Vehicle front
: Sealed portions

Revision: 2011 October BRM-27 2012 JUKE

 BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
BODY CONSTRUCTION
Body Construction (Standard roof Models) INFOID:0000000007578118

JSKIA2203ZZ

1. Outer side body 2. Outer front pillar reinforcement 3. Upper inner front pillar
4. Lower dash 5. Hoodledge reinforcement 6. Lower front pillar hinge brace
7. Weld nut 8. Side dash 9. Inner front pillar reinforcement

Revision: 2011 October BRM-28 2012 JUKE

 BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
10. Upper hinge plate 11. Lower hinge plate 12. Lower front pillar bulkhead
13. Inner front pillar reinforcement 14. Front floor reinforcement 15. Front floor A
16. Front outrigger 17. Inner sill 18. Outer sill reinforcement
19. Inner center pillar reinforcement 20. Inner center pillar 21. Center pillar reinforcement
22. Center pillar hinge brace 23. Inner sill reinforcement 24. Center sill reinforcement B
25. Inner sill extension 26. Inner rear wheelhouse 27. Outer rear wheelhouse
28. Rear roof rail brace 29. Inner rear pillar reinforcement 30. Rear fender extension
31. Inner rear pillar 32. Inner rear wheelhouse reinforce- C
ment

BRM

Revision: 2011 October BRM-29 2012 JUKE

 BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
Body Construction (With sunroof Models) INFOID:0000000007578119

JSKIA2204ZZ

1. Outer side body 2. Outer front pillar reinforcement 3. Upper inner front pillar
4. Lower dash 5. Hoodledge reinforcement 6. Lower front pillar hinge brace
7. Weld nut 8. Side dash 9. Inner front pillar reinforcement
10. Upper hinge plate 11. Lower hinge plate 12. Lower front pillar bulkhead
13. Inner front pillar reinforcement 14. Front floor reinforcement 15. Front floor

Revision: 2011 October BRM-30 2012 JUKE

 BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
16. Front outrigger 17. Inner sill 18. Outer sill reinforcement
19. Nut plate 20. Inner center pillar 21. Center pillar reinforcement A
22. Center pillar hinge brace 23. Inner sill reinforcement 24. Center sill reinforcement
25. Inner sill extension 26. Inner rear wheelhouse 27. Outer rear wheelhouse
28. Rear roof rail brace 29. Inner rear pillar reinforcement 30. Rear fender extension B
31. Inner rear pillar 32. Inner rear wheelhouse reinforce-
ment
C
Rear Fender Hemming Process INFOID:0000000007578120

1. A wheel arch is to be installed and hemmed over the left and right outer wheel houses.
2. In order to hem the wheel arch, it is necessary to repair any damaged or defaced parts around outer D
wheel house.
CAUTION:
Ensure that the area that is to be glued around the outer wheelhouse is undamaged or defaced. E
PROCEDURE OF THE HEMMING PROCESS
• Peel off old bonding material on the surface of the outer wheel-
house and clean thoroughly. F
• Peel off a primer coat in the specified area where new adhesive is
to be applied on rear fender (the replacing part).
• Apply new adhesive to both specified areas of the outer wheel- G
house and rear fender.

<Adhesive> 3M™ Automix™ Panel Bonding Adhe-

H
sive 08115 or equivalent
• Attach rear fender to the body of the car, and weld the required
part except the hemming part. JSKIA0136GB
I

• Bend the welded part starting from the center of the wheel arch
gradually with a hammer and a dolly. (Also hem the end of the
J
flange.)
• Hemming with a hammer is conducted to an approximate angle of
80 degrees.
BRM

SIIA2245E

M
• Starting from the center, hem the wheel arch gradually, using slight
back and forth motion with a hemming tool.
N

P
SIIA2246E

Revision: 2011 October BRM-31 2012 JUKE

 BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
• Seal up the area around the hemmed end of the flange.

JSKIA0137GB

Revision: 2011 October BRM-32 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
REPLACEMENT OPERATIONS
A
Description INFOID:0000000007578121

• This section is prepared for technicians who have attained a high level of skill and experience in repairing B
collision-damaged vehicles and also use modern service tools and equipment. Persons unfamiliar with body
repair techniques should not attempt to repair collision-damaged vehicles by using this section.
• Technicians are also encouraged to read the Body Repair Manual (Fundamentals) in order to ensure that the
original functions and quality of the vehicle are maintained. The Body Repair Manual (Fundamentals) con- C
tains additional information, including cautions and warnings, that are not including in this manual. Techni-
cians should refer to both manuals to ensure proper repair.
• Please note that this information is prepared for worldwide usage, and as such, certain procedures might not D
apply in some regions or countries.
The symbols used in this section for welding operations are shown below.
Symbol marks Description
E

F
2-spot welds

G
JSKIA0049ZZ

H
JSKIA0053ZZ
3-spot welds
I

JSKIA0050ZZ

BRM

JSKIA0054ZZ L
MIG plug weld
For 3 panels plug weld method

M
JSKIA0051ZZ

N
JSKIA0055ZZ

MIG seam weld / Point weld

P

JSKIA0052ZZ JSKIA0056ZZ

Revision: 2011 October BRM-33 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
• Front pillar butt joint can be determined anywhere within shaded
area as shown in the figure. The best location for the butt joint is at
position A due to the construction of the vehicle.

PIIA0150E

• Determine cutting position and record distance from the locating

indent. Use this distance when cutting the service part. Cut outer
front pillar over 60 mm (2.36 in) above the inner front pillar cut
position.

JSKIA0104GB

• Prepare a cutting jig to make outer pillar easier to cut. Also, this will
permit the service part to be accurately cut at the joint position.

JSKIA0105GB

• An example of cutting operation using a cutting jig is as per the fol-

lowing.
1. Mark cutting lines.
A: Cut position of outer pillar
B: Cut position of inner pillar
2. Align cutting line with notch on jig. Clamp jig to pillar.
3. Cut outer pillar along groove of jig (at position A).
4. Remove jig and cut remaining portions.
5. Cut inner pillar at position B in same manner.

PIIA0153E

Revision: 2011 October BRM-34 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Radiator Core Support INFOID:0000000007578122

BRM

JSKIA2008ZZ O

: Vehicle front
Replacement parts P
z Side radiator core support (LH Up- z Side radiator core support (LH Low- z Hoodledge connector (LH)
per) er)

Hoodledge INFOID:0000000007578123

Work after radiator core support is removed.

Revision: 2011 October BRM-35 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2157ZZ

: Vehicle front
Replacement parts
z Front strut housing (LH) z Hoodledge reinforcement (LH)

View B: Before installing hoodledge reinforcement

Hoodledge (Partial Replacement) INFOID:0000000007578124

Work after radiator core support is removed.

Remove the welding points ″f″ for easier installation.

Revision: 2011 October BRM-36 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

BRM

N
JSKIA2158ZZ

: Vehicle front O
Replacement parts
z Upper hoodledge (RH) z Lower front hoodledge (RH) z Hoodledge reinforcement (RH)
P
View B: Before installing hoodledge reinforcement

Revision: 2011 October BRM-37 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2159GB

Unit: mm (in)
: Vehicle front

View D: Before installing hoodledge reinforcement

Front Side Member INFOID:0000000007578125

Work after radiator core support and hoodledge are removed.

Revision: 2011 October BRM-38 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

BRM

N
JSKIA2165ZZ

: Vehicle front O
: Weld the parts onto the back of the component part.
Replacement parts
z Front side member assembly (LH) z Front side member closing plate as- z Front suspension mounting bracket P
sembly (LH) (LH Rear)

Revision: 2011 October BRM-39 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2164ZZ

: Vehicle front
: Weld the parts onto the back of the component part.

View D and H: Before installing front suspension mounting bracket (Rear)

Front Side Member (Partial Replacement) INFOID:0000000007578126

Work after radiator core support is removed.

Revision: 2011 October BRM-40 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

BRM

N
JSKIA2013ZZ

: Vehicle front O
: Weld the parts onto the back of the component part.
Replacement parts
z Front suspension mounting bracket z Add on frame bracket (RH) P
(RH Front)

POINT
The front side member on the left can also be replaced partially by butt welding.

Revision: 2011 October BRM-41 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2014GB

Unit: mm (in)
: Vehicle front
Replacement parts
z Front side member assembly (LH) z Front side member closing plate as-
sembly (LH)

NOTE:
For welding method and the number of welding points, refer to BRM-38, "Front Side Member".

Front Pillar INFOID:0000000007578127

Work after hoodledge reinforcement is removed.

Revision: 2011 October BRM-42 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

BRM

N
JSKIA2168GB

1. Body sealing O
Unit: mm (in)
: Vehicle front
Replacement parts P
z Outer front side body (LH) z Front pillar brace (LH) z Side dash (LH)
z Upper inner front pillar (LH) z Front fender bracket assembly (LH)

View A: Before installing outer front side body, front fender bracket assembly, and front pillar brace

Revision: 2011 October BRM-43 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2210ZZ

1. Urethane foam
: Vehicle front

View E: Before installing outer front side body and front fender bracket assembly

Revision: 2011 October BRM-44 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

BRM

N
JSKIA2170GB

Unit: mm (in) O
: Vehicle front
: Drill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel plate).
: Weld the parts onto the back of the component part. P

View G: Before installing outer front side body, front fender bracket assembly, and front pillar brace
View M: Before installing outer front side body
Center Pillar (Standard Roof Models) INFOID:0000000007578128

Remove the outer sill reinforcement (reusable).

Revision: 2011 October BRM-45 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2171GB

1. Outer sill reinforcement (reusable) 2. Lower center pillar brace 3. Inner center pillar
Unit: mm (in)
: Vehicle front
Replacement parts
z Outer front side body (LH) z Lower center pillar brace (LH) z Inner center pillar (LH)

Revision: 2011 October BRM-46 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

BRM

N
JSKIA2172GB

1. Outer sill reinforcement (reusable) 2. Lower center pillar brace O

Unit: mm (in)
: Vehicle front
P
View B, D, E, and G: Before installing outer front side body
Center Pillar (With Sunroof Models) INFOID:0000000007578129

Remove the outer sill reinforcement (reusable).

Revision: 2011 October BRM-47 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2018GB

1. Outer sill reinforcement (reusable) 2. Lower center pillar brace 3. Inner center pillar
Unit: mm (in)
: Vehicle front
Replacement parts
z Outer front side body (LH) z Lower center pillar brace (LH) z Inner center pillar (LH)

Revision: 2011 October BRM-48 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

BRM

N
JSKIA2172GB

1. Outer sill reinforcement (reusable) 2. Lower center pillar brace O

Unit: mm (in)
: Vehicle front
P
View B, D, E, and G: Before installing outer front side body

Revision: 2011 October BRM-49 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Outer Sill (Partial Replacement) INFOID:0000000007578130

JSKIA2020GB

Unit: mm (in)
: Vehicle front
Replacement parts
z Outer sill (LH) z Outer sill reinforcement (LH)

View A: Before installing outer sill

Revision: 2011 October BRM-50 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Outer Sill INFOID:0000000007578131

BRM

JSKIA2175GB O

1. Body sealing 2. Adhesive 3. Urethane foam

Unit: mm (in) P
: Vehicle front
Replacement parts
z Outer sill (LH) z Outer sill reinforcement (LH) z Front fender bracket assembly (LH)

View B: Before installing outer sill and front fender bracket assembly

Revision: 2011 October BRM-51 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2174GB

1. Hemming portion
Unit: mm (in)
: Vehicle front

View J: Before installing outer sill

POINT

Revision: 2011 October BRM-52 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
• Perform the hemming to the flange of wheelarch after applying the
adhesive. A
• Apply the sealing to the flange end.
• Refer to BRM-31, "Rear Fender Hemming Process".
B
1. Outer rear wheelhouse
2. Rear fender
3. Adhesive C
4. Sealant
JSKIA0204GB

BRM

Revision: 2011 October BRM-53 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Fender (2WD Models) INFOID:0000000007578132

JSKIA2023GB

1. Urethane foam 2. Body sealing 3. Adhesive

4. Hemming portion
Unit: mm (in)
: Vehicle front
Replacement parts
z Rear fender (LH) z Rear fender extension (LH) z Rear fender corner (LH)

Revision: 2011 October BRM-54 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

BRM

N
JSKIA2616GB

1. Adhesive O
Unit: mm (in)
: Vehicle front
: Weld the parts onto the back of the component part. P
View F: Before installing rear fender
View H: Right side rear fender
POINT

Revision: 2011 October BRM-55 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
• Perform the hemming to the flange of wheelarch after applying the
adhesive.
• Apply the sealing to the flange end.
• Refer to BRM-31, "Rear Fender Hemming Process".

1. Outer rear wheelhouse

2. Rear fender
3. Adhesive
4. Sealant
JSKIA0204GB

Revision: 2011 October BRM-56 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Fender (AWD Models) INFOID:0000000007578133

BRM

JSKIA2178GB O

1. Urethane foam 2. Body sealing 3. Adhesive

4. Hemming portion P
Unit: mm (in)
: Vehicle front
Replacement parts
z Rear fender (LH) z Rear fender extension (LH) z Rear fender corner (LH)

Revision: 2011 October BRM-57 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2617GB

1. Adhesive
Unit: mm (in)
: Vehicle front
: Weld the parts onto the back of the component part.

View F: Before installing rear fender

View H: Right side rear fender
POINT

Revision: 2011 October BRM-58 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
• Perform the hemming to the flange of wheelarch after applying the
adhesive. A
• Apply the sealing to the flange end.
• Refer to BRM-31, "Rear Fender Hemming Process".
B
1. Outer rear wheelhouse
2. Rear fender
3. Adhesive C
4. Sealant
JSKIA0204GB

BRM

Revision: 2011 October BRM-59 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Fender Extension (2WD Models) INFOID:0000000007578134

JSKIA2025ZZ

1. Body sealing
Replacement parts
z Rear fender corner (LH)

Revision: 2011 October BRM-60 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Fender Extension (AWD Models) INFOID:0000000007578135

BRM

JSKIA2180ZZ O

1. Body sealing
Replacement parts P
z Rear fender corner (LH)

Revision: 2011 October BRM-61 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Panel (2WD Models) INFOID:0000000007578136

JSKIA2522GB

Unit: mm (in)
: Vehicle front
: Welding method, the number of welding points, and the distance in the figure apply to both side of the vehicle.
Replacement parts
z Upper rear panel

Revision: 2011 October BRM-62 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Panel (AWD Models) INFOID:0000000007578137

BRM

JSKIA2523GB O

Unit: mm (in)
: Vehicle front P
: Welding method, the number of welding points, and the distance in the figure apply to both side of the vehicle.
Replacement parts
z Upper rear panel

Rear Floor Rear (2WD Models) INFOID:0000000007578138

Work after rear panel is removed.

Revision: 2011 October BRM-63 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2208ZZ

: Vehicle front
: Welding method and the number of welding points apply to both side of the vehicle.
: Weld the parts onto the back of the component part.
Replacement parts
z Rear floor rear z Spare tire clamp bracket z Rear towing hook bracket
z Muffler mounting bracket z Canister bracket (rear) z Spare wheel clamp reinforcement
z Canister mounting bracket

Rear Floor Rear (AWD Models) INFOID:0000000007578139

Work after rear panel is removed.

Revision: 2011 October BRM-64 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

BRM

N
JSKIA2209ZZ

: Vehicle front O
: Welding method and the number of welding points apply to both side of the vehicle.
Replacement parts
z Rear floor rear z Spare tire clamp bracket z Jack mounting bracket P
z Canister bracket z Spare wheel clamp reinforcement

Rear Side Member (AWD Models Partial Replacement) INFOID:0000000007578140

Work after rear panel and rear floor rear are removed.

Revision: 2011 October BRM-65 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2188GB

Unit: mm (in)
: Vehicle front
: Weld the parts onto the back of the component part.
Replacement parts
z Rear side member (LH)

Rear Side Member Extension (2WD Models) INFOID:0000000007578141

Work after rear panel is removed.

Revision: 2011 October BRM-66 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

BRM

N
JSKIA2032ZZ

: Vehicle front O
: Weld the parts onto the back of the component part.
Replacement parts
z Rear side member extension (LH) P

Rear Side Member Extension (AWD Models) INFOID:0000000007578142

Work after rear panel is removed.

Revision: 2011 October BRM-67 2012 JUKE

 REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >

JSKIA2189ZZ

: Vehicle front
: Weld the parts onto the back of the component part.
Replacement parts
z Rear side member extension (LH)

Revision: 2011 October BRM-68 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
BODY ALIGNMENT
Body Center Marks INFOID:0000000007578143
B
A mark is placed on each part of the body to indicate the vehicle center. When repairing the vehicle frame
(members, pillars, etc.) damaged by an accident which it enables more accurate and effective repair by using
these marks together with body alignment specifications. C

BRM

JSKIA2144ZZ
O

: Vehicle front
P
Unit: mm (in)
Points Portion Marks
A Front roof Embossment
B Cowl top Embossment
C Upper dash Embossment
D Trans control reinforcement Hole φ16 (0.63)

Revision: 2011 October BRM-69 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Points Portion Marks
E Parking brake reinforcement Hole φ12 (0.47)
F Rear panel Indent
G Rear roof Embossment

Description INFOID:0000000007578144

• All dimensions indicated in the figures are actual.

• When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself
to make sure there is no free play.
• When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
• Measurements should be taken at the center of the mounting holes.
• An asterisk (*) following the value at the measuring point indicates that the measuring point on the other side
is symmetrically the same value.
• The coordinates of the measurement points are the distances measured from the standard line of ″X″, ″Y″
and ″Z″.
• ″Z″: Imaginary base line [200 mm (7.87 in) below datum line (″0Z″ at design plan)]

JSKIA0073GB

1. Vehicle center 2. Front axle center 3. Imaginary base line

Engine Compartment INFOID:0000000007578145

MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.

Revision: 2011 October BRM-70 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)

I
JSKIA2151GB

Unit: mm (in)
J
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo Point Dimension Memo
BRM
A-C 729 (28.70)* B-E 298 (11.73)* D-d 1429 (56.26) G-h 1192 (46.93)*
A-D 729 (28.70)* B-e 1233 (48.54)* E-e 1037 (40.83) J-j 958 (37.72)
A-F 798 (31.42)* C-c 1441 (56.73) F-f 1366 (53.78) L

MEASUREMENT POINTS
M

Revision: 2011 October BRM-71 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)

JSKIA2152ZZ

: Vehicle front

Unit: mm (in)

Point Material Point Material

Upper radiator core support hole center
Upper dash positioning mark of center position-
A G, g, H, h G, g: φ12 (0.47)
ing mark
H, h: 14×12 (0.55×0.47)
Hoodledge reinforcement hole center 14×10
B, b J Front side member hole center φ7 (0.28)
(0.55×0.39)
C, c, F, f Front fender installing hole center φ7 (0.28) j Engine mounting bracket hole center φ11 (0.43)
Front combination lamp installing hole center φ7 Front bumper stay installing hole center φ15
D, d K, k, M, m
(0.28) (0.59)
Front strut installing hole center 16×10
E, e
(0.63×0.39)

Revision: 2011 October BRM-72 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Underbody (2WD Models) INFOID:0000000007578146

A
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle. B
The following figure shows a bottom view and a side view of the vehicle.

BRM

JSKIA1991GB

Revision: 2011 October BRM-73 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)

Unit: mm (in)
: Vehicle front
: Vehicle left side

MEASUREMENT POINTS

JSKIA2153ZZ

: Vehicle front

Unit: mm (in)
Coordinates Coordinates
Points Remarks Points Remarks
X Y Z X Y Z
473.5 −557.0 293.0 ±482.3 2374.2 348.3
A Hole φ11 (0.43) H, h Hole φ12 (0.47)
(18.642) (−21.929) (11.535) (±18.988) (93.472) (13.713)
−491.0 −557.0 301.9 499.5 2448.0 378.0
a Hole φ11 (0.43) J Hole φ21 (0.83)
(−19.331) (−21.929) (11.886) (19.665) (96.378) (14.882)
472.4 −455.0 328.9 −487.5 2448.0 378.0
B Hole φ18 (0.71) j Hole φ21 (0.83)
(18.598) (−17.913) (12.949) (−19.193) (96.378) (14.882)

Revision: 2011 October BRM-74 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Coordinates Coordinates
Points Remarks Points Remarks A
X Y Z X Y Z
−489.7 −455.0 328.9 498.0 2743.0 378.0 Hole 17×16
b Hole φ18 (0.71) K
(−19.279) (−17.913) (12.949) (19.606) (107.992) (14.882) (0.67×0.63)
B
±410.0 547.0 190.2 −487.5 2743.0 378.0 Hole 17×16
C, c Hole φ16 (0.63) k
(±16.142) (21.535) (7.488) (−19.193) (107.992) (14.882) (0.67×0.63)
±410.0 815.0 184.0 498.0 2970.0 375.4
D, d Hole φ12 (0.47) M Hole φ16 (0.63) C
(±16.142) (32.087) (7.244) (19.606) (116.929) (14.779)
±410.0 1173.0 170.1 Hole 14×2 −485.1 2965.8 375.4
E, e m Hole φ16 (0.63)
(±16.142) (46.181) (6.697) (0.55×0.47) (−19.098) (116.764) (14.779)
D
±633.0 2032.3 318.0 ±583.6 6.6 868.2
F, f Hole φ16 (0.63) N, n Hole φ98 (3.86)
(±24.921) (80.012) (12.520) (±22.976) (0.261) (34.181)
±350.0 2253.0 390.4 ±575.4 2569.2 734.4
G, g Hole †16 (0.63) O, o Hole φ20 (0.79) E
(±13.780) (88.701) (15.370) (±22.653) (101.149) (28.913)

Underbody (AWD Models) INFOID:0000000007578147

F
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle. G
The following figure shows a bottom view and a side view of the vehicle.

BRM

Revision: 2011 October BRM-75 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)

JSKIA2154GB

Unit: mm (in)
: Vehicle front
: Vehicle left side

MEASUREMENT POINTS

Revision: 2011 October BRM-76 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)

BRM

L
JSKIA2155ZZ

: Vehicle front M

Unit: mm (in)
Coordinates Coordinates
Points Remarks Points Remarks N
X Y Z X Y Z
473.5 −557.0 293.0 ±515.1 2318.6 357.2
A Hole φ11 (0.43) G, g Hole φ12 (0.47)
(18.642) (−21.929) (11.535) (±20.279) (91.283) (14.063) O
−491.0 −557.0 301.9 ±330.0 2339.7 419.0 Hole 33×30
a Hole φ11 (0.43) H, h
(−19.331) (−21.929) (11.886) (±12.992) (92.114) (16.496) (1.30×1.18)
472.4 −455.0 328.9 ±482.0 2648.0 422.2 Hole 20×6 P
B Hole φ18 (0.71) J, j
(18.598) (−17.913) (12.949) (±18.976) (104.252) (16.622) (0.79×0.63)
−489.7 −455.0 328.9 ±300.0 2815.0 417.2 Hole 18×6
b Hole φ18 (0.71) K, k
(−19.279) (−17.913) (12.949) (±11.811) (110.827) (16.425) (0.71×0.63)
±410.0 547.0 190.2 ±482.7 2910.5 421.4
C, c Hole φ16 (0.63) M, m Hole φ23 (0.91)
(±16.142) (21.535) (7.488) (±19.004) (114.586) (16.591)
±410.0 815.0 184.0 ±583.6 6.6 868.2
D, d Hole φ12 (0.47) N, n Hole φ98 (3.86)
(±16.142) (32.087) (7.244) (±22.976) (0.261) (34.181)

Revision: 2011 October BRM-77 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Coordinates Coordinates
Points Remarks Points Remarks
X Y Z X Y Z
±410.0 1173.0 170.1 Hole 14×2 ±558.8 2568.4 734.4
E, e O, o Hole φ20 (0.79)
(±16.142) (46.181) (6.697) (0.55×0.47) (±22.000) (101.118) (28.913)
±601.8 2016.4 315.0
F, f Hole φ15 (0.59)
(±23.693) (79.386) (12.402)

Passenger Compartment INFOID:0000000007578148

MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.

JSKIA1996GB

Unit: mm (in)

«The others»

Revision: 2011 October BRM-78 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo Point Dimension Memo A
A-E 724 (28.50)* H-h 1406 (55.35) N-n 1423 (56.02) R-J 1394 (54.88)*
B-E 1028 (40.47)* H-j 1829 (72.01)* N-o 1585 (62.40)* R-K 1072 (42.20)*
B
C-d 1290 (50.79)* H-k 1663 (65.47)* N-p 1554 (61.18)* S-M 1094 (43.07)*
C-e 1423 (56.02)* J-j 1257 (49.49) N-q 1506 (59.29)* S-N 786 (30.94)*
F-f 1222 (48.11) J-k 1463 (57.60)* O-o 1326 (52.20) S-O 1248 (49.13)* C
F-h 1569 (61.77)* K-k 1425 (56.10) O-q 1518 (59.76)* S-P 1126 (44.33)*
F-j 1386 (54.57)* M-m 1248 (49.13) P-p 1397 (55.00) S-Q 905 (35.63)*
F-k 1519 (59.80)* M-n 1451 (57.13)* Q-q 1444 (56.85) T-V 1128 (44.41)* D
G-g 1359 (53.50) M-o 1441 (56.73)* R-F 1104 (43.46)* T-W 1105 (43.50)*
G-j 1630 (64.17)* M-p 1486 (58.50)* R-G 885 (34.84)* U-V 1204 (47.40)*
E
G-k 1616 (63.62)* M-q 1578 (62.13)* R-H 720 (28.35)* U-W 1091 (42.95)*

MEASUREMENT POINTS
F

BRM

JSKIA1997ZZ

Revision: 2011 October BRM-79 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)

: Vehicle front

Unit: mm (in)

Point Material Point Material

J, j, K, k, M, M,
A Cowl top flange end of center positioning mark Center pillar indent
N, n
B Roof flange end of center positioning mark O, o, Q, q Rear fender indent
C, c Outer side body joggle P, p Outer rear wheelhouse joggle
Trans control reinforcement hole center of center
D, d, G, g Upper inner front pillar joggle R
positioning mark φ16 (0.63)
Parking brake reinforcement hole center of cen-
E, e Hood hinge installing hole center φ12 (0.47) S
ter positioning mark φ12 (0.47)
Door hinge installing hole center
T, t, U, u, V, v,
F, f, H, h Front pillar indent T, t, U, u, W, w: φ12 (0.47)
W, w
V, v: φ9 (0.35)

Rear Body INFOID:0000000007578149

MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.

JSKIA1998GB

Unit: mm (in)

MEASUREMENT POINTS

Revision: 2011 October BRM-80 2012 JUKE

 BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)

I
JSKIA1999ZZ

: Vehicle front J

Point Material Point Material

A Roof flange end of center positioning mark C, c, D, d Rear combination lamp base joggle BRM
Upper rear panel indent of center positioning
B, b Rear fender extension joggle E
mark
L

Revision: 2011 October BRM-81 2012 JUKE

 LOCATION OF PLASTIC PARTS
< SERVICE DATA AND SPECIFICATIONS (SDS)
LOCATION OF PLASTIC PARTS
Precautions for Plastics INFOID:0000000007578150

Heat resisting
Abbre- Resistance to gasoline and
Material name temperature Other cautions
viation solvents
°C (°F)
Gasoline and most solvents are
PE Polyethylene 60 (140) harmless if applied for a very Flammable
short time (wipe out quickly).
ABS Acrylonitrile Butadiene Styrene 80 (176) Avoid gasoline and solvents. —
AES Acrylonitrile Ethylene Styrene 80 (176) ↑ —
Gasoline and most solvents are
EPM/ Ethylene Propylene (Diene) co-
80 (176) harmless if applied for a very Flammable
EPDM polymer
short time (wipe out quickly).
PS Polystyrene 80 (176) Avoid solvents. Flammable
Gasoline and most solvents are
Poisonous gas is emitted
PVC Poly Vinyl Chloride 80 (176) harmless if applied for a very
when burned.
short time (wipe out quickly).
TPO Thermoplastic Olefine 80 (176) ↑ Flammable
AAS Acrylonitrile Acrylic Styrene 85 (185) Avoid gasoline and solvents. —
PMMA Poly Methyl Methacrylate 85 (185) ↑ —
EVAC Ethylene Vinyl Acetate 90 (194) ↑ —
Gasoline and most solvents are
Flammable, avoid bat-
PP Polypropylene 90 (194) harmless if applied for a very
tery acid.
short time (wipe out quickly).
PUR Polyurethane 90 (194) Avoid gasoline and solvents. —
UP Unsaturated Polyester 90 (194) ↑ Flammable
ASA Acrylonitrile Styrene Acrylate 100 (212) ↑ Flammable
PPE Poly Phenylene Ether 110 (230) ↑ —
TPU Thermoplastic Urethane 110 (230) ↑ —
PBT+ Poly Butylene Terephthalate +
120 (248) ↑ Flammable
PC Polycarbonate
PC Polycarbonate 120 (248) ↑ —
POM Poly Oxymethylene 120 (248) ↑ Avoid battery acid.
Avoid immersing in wa-
PA Polyamide 140 (284) ↑
ter.
PBT Poly Butylene Terephthalate 140 (284) ↑ —
PAR Polyarylate 180 (356) ↑ —
PET Polyethylene terephthalate 180 (356) ↑ —
PEI Polyetherimide 200 (392) ↑ —
CAUTION:
• When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics (influence of heat
and solvent) and remove them if necessary or take suitable measures to protect them.
• Plastic parts should be repaired and painted using methods suiting the materials, characteristics.

Revision: 2011 October BRM-82 2012 JUKE

 LOCATION OF PLASTIC PARTS
< SERVICE DATA AND SPECIFICATIONS (SDS)
Location of Plastic Parts INFOID:0000000007578151

JSKIA2000ZZ
I
Component Material Component Material
1 Windshield molding PVC 10 Door outside molding PVC + Stainless
J
Lens PMMA Front PC + PET
2 Front combination lamp 11 Door outside handle PC + PET +
Housing PP Rear
Glass fiber
BRM
3 Front grille ABS Lens PMMA
12 Rear combination lamp
4 Bumper fascia PP + EPM Housing ASA
Lens PC Lens PMMA L
5 Head lamp 13 High mount stop lamp
Housing PP Housing PC + ABS
6 Fillet molding PP + EPM 14 Back door finisher ABS
M
7 Front fender protector PP Lens PC
15 License plate lamp
Lens PMMA Housing PC
8 Side turn signal lamp
Housing PC + ABS Lens PMMA N
16 Reflex reflector
Housing ASA Housing ABS

Door outside Base PBT + PET 17 Center mudguard PP + EPM

9
mirror Material color ASA O
Cover
Body color ABS

Revision: 2011 October BRM-83 2012 JUKE

 LOCATION OF PLASTIC PARTS
< SERVICE DATA AND SPECIFICATIONS (SDS)

JSKIA2205ZZ

Component Material Component Material

1 Front pillar garnish PP Lens PC
6 Multi display unit
Lens PC Finisher PC + ABS
2 Map lamp
Housing PA 7 Glove box PP
3 Center pillar garnish PP 8 Instrument panel PP
4 Rear pillar finisher PP 9 Cluster lid C PC + ABS
5 Center console PP 10 Cluster lid A PP

Revision: 2011 October BRM-84 2012 JUKE