Tfcel-We-1211th 2nd WSMW 120 TF Tis 12tf

2012MY
WORKSHOP MANUAL
BODY, CAB, CHASSIS ELECTRICAL

AND ACCESSORIES
No.TFCEL-WE-1211TH
67209_Maegaki 2011.7.22 1:06 PM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0 Introduction
14A Service Information Guide
14B Vehicle Information
1 ENGINE 15B Maintenance Information
15C Functional Inspection
15D Symptom
15E DTC Information
1A Engine Control
1B Mechanical
1C Fuel System
1D Cooling
1E Lubrication
1F Induction
1G Exhaust
1H Aux. Emission Control Devices
1I Speed Control Systems
1J Electrical
2 SUSPENSION 16B Maintenance Information
16D Symptom
2B Front Suspension
2C Rear Suspension
2D Wheel, Tire System
3 DRIVELINE, AXLE 17B Maintenance Information
17D Symptom
17E DTC Information
3A Driveline Control
3B Differentials
3C Drive Shaft System
3D Transfer Case
4 BRAKES 18B Maintenance Information
18D Symptom
18E DTC Information
4A Brake Control
4B Brake System
4C Parking Brake System
4D ABS
5 TRANSMISSION, TRANSAXLE 19B Maintenance Information
19D Symptom
19E DTC Information
5A Transmission Control
5B Automatic
5C Manual
5E Clutch System
6 STEERING 20B Maintenance Information
20D Symptom
6B Power Assisted System
67209_Maegaki 2011.7.22 1:06 PM ページ 2
Section Sub Section

7 HVAC 21B Maintenance Information
21D Symptom
7B Heater, Ventilator, Airconditioner
8 RESTRAINTS 22B Maintenance Information
22D Symptom
22E DTC Information
8A SRS Control
8B Air Bag Systems
8C Seat Belt Systems
9 BODY, CAB, ACCESSORIES 23B Maintenance Information
23D Symptom
9A Lighting Systems
9B Wiper, Washer Systems
9C Electrical Control, Entertainment
9E Instrumentation, Driver Info.
9G Hood, Fenders, Doors
9H Cab Structure
9I Seats
9J Security and Locks
9L Exterior, Interior Trim
9P Unibody Sub-frames
9T Glass, Windows, Mirrors
10 BODY CONTROL 36B Maintenance Information
36D Symptom
36E DTC Information
10I Body Control
10 SECURITY AND LOCKS CONTROL 42B Maintenance Information
42E DTC Information
10S Security and Locks Control
11 FRAME 24B Maintenance Information
- ETM - Using the Wiring Diagram
- Power System
- Engine
- Chassis
- Brake
- Safety
- Driver Assist
- Accessory
- Light
- Data Communications
- Location Diagram
- Connector List
Maintenance Information (All models) 23B-1
Description Body, Cab, Accessories

Maintenance Information
(All models)
Table of Contents
Maintenance precautions of body, cab, accessories......23B-2
Function, structure, operation of body, cab, accessories
.......................................................................................23B-3
Primary specifications of body, cab, accessories........23B-23
Introduction to the trouble diagnosis of body, cab,
accessories...................................................................23B-48
23B-2 Maintenance Information (All models)
Maintenance precautions of body, cab, accessories

1. Maintenance precautions of body, cab, accessories
Caution：
・ Projector or Halogen headlights become very
hot when they are used, so if the bulb surface
is stained with grease, the life of the bulb will
be shortened. Therefore, hold the flange part
when replacing the bulb and do not touch the
glass part directly by the hands.
・ The pressure inside the glass bulb in projector
or halogen lights is high. If you drop, hit or
damage it, broken glass may fly out.
・ If the bulb is removed and left for an extended
period of time, dust or moisture may
accumulate inside the lens. Prepare a new
bulb before replacing the bulb.
・ Be sure to use a bulb with the same wattage
for replacement.
・ Improper installation of the socket may cause
foggy or misty lens, so firmly install it after
replacing the bulb.
Function, structure, operation of body, cab, accessories

1. Function, structure, operation of body, cab, This circuit comprises a license plate light, ignition
accessories switch, the lighting switch of the combination switch and
relays.
Halogen headlight system
When the lighting switch is turned ON at the headlight or
This circuit comprises headlight, cornering light, ignition
tail light position, the tail light relay will be activated and
switch, lighting switch of combination switch, passing
the license plate light will be illuminated.
switch, high beam indication light and relays.
When the lighting switch is turned ON at the headlight Illumination light system
position, the headlight relay will be activated and the This circuit comprises illumination lights, ignition switch,
headlight will be illuminated. When the headlight is on, the lighting switch of the combination switch and relays.
the optical axis of the headlight can be faced upward and When the lighting switch is turned ON at the headlight or
downward alternately using the lighting switch. the tail position, the tail light relay will be activated and
The passing switch is not related to the position of the the illumination lights will be illuminated.
headlight switch. The optical axis will face upward only
Illumination light, LED type
when the switch lever is being pulled up.
Meter
Clearance light system Air conditioner panel, Fan switch
This circuit comprises a clearance light, ignition switch, Hazard warning flasher switch
the lighting switch of the combination switch and relays. 4WD switch signal
When the lighting switch is turned ON at the headlight or Remote control mirror switch
tail light position, the tail light relay will be activated and Illumination light, Power supply
the clearance light will be illuminated. Radio/audio
Fog light system Note：
This circuit comprises a fog light, ignition switch, the ・ Backup light system
lighting switch of the combination switch, fog light This circuit comprises a backup light and
switch, and relays. backup light switch. When the backup light
When the lighting switch is turned on at the headlight or switch installed to the transmission is turned
tail light position, the tail light relay will be activated. ON, the backup light will illuminate.
While keeping this state, when the fog light switch is
turned ON, the fog light relay will be activated and the Windshield wiper and washer system
fog light will be illuminated. The wiper and washer system comprise the following
units. The system is activated when the ignition switch is
Turn signal light and hazard light system in the ON position.
This circuit comprises turn signal lights, ignition switch, Wiper Washer switch
turn signal switch of combination switch, flasher unit, Intermittent relay
hazard warning switch, etc. When the turn signal switch Wiper motor
or the hazard switch is turned ON, the flasher unit will be Washer motor
activated and the turn signal light will be illuminated. The Washer nozzle
turn signal light is also illuminated by the answer-back Washer tank
function of the keyless entry system, etc. Wiper arm and blade
Doom light system The intermittent relay controls the low speed operation of
This circuit comprises room light, door switch, keyless the wiper motor. The washer motor and the high speed
entry control unit, etc. When the door switch is ON, the operation are controlled directly by the wiper and washer
keyless entry control unit will illuminate the room light. switch. The intermittent relay detects the operation signal
of the wiper and washer switch.
Tail light and stop light system
This circuit comprises a tail light, stop light, ignition Windshield washer
switch, the lighting switch of the combination switch, When the windshield washer switch is turned ON, the
stop light switch, and relays. When the lighting switch is voltage will be supplied to the washer motor. The
turned ON at the headlight or tail light position, the tail intermittent relay monitors this circuit voltage in order to
light relay will be activated and the tail light will be detect the wiper interlinking request signal. Shortly after
illuminated. The stop light illuminates according to the it detects the signal, it activates the wiper main relay and
operation of the stop light switch. drives the wiper motor at low speed.
License plate light system Wiper intermittent drive

This drives the wiper intermittently at low speed. When Wiper high speed drive
the wiper switch is at the "INT" position, the intermittent When the wiper switch is at the "HI" position, the wiper
relay activates the wiper main relay only for a fixed time main relay and the wiper high low relay are activated to
with a fixed interval and drives the wiper motor at low drive the wiper motor at high speed.
speed.
Note：
Wiper low speed drive ・ Windshield wiper and washer system
When the wiper switch is at the "LO" position, the wiper components
main relay is activated to drive the wiper motor at low
speed. The low speed drive can be tested with the wiper
output of the actuator test in a scan tool.
1. Wiper arm RH 7. Washer motor

2. Washer nozzle RH 8. Link rod LH
3. Washer nozzle LH 9. Wiper motor
4. Wiper arm LH 10. Link rod RH
5. Washer hose
6. Washer tank
Note：
・ Layout of switches
Vehicle speed detection is performed in the vehicle speed
sensor installed on the transmission (the same as the
current model), and the pulse signal is output from this
vehicle speed sensor to the ECM.
Tachometer
The tachometer displays the engine rpm based on the
engine rpm signal outputted from the ECM. The ECM
detects the signal from the crankshaft position sensor and
inputs the engine speed signal to the instrument panel
cluster via CAN communication.
Fuel gauge
The fuel gauge displays the remaining fuel level based on
the signal outputted from the fuel tank unit. Fuel gauge
displays the remaining fuel level as low when the
resistance detected by the fuel tank unit is high. Fuel
gauge displays the remaining fuel level as high when the
resistance detected by the fuel tank unit is low.
1. Hazard warning flasher switch
Thermometer
2. Illumination control switch (Model with MID)
The thermometer displays the engine coolant temperature
*Exclusive for instrument cluster.
based on the engine coolant temperature signal outputted
3. Volume control switch (Seek switch, Mode
from the ECM. The ECM detects an engine coolant
switch, Phone switch)
temperature signal from the water temperature sensor,
4. MID switch (Model with MID)
and the signal is input to the thermometer through CAN
5. Remote control mirror switch
communication.
6. Remote control mirror switch
7. Driver's SRS airbag Odometer, Trip meter
The odometer and trip meter calculate and display the
Instrument panel cluster system mileage based on the vehicle speed signal from ECM.
The following gauges and various warning lights and
indication lights are assembled to the instrument panel Note：
cluster. ・ Without MID
Speedometer
Tachometer
Fuel meter
Thermometer
Odometer, Trip meter
Shift indicator
Multi-information display, Vehicles with multi-
information display.
These components cannot be replaced separately because
they are integrated with the instrument panel cluster.
They communicate through CAN and control units such
as ECM, TCM, BCM, and EHCU.
Speedometer (Common to models with and without
ABS)
The indication on the speedometer is made in accordance
with the vehicle speed signal (CAN communication) from
the ECM. The vehicle speed signal (CAN
communication) is corrected to the actual vehicle speed
in the ECM to be output. Note：
Models with ABS ・ With MID
Vehicle speed detection is performed in the ABS wheel
speed sensor, and the pulse signal is output from the
EHCU to the ECM.
Models except ABS
Trip meter
Shift indicator
Out side temperature
4WD indicator (4H)
4WD indicator (4L)
Cruise indicator (main supply)
Cruise indicator (set)
Fuel gauge
Coolant temp gauge
Clock
There is only a clock display when an Isuzu Genuine
Audio System is not equipped.
INST.
Instantaneous fuel economy　numerical display
INST.
Instantaneous fuel economy　graphical display
AVG.
Average fuel economy　DISTANCE Section distance
Switch the display of odometer and trip meter, TRIP A, VG. SPEED
TRIP B, Clock Driving Distance and Average　Vehicle Speed
RANGE
Note：
Distance where it can run
・ There is only a clock display when an Isuzu ELAPSE TIME
Genuine Audio System is not equipped. Forgetting to pull out key warning
The multi-information display Forgetting light cancellation warning
The display functions to display information, warning Forgetting parking brake return warning
light, indication light and maintenance information. MID Screen function selection/setting
Information display Note：
ODO meter ・ Multi-information display operation procedures
Note：・ Model without MID

・ Warning light, Indication light
Note：
・ Model with MID
1. Generator warning light 8. Check 4WD warning light

2. Fuel filter warning light 9. Check trans warning light
3. Turn signal indicator light – left 10. Check engine warning light
4. Turn signal indicator light – right 11. Water separator warning light
5. SRS airbag warning light 12. Front fog light indicator light
6. Door open warning light 13. Shift indicator
7. High beam indicator light 14. 4WD low indicator light
15. 4WD indicator light 22. ABS warning light
16. Engine oil pressure warning light 23. Light position indicator light
17. Low fuel warning light 24. MID
18. Automatic transmission fluid temperature 25. TCS/ESC warning light
warning 26. TCS OFF indicator light
19. Brake system/parking brake warning light 27. ECS OFF indicator light
20. Engine overheat warning light
21. Seat belt warning light
Power window
This circuit is comprised of the ignition switch as well as
the power window switch and power window motor for
each window.
When the ignition switch is turned ON, the battery
voltage is applied to each power window switch through
the fuse and power window relay in the circuit. This
enables for up or down selection with each switch to
toggle the rotational direction of the power window
motor, which opens or closes the window. The switch at
the driver side has a built-in one touch circuit, which
automatically moves the window down by operating the
switch to the auto position.
Note：
・ Maintenance display (Model with MID)
* To return to the maintenance display, reset the distance

on the maintenance setting screen.
・Even when the battery is removed, the set value is
retained and continues.
・At the shipment from the factory, this function is not set
and not activated.
・The minus distance of display distance is displayed up
to the set distance in minus.
* When the set distance is 5,000 km, it is displayed up to
-5,000 km.
At this time, the subtraction display for -5,000 km or
further is not made, and -5,000 km display is maintained
in blinking at 2 Hz. While the display is blinking, it is
displayed after every ignition switch ON, and the display
cancellation operation is possible.
・It is displayed for 3 seconds after the end of the ignition Note：
switch ON "WELCOME Message" for every 200 km
・ Service reminder display items and settings
from the remaining distance of 1000 km.
・After the ignition switch ON, when it is once displayed 1.Engine Oil
for 3 times, it is not displayed up until the next 200 km. * The set distance is available within the range of
・When there are multiple maintenance display items, 5,000km to 10,000 km (owner's manual recommended　
each item is displayed for 3 seconds in ascending order of distance), and it can be set in increments of 1,000 km.
remaining distance.
2.Air cleaner element
・The maintenance display can be cancelled depending
* The distance is available within the range of 20,000 km
on user preference.
to 40,000 km (owner's manual recommended distance),
* When the operation switch is pressed while the
and it can be set in increments of 5,000 km.
maintenance display is being shown, "Display OFF"
* The display screen shown from the remaining distance
indicated in the diagram below is displayed for 3 seconds
of 1,000 km.
on the display screen, and the subtraction display is
cancelled after the currently shown display item.
3.User preference settings → The reminder screen is displayed only 3 times for
* The set distance is available within the range of 5,000 every ignition switch ON.
km to 20,000 km, and it can be set in increments of 1,000 → The reminder screen is displayed for every 100 km
km. between remaining 1,000 km and 0 km.
* The display screen shown at the remaining distance of → When the MID switch is pressed once while the
1,000 km. reminder screen is being displayed, the reminder screen
"OFF" screen is displayed, and the reminder screen is not
displayed after that.
Service (Engine Oil Reminder Distance Setting)

The setting for the engine oil replacement distance can be
Service (Air Cleaner Element Reminder Distance　
made between 5,000 km and 10,000 km in increments of
Setting)
1,000 km.
→ After selecting a distance by pressing the MID switch, ・ The setting for the air cleaner element replacement
press and hold the MID switch to set the distance. distance can be made between 20,000 km and 40,000 km
・After the distance is set, distance subtraction is in increments of 5,000 km.
displayed depending on the distance traveled. → After selecting a distance by pressing the MID switch,
･ When subtraction is made from the set distance and the press and hold the MID switch to set the distance.
remaining distance becomes 1,000 km, the reminder ・ After the distance is set, distance subtraction is
screen indicating [Remaining 1,000 km] is displayed on displayed depending on the distance traveled.
the MID. ・ When subtraction is made from the set distance and the
remaining distance becomes 1,000 km, the reminder
screen indicating [Remaining 1,000 km] is displayed on ・ When an arrow is displayed at the bottom of the setting
the MID. screen, it indicates that there is the next setting screen.
→ The reminder screen is displayed only 3 times for When subtraction is made from the set distance and the
every ignition switch ON. remaining distance becomes 1,000 km, the reminder
→ The reminder screen is displayed for every 100 km screen indicating [Remaining 1,000 km] is displayed on
between remaining 1,000 km and 0 km. the MID.
→ When the MID switch is pressed once while the
reminder screen is being displayed, the reminder screen
→ The reminder screen is displayed only 3 times for

every ignition switch ON.
→ The reminder screen is displayed for every 100 km
between remaining 1,000 km and 0 km.
Service (Maintenance Reminder Distance Setting) → When the MID switch is pressed once while the
reminder screen is being displayed, the reminder screen
・ The setting for the maintenance distance can be made
between 5,000 km and 20,000 km in increments of 1,000
km.
→ After selecting a distance by pressing the MID switch,
press and hold the MID switch to set the distance.
・ After the distance is set, distance subtraction is
displayed depending on the distance traveled.
Customize (Reset Mode)
With "RESET MODE", the resetting method can be
changed for "fuel economy (average fuel economy)",
"driving distance and average vehicle speed", and "elapse
time".
Select "LINK" and then in one of the fuel economy
(average fuel economy), driving distance and average
vehicle speed, and elapse time screens, press and hold the
MID switch. The fuel economy (average fuel economy),
driving distance and average vehicle speed, and elapse
time will all be reset at simultaneously. To reset a value
only for the screen that is currently displayed, select
"SEPARATE" and then in one of the fuel economy
(average fuel economy), driving distance and average
vehicle speed, and elapse time screens, press and hold the
MID switch.
Note：
・ Bulb location diagram
・ Without projector type
1. Turn signal light (outside rearview mirror type) 1. High mounted stop light
2. Turn signal light 2. Taillight and stop light
3. Front fog light 3. Rear turn signal light
4. Headlight /clearance light 4. Backup light / rear fog light
5. Turn signal light (front door type) 5. Licence plate light
Note： Note：
・ Projector type ・ Flat deck type
1. Turn signal light (outside rearview mirror type) 1. Licence plate light
2. Turn signal light 2. Backup light
3. Front fog light 3. Rear turn signal light
4. Headlight /clearance light 4. Taillight and stop light
Note： Note：
・ Standard type ・ Backup light system component views
・ Without ABS
Note： 1. Backup light switch, M/T

・ With ABS
Note：
・ Instrument panel cluster system circuit with
MID
Note：
・ Instrument panel cluster system circuit
diagram, without MID
Note：
・ Connector Face
Primary specifications of body, cab, accessories

1. Primary specifications of body, cab, accessories Note：
・ Primary specifications of the body, cab,
accessories
2. Body size Note：

・ Vehicle body dimensions, front body diagonal
dimensions
1： 916 mm { 36.06 in } 2： 490 mm { 19.29 in }

3： 490 mm { 19.29 in } 5： 818 mm { 32.20 in }
4： 820 mm { 32.28 in } 6： 411 mm { 16.18 in }
1： 1420 mm { 55.91 in } 2： 1500 mm { 59.06 in }

3： 1438 mm { 56.61 in } Note：
4： 929 mm { 36.57 in } ・ Vehicle body dimensions, front window
opening dimensions
5： 929 mm { 36.57 in }
1： 1392 mm { 54.80 in } 2： 1416 mm { 55.75 in }

3： 1416 mm { 55.75 in } Note：
4： 1133 mm { 44.61 in } ・ Regular cab vehicle body dimensions, cabin's
diagonal dimensions
1： 1042 mm { 41.02 in } 2： 1705 mm { 67.13 in }

3： 1247 mm { 49.09 in } Note：
4： 1421 mm { 55.94 in } ・ Extend cab vehicle body dimensions, cabin's
diagonal dimensions
5： 1993 mm { 78.46 in }
6： 1475 mm { 58.07 in }
1： 1901 mm { 74.84 in } 9： 1882 mm { 74.09 in }

2： 1042 mm { 41.02 in } 10： 1421 mm { 55.94 in }
3： 1776 mm { 69.92 in } 11： 2545 mm { 100.20 in }
4： 1712 mm { 67.40 in } 12： 1475 mm { 58.07 in }
5： 1154 mm { 45.43 in } Note：
6： 1997 mm { 78.62 in } ・ Crew cab vehicle body dimensions, cabin's
diagonal dimensions
7： 1247 mm { 49.09 in }
8： 1409 mm { 55.47 in }
1： 2059 mm { 81.06 in } 9： 1882 mm { 74.09 in }

2： 1042 mm { 41.02 in } 10： 1421 mm { 55.94 in }
3： 1705 mm { 67.13 in } 11： 2545 mm { 100.20 in }
4： 1764 mm { 69.45 in } 12： 1475 mm { 58.07 in }
5： 1306 mm { 51.42 in } Note：
6： 2002 mm { 78.82 in } ・ Regular cab vehicle body dimensions, door
opening dimensions
7： 1247 mm { 49.09 in }
8： 1409 mm { 55.47 in }
1： 1045 mm { 41.14 in } 2： 1020 mm { 40.16 in }

3： 1208 mm { 47.56 in } Note：
4： 1009 mm { 39.72 in } ・ Extend cab vehicle body dimensions, door
opening dimensions
5： 1461 mm { 57.52 in }
6： 938 mm { 36.93 in }
1： 1537 mm { 60.51 in } 2： 1587 mm { 62.48 in }

3： 1652 mm { 65.04 in } 8： 1167 mm { 45.94 in }
4： 1578 mm { 62.13 in } 9： 1167 mm { 45.94 in }
5： 1886 mm { 74.25 in } Note：
6： 1525 mm { 60.04 in } ・ Crew cab vehicle body dimensions, door
opening dimensions
7： 1005 mm { 39.57 in }
1： 1029 mm { 40.51 in } 8： 833 mm { 32.80 in }

2： 1020 mm { 40.16 in } 9： 1103 mm { 43.43 in }
3： 1208 mm { 47.56 in } 10： 1331 mm { 52.40 in }
4： 1009 mm { 39.72 in } 11： 837 mm { 32.95 in }
5： 1438 mm { 56.61 in } Note：
6： 938 mm { 36.93 in } ・ Regular cab vehicle body dimensions, door
opening clearance, level difference
7： 997 mm { 39.25 in }
1： 4.0 to 7.0 mm { 0.16 to 0.28 in } Clearance, right 2： 1.5 to 4.5 mm { 0.06 to 0.18 in } Level difference,
and left difference 3.0 mm ｛ 0.12 in ｝ right and left difference 2.0 mm ｛ 0.08 in ｝
3： 4.0 to 7.0 mm { 0.16 to 0.28 in } Clearance, right 9： 3.5 to 7.5 mm { 0.14 to 0.30 in } Clearance, right
and left difference 3.0 mm ｛ 0.12 in ｝ and left difference 2.0 mm ｛ 0.08 in ｝
4： 1.5 to 4.5 mm { 0.06 to 0.18 in } Level difference, 10： 7.0 to 11.0 mm { 0.28 to 0.43 in } Level difference,
right and left difference 2.0 mm ｛ 0.08 in ｝ right and left difference 2.0 mm ｛ 0.08 in ｝
6： 4.0 to 7.0 mm { 0.16 to 0.28 in } Level difference, 12： -1.0 to 1.0 mm { -0.04 to 0.04 in } Level difference,
7： 3.5 to 5.9 mm { 0.14 to 0.23 in } Clearance, right Note：
and left difference 1.5 mm ｛ 0.06 in ｝・ Extend cab vehicle body dimensions, door
8： -1.0 to 1.0 mm { -0.04 to 0.04 in } Level difference, opening clearance, level difference
right and left difference 2.0 mm ｛ 0.08 in ｝
4： 1.5 to 4.5 mm { 0.06 to 0.18 in } Level difference, 14： 7.0 to 11.0 mm { 0.28 to 0.43 in } Level difference,
6： -1.0 to 2.4 mm { -0.04 to 0.09 in } Level difference, 16： -1.5 to 1.5 mm { -0.06 to 0.06 in } Level difference,
8： 2 to 5 mm { 0.06 to 0.18 in } Level difference, right 18： 7.0 to 11.0 mm { 0.28 to 0.43 in } Level difference,
10： -1.5 to 1.5 mm { -0.06 to 0.06 in } Level difference, 20： -1.0 to 1.0 mm { -0.04 to 0.04 in } Level difference,
11： 3.5 to 5.9 mm { 0.14 to 0.23 in } Clearance, right Note：
and left difference 1.5 mm ｛ 0.06 in ｝・ Crew cab vehicle body dimensions, door
12： -1.0 to 1.0 mm { -0.04 to 0.04 in } Level difference, opening clearance, level difference
3： 4.0 to 7.0 mm { 0.16 to 0.28 in } Clearance, right
and left difference 3.0 mm ｛ 0.12 in ｝
4： 1.5 to 4.5 mm { 0.06 to 0.18 in } Level difference,
6： -1.0 to 2.4 mm { -0.04 to 0.09 in } Level difference,
Introduction to the trouble diagnosis of body, cab, accessories

1. Introduction to the trouble diagnosis of body, cab, Shift to the self diagnostic mode according to the
accessories following
LED display test 1. When the Odd/trip reset is continuously turned ON,
The instrument panel cluster verifies that the system ignition switch is also turned ON.
functions properly when the ignition switch is ON. 2. Odd/trip switch is continuously pressed for more then
When the system is running normal, the LEDs will light 600±50ms after ignition switch ON.
up or blink for a certain period of time as shown below. 3. Odd/trip reset button is turned OFF.
4. Odd/trip reset button is turned ON-OFF 3 times.
ABS warning light
5. Carry out 1 - 4 within 7.0±0.1 second.
ESC warning light
6. Press and hold the reset button. If the assembly is
Fuel filter warning light
Functioning correctly, the needles will move to the
Check 4WD warning light
positions specified in the table below.
Check trans warning light
Water separator warning light Functioning correctly, the needles will move to the
Engine overheat warning light positions specified in the table below.
Automatic transmission fluid temperature warning light
Speedometer 100km/h
Turns off after lighting up for 3 seconds.
Tachometer 3,000rpm
SRS air bag warning light turns off after blinking for 7
7. Release the reset button.
seconds.
The needles return to their home position.
Note：
8. Turn the ignition switch to the OFF position to cancel
・ The following lights light up until the engine is The self-diagnosis mode.
started.
Brake system warning /parking brake warning If the instrument panel cluster needles move as described
light above, there is no problem with the instrument panel
Turns off after the engine is started. cluster assembly.
Engine oil pressure warning light Problems may exist in other vehicle components related
Turns off after the engine is started. instrument panel cluster assembly operation.
Check engine warning light
Turns off after the engine is started. If the instrument panel cluster needles move as described
above, there is a problem with the instrument panel
Generator warning light cluster assembly.
Turns off after the engine is started.
Low fuel warning light The assembly must be replaced.
Lights at ten liters or less. Note：
Self-diagnosing function ・ Model except MID
Note：
・ Model except MID
Function checking whether each pointer the speedometer,
tachometer, and also the LCD segment display are
moving normally or not.
Note： Speedometer 100km/h
・ Model with MID Tachometer 3,000rpm
Function checking whether each pointer the speedometer, 7. Release the MID switch.
tachometer, and also the MID display are moving The needles return to their home position.
normally or not. 8. Turn the ignition switch to the OFF position to cancel
Shift to the self diagnostic mode according to the The self-diagnosis mode.
following If the instrument panel cluster needles move as described
1. When the MID switch is continuously turned ON, above, there is no problem with the instrument panel
ignition switch is also turned ON. cluster assembly.
2. MID switch is continuously pressed for more then Problems may exist in other vehicle components related
600±50ms after ignition switch ON. instrument panel cluster assembly operation.
3. MID switch is turned OFF.
4. MID switch is turned ON-OFF 3times. If the instrument panel cluster needles move as described
5. Carry out 1 - 4 within 7.0±0.1 second. above, there is a problem with the instrument panel
6. Press and hold the MID switch. cluster assembly.
If the assembly is Functioning correctly, the needles will The assembly must be replaced.
move to the positions specified in the table below.
Note：
Functioning correctly, the needles will move to the
・ Model with MID
positions specified in the table below.
Functional Inspection (All models) 23C-1

Functional Inspection
(All models)
Table of Contents
Tachometer representational accuracy check................23C-2
inspection..................................................................23C-2
Speedometer representational accuracy check..............23C-3
inspection..................................................................23C-3
23C-2 Functional Inspection (All models)
Tachometer representational accuracy check
inspection Note：
・ Use a scan tool to display the engine rpm.
1. Tachometer representational accuracy check
・ Compare the tachometer display and scan tool
inspection
display.
1. Connect a scan tool to the DLC.
2. Start the engine.
Meter indicator
Tester indicator
Tolerance range
750 rpm 700 - 820 rpm
2000 rpm 1915 - 2085 rpm
3000 rpm 2915 - 3085 rpm
Note：
・ Since the meter display tolerance range shown
in the table is an individual meter standard, it is
a reference value when making vehicle
inspections.
・ Confirm that the needle movement is not
sluggish when gradually increasing and
decreasing the engine rpm.
・ Compare with the engine rpm display and
confirm that it is within the meter display
tolerance range.
Functional Inspection (All models) 23C-3
Speedometer representational accuracy check
inspection ・ If the tire pressure is improper, the display

errors will increase.
1. Speedometer representational accuracy check
・ Be sure to follow the usage guidelines for the
inspection
speedometer tester used.
Note：・ km/h specification
・ Use a speedometer tester and inspect the
meter display accuracy and odometer
operation.
Tester Meter indicator

Displayed speed Tolerance range
20 km/h 20.5 - 24.8 km/h
40 km/h 41 - 45.3 km/h
60 km/h 61.5 - 65.8 km/h
80 km/h 82.2 - 86.5 km/h
Note：
・ Since the meter display tolerance range shown
in the table is an individual meter standard, it is
a reference value when making vehicle
inspections.
Symptom (All models) 23D-1

Symptom
(All models)
Table of Contents
Water separator warning light does not light even when Rear left side window does not operate......................23D-27
water exceeds water separator drain line......................23D-2 Wiper does not operate regardless of the switch position
Water separator warning light lights even when water level .....................................................................................23D-28
is low in water separator...............................................23D-3 Wiper does not operate at the "INT" position.............23D-29
Driving information is not displayed............................23D-4 Wiper does not operate at the "LO" position..............23D-30
Low fuel warning light does not light even when the fuel Wiper does not operate at the "HI" position...............23D-31
tank is empty.................................................................23D-5
None of the windows operate......................................23D-32
Brake system warning light does not light up even when the
Window at the driver side does not operate................23D-33
parking brake lever is engaged......................................23D-6
Window at the front left side does not operate...........23D-34
Brake system warning light does not turn off even when the
parking brake lever is fully released.............................23D-7 Both of the rear windows do not operate....................23D-35
Brake system warning light does not light up even when the Operation abnormality of the dome light function......23D-36
brake fluid in the tank decreases...................................23D-8 Operation abnormality of the taillight/stoplight function
Brake system warning light lights even when brake fluid is .....................................................................................23D-37
filled to specified level..................................................23D-9 Operation abnormality of the license plate light function
Engine oil pressure warning light does not turn off even .....................................................................................23D-38
when the engine is running.........................................23D-10 Operation abnormality of the illumination light function
Reading of the engine coolant temperature gauge is lower without instrument panel cluster assembly.................23D-39
(higher) than reality.....................................................23D-11 Operation abnormality of the instrument panel cluster
Segment display of the engine coolant temperature gauge illumination function...................................................23D-40
does not move change.................................................23D-12 Operation abnormality of the backup light function...23D-44
Segment display of the fuel gauge does not indicate "f" even Operation abnormality of the headlight function........23D-45
when the fuel tank is full.............................................23D-13 Operation abnormality of the clearance light function
Segment display of the fuel gauge ( goes up to "f") even .....................................................................................23D-46
when the fuel tank is not full.......................................23D-14 Operation abnormality of the fog light function.........23D-47
Low fuel warning light lights even when the fuel tank is full Operation abnormality of the turn signal light function
.....................................................................................23D-15 .....................................................................................23D-48
Pointer of the speedometer shakes..............................23D-16
Indicated error of the speedometer is significantly large
.....................................................................................23D-17
Pointer of the tachometer shakes.................................23D-18
Indicated error of the tachometer is significantly large
.....................................................................................23D-19
Segment display of the fuel gauge does not change. . .23D-20
Wiper motor does not stop..........................................23D-21
Washer motor does not operate...................................23D-22
Speedometer and odometer do not operate.................23D-23
Odometer does not count up (speedometer is normal)23D-24
Speedometer does not operate (odometer is normal). .23D-25
Right rear window does not operate............................23D-26
23D-2 Symptom (All models)
Water separator warning light does not light even when water exceeds water
separator drain line
1. Water separator warning light does not light even when Check the following circuits for a break, short-circuiting
water exceeds water separator drain line diagnostics of the power supply and GND, and high resistance. If any
abnormality is found in the circuit, repair or replace the
Note：
relevant circuit.
・ Prior confirmation and visual inspection Between the instrument panel cluster and the water
Check that the battery voltage is normal. sedimenter switch.
If the battery voltage is not normal, charge or replace the
battery.
Check that the fuses are in normal condition.
If any abnormality is found in a fuse such as wire-
melting, inspect and repair the cause of the melting first,
and then replace the fuse.
Check that the ground connection is normal.
If the ground connection has an abnormality, repair and
clean.
Check that the harnesses and connectors are normal.
Check the connector for connection failures and the
harness for abnormalities such as abrasion or bends.
Check that the wire inside the harness is not short-
circuited to another circuit.
Check the effect of the post-mounted electrical
components such as wireless devices and lights.
Turn OFF or remove the post-mounted electrical
components, so that they do not affect the inspection or
the operation.
Note：
・ Structural components inspection
Check the water sedimenter switch.
If any abnormality is found in the water sedimenter
switch, replace it.
Inspect the instrument panel cluster.
If the water sedimenter switch and the circuit are normal,
replace the instrument panel cluster.
Confirm whether the warning light of the instrument
panel cluster turns on for 3 seconds when the ignition
switch is ON. When it does not turn on, the meter is
faulty.
Caution
If the warning light of the instrument panel cluster turns
on for 3 seconds when the ignition switch is ON, the
instrument panel cluster itself is being controlled by the
CPU inside the instrument panel cluster. Therefore, when
the warning light turns on for 3 seconds, lighting of the
warning light is performed regardless of the sedimenter
switch status.
Note：
・ Inspection of the circuit
Water separator warning light lights even when water level is low in water
separator
1. Water separator warning light lights even when water
level is low in water separator diagnostics
Note：
・ Prior confirmation and visual inspection
Check that the battery voltage is normal.
battery.
clean.
the operation.
Note：
Check the water sedimenter switch.
If any abnormality is found in the water sedimenter
switch, replace it.
If the water sedimenter switch and the circuit are normal,
Note：
Check the following circuits for a break, short-circuiting
of the power supply and GND, and high resistance. If any
relevant circuit.
Between the instrument panel cluster and the water
sedimenter switch.
Driving information is not displayed

1. Driving information is not displayed diagnostics
Display Check the Parts

Fuel consumption is not Instant Fuel consumption ECM
1
displayed Average Fuel consumption ECM
2 Range is not displayed ECM and Tank Unit
3 Average Speed is not displayed ECM
4 Distance is not displayed ECM
It is meter CPU operation and other systems do not
5 Elapse time is not displayed
influence it for the self-conclusion.
6 Outside Temperature is not displayed AMB Sensor
Note：
Perform trouble diagnosis of the instrument panel cluster.
If any abnormality is found in its operation, replace the
instrument panel cluster.
When the instrument panel cluster is functioning
properly, but a failure is found with the input signal, an
error screen is displayed on the multi-display.
・RANGE "----"
・ELAPSE TIME There is no display
・DISTANCE There is no display
・AVG.SPEED There is no display
・INS "E"
There is no malfunction
indication for the bar segment
・AVG. "E"
If normal operation is confirmed, the problem is in a
component or system other than the instrument panel
cluster.
If there is no abnormality in the instrument panel cluster,
check each part in the table.
Low fuel warning light does not light even when the fuel tank is empty
1. Low fuel warning light does not light even when the
fuel tank is empty diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the fuel tank unit.
If any abnormality is found in the fuel tank unit, replace
it.
If the fuel tank unit and the circuit are normal, replace the
Brake system warning light does not light up even when the parking brake lever is
engaged
1. Brake system warning light does not light up even
when the parking brake lever is engaged diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the parking brake switch.
If the installation position of the parking brake switch is
improper, adjust it. Replace the switch if abnormalities
are discovered in the switch itself.
If the parking brake switch and the circuit are normal,
Note：
relevant circuit.
Between the instrument panel cluster and the parking
brake switch.
Brake system warning light does not turn off even when the parking brake lever is
fully released
1. Brake system warning light does not turn off even
when the parking brake lever is fully released
diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the parking brake switch.
If the installation position of the parking brake switch is
improper, adjust it. Replace the switch if abnormalities
are discovered in the switch itself.
If the parking brake switch and the circuit are normal,
Note：
relevant circuit.
Between the instrument panel cluster and the parking
brake switch.
Brake system warning light does not light up even when the brake fluid in the tank
decreases
1. Brake system warning light does not light up even
when the brake fluid in the tank decreases diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the brake fluid switch.
If any abnormality is found in the brake fluid switch,
replace the brake fluid tank.
If the brake fluid switch and the circuit are normal,
Note：
relevant circuit.
Between the instrument panel cluster and the brake fluid
switch.
Between the brake fluid switch and CAB right GND.
Brake system warning light lights even when brake fluid is filled to specified level
1. Brake system warning light lights even when brake
fluid is filled to specified level diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the brake fluid switch.
If any abnormality is found in the brake fluid switch,
replace the brake fluid tank.
If the brake fluid switch and the circuit are normal,
Note：
relevant circuit.
Between the instrument panel cluster and the brake fluid
switch.
Between the brake fluid switch and CAB right GND.
Engine oil pressure warning light does not turn off even when the engine is running
1. Engine oil pressure warning light does not turn off
even when the engine is running diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the engine oil pressure.
Check the engine oil pressure switch.
If any abnormality is found in the engine oil pressure
switch, replace it.
If the engine oil pressure switch and the circuit are
normal, replace the instrument panel cluster.
Note：
relevant circuit.
Between the instrument panel cluster and the engine oil
pressure switch.
Reading of the engine coolant temperature gauge is lower (higher) than reality
1. Reading of the engine coolant temperature gauge is
lower (higher) than reality diagnostics
WARNING
TEMP SEGMENT
TEMP RANGE (˚C) LAMP
SEGMENT (No.) CONDITION
CONDITION
6 120- BLINK (1Hz) TURN ON
5 114-119 TURN ON TURN OFF
0 -44 TURN ON TURN OFF
Note： Check that the wire inside the harness is not short-
・ DETAILED DRAWING OF DISPLAY circuited to another circuit.
the operation.
Note：
Inspect the related system and the communication circuit.
Inspect the CAN communication circuit and the systems
connected to the CAN communication circuit, and repair
them if abnormalities are discovered.
Note：
・ When you replace a control unit of a related
system, it is necessary to perform writing and
setting.
Note： Perform a self-diagnosis of the instrument panel cluster,
・ Prior confirmation and visual inspection and conduct a road test. If any abnormality is found,
battery.
clean.
Segment display of the engine coolant temperature gauge does not move change
1. Segment display of the engine coolant temperature
gauge does not move change diagnostics
Note：
battery.
clean.
the operation.
Note：
Note：
setting.
Perform a self-diagnosis of the instrument panel cluster,
and conduct a road test. If any abnormality is found,
Segment display of the fuel gauge does not indicate "f" even when the fuel tank is
full
1. Segment display of the fuel gauge does not indicate "f"
even when the fuel tank is full diagnostics
Note：
battery.
clean.
the operation.
Note：
it.
Note：
of the power supply and GND, and high resistance.
If any abnormality is found in the circuit, repair or
replace the relevant circuit.
Between the instrument panel cluster and the fuel tank
unit.
Between the fuel tank unit and GND.
Segment display of the fuel gauge ( goes up to "f") even when the fuel tank is not
full
1. Segment display of the fuel gauge ( goes up to "f")
even when the fuel tank is not full diagnostics
Note：
battery.
clean.
the operation.
Note：
it.
Note：
unit.
Between the fuel tank unit and GND.
Low fuel warning light lights even when the fuel tank is full
1. Low fuel warning light lights even when the fuel tank
is full diagnostics
Note：
battery.
clean.
the operation.
Note：
it.
Pointer of the speedometer shakes

1. Pointer of the speedometer shakes diagnostics
Note：
battery.
clean.
the operation.
Note：
Note：
setting.
Indicated error of the speedometer is significantly large

1. Indicated error of the speedometer is significantly Perform a self-diagnosis of the instrument panel cluster,
large diagnostics and conduct a road test. If any abnormality is found,
When the instrument panel cluster instruction speed is
outside the vehicle acceptable range, against the tester
display speed, or even when it is within the vehicle
acceptable range, the allowance of the instrument panel
cluster itself is largely deviated from the range
[Functional Inspection (ALL)].
Note：
battery.
clean.
the operation.
Note：
・ Confirm whether the tire size and the tire air
pressure are the specified values.
Note：
setting.
・ The speedometer and the odometer will not
display the correct value, if the vehicle speed
correction value is not set properly at ECM.
Pointer of the tachometer shakes

1. Pointer of the tachometer shakes diagnostics
Note：
battery.
clean.
the operation.
Note：
Note：
setting.
Indicated error of the tachometer is significantly large

1. Indicated error of the tachometer is significantly large
diagnostics
When the instrument panel cluster instruction rotation
speed is not within the acceptable range [Functional
Inspection (ALL)], against the tester display rotation.
Note：
battery.
clean.
the operation.
Note：
Note：
setting.
Segment display of the fuel gauge does not change

1. Segment display of the fuel gauge does not change
diagnostics
Note：
battery.
clean.
the operation.
Note：
it.
Note：
unit.
Wiper motor does not stop

1. Wiper motor does not stop diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the wiper and the washer switch.
Operate the wiper and the washer switch and check that
the circuit operates normally in a continuity test. If a
problem is found, replace the switch.
Check the wiper motor.
Replace the wiper motor if a defect is found.
Washer motor does not operate

1. Washer motor does not operate diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the wiper fuse.
If any abnormality is found in a fuse, replace the fuse.
Check the washer motor.
Replace the washer motor if a failure is found.
Note：
{power supply and GND} and high resistance. If any
relevant circuit.
Between the cab junction block and the washer motor.
Between the washer motor and the wiper, washer switch.
Between the wiper, washer switch and GND {cab}.
Speedometer and odometer do not operate

1. Speedometer and odometer do not operate diagnostics
Note：
battery.
clean.
the operation.
Note：
Note：
setting.
Odometer does not count up (speedometer is normal)

1. Odometer does not count up (speedometer is normal)
diagnostics
Note：
battery.
clean.
the operation.
Note：
Note：
setting.
Speedometer does not operate (odometer is normal)

1. Speedometer does not operate (odometer is normal)
diagnostics
Note：
battery.
clean.
the operation.
Note：
Note：
setting.
Right rear window does not operate

1. Right rear window does not operate diagnostics The power supply and the GND circuit of the power
window switch
Note：
battery.
clean.
the operation.
Note：
Check the rear right side power window switch.
After inspecting the power window circuit, operate the
rear right side power window switch and check that it
operates normally. If a problem is found, replace the
switch.
Check the rear right side power window switch for the
driver's seat.
rear right side power window switch for the driver's seat
and check that it operates normally. If a problem is found,
replace the switch.
Check the rear right side power window motor.
Replace the power window motor if it is defective.
Note：
relevant circuit.
Between the rear right side power window switch and the
rear right side power window motor.
Between the rear right side power window switch for the
driver's seat and the rear right side power window switch.
Rear left side window does not operate

1. Rear left side window does not operate diagnostics The power supply and the GND circuit of the power
window switch
Note：
battery.
clean.
the operation.
Note：
Check the rear left side power window switch.
rear left side power window switch and check that it
switch.
Check the rear left side power window switch for the
driver's seat.
rear left side power window switch for the driver's seat
and check that it operates normally. If a problem is found,
replace the switch.
Check the rear left side power window motor.
Note：
relevant circuit.
Between the rear left side power window switch and the
rear left side power window motor.
Between the rear left side power window switch for the
driver's seat and the rear left side power window switch.
Wiper does not operate regardless of the switch position

1. Wiper does not operate regardless of the switch Check the following circuits for a break, short-circuiting
position diagnostics {power supply and GND} and high resistance. If any
Note：
relevant circuit.
・ Prior confirmation and visual inspection Between the cab junction block and the wiper, washer
Check that the battery voltage is normal. switch.
If the battery voltage is not normal, charge or replace the Between the cab junction block and the wiper motor.
battery. Between the wiper, washer switch and GND {cab}.
clean.
the operation.
Note：
Check the wiper fuse.
If any abnormality is found in the fuse such as wire-
melting, inspect or repair the cause of the melting first,
Check the key-on relay function.
Check whether an abnormality exists in the key-on relay.
Replace it if any abnormality is found.
Check the wiper main relay function.
Check whether an abnormality exists in the wiper main
relay. Replace it if any abnormality is found.
Check the wiper high/low relay function.
Check whether an abnormality exists in the wiper high/
low relay. Replace it if any abnormality is found.
Note：
Wiper does not operate at the "INT" position

1. Wiper does not operate at the "INT" position
diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the BCM.
Check the DTC and replace the BCM if any abnormality
is found.
Note：
relevant circuit.
Between the wiper, washer switch and the BCM.
Wiper does not operate at the "LO" position

1. Wiper does not operate at the "LO" position
diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the wiper main relay function.
Check whether an abnormality exists in the wiper main
Note：
relevant circuit.
Between the cab junction block and the wiper, washer
switch.
Between the cab junction block and the wiper motor.
Wiper does not operate at the "HI" position

1. Wiper does not operate at the "HI" position
diagnostics
Note：
battery.
clean.
the operation.
Note：
Note：
relevant circuit.
Between the cab junction block and the wiper, washer
switch.
Between the cab junction block and the wiper motor.
None of the windows operate

1. None of the windows operate diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the fuse.
melting, inspect or repair the cause of the melting first,
Check the power window relay function.
If a problem is found, replace the power window relay.
Check the power window switch for the driver's seat side.
power window switch and check that it operates
normally. If a problem is found, replace the switch.
Note：
relevant circuit.
Between the fuse and each power window switch.
Between the power window switch and GND {cab}.
Window at the driver side does not operate

1. Window at the driver side does not operate diagnostics
Note：
battery.
clean.
the operation.
Note：
power window switch and check that it operates
normally. If a problem is found, replace the switch.
Check the power window motor for the driver's seat side.
Note：
relevant circuit.
Between the driver's seat side power window switch and
the power window motor.
Between the power supply and the GND circuit of the
power window switch.
Window at the front left side does not operate

1. Window at the front left side does not operate The power supply and the GND circuit of the power
diagnostics window switch
Note：
battery.
clean.
the operation.
Note：
Check the front left side power window switch.
front left side power window switch and check that it
switch.
power window switch for the driver's seat side and check
that it operates normally. If a problem is found, replace
the switch.
Check the front left side power window motor.
Note：
relevant circuit.
Between the front left side power window switch and the
front left side power window motor.
Between the driver's seat side power window switch and
the front left side power window switch.
Both of the rear windows do not operate

1. Both of the rear windows do not operate diagnostics
Note：
battery.
clean.
the operation.
Note：
Check the rear power window fuse.
If any abnormality is found in a fuse such as meltdown,
etc., inspect and repair the cause for the meltdown first,
Check the rear power window fuse.
If any abnormality is found in a fuse such as meltdown,
etc., inspect and repair the cause for the meltdown first,
Note：
relevant circuit.
Between cab junction block and the rear power window
relay.
Between the rear power window relay and the left and
right rear power window switches for the driver's seat.
Between the left and right rear power window switches
for the driver's seat and GND.
Between the power supply and the GND circuit of the
power window switch.
Operation abnormality of the dome light function

1. Operation abnormality of the dome light function Note：
diagnostics ・ Inspection of the circuit
Note： Check the following circuits for an open circuit, short
・ Prior confirmation and visual inspection circuit (power supply and GND), and high resistance. If
any abnormality is found in the circuit, repair or replace
the relevant circuit.
Between the slow blow fuse and the fuse.
battery.
Between the fuse and the room light, fluorescent light.
Check that the fuses are in normal condition. Between the room light, fluorescent light and BCM.
If any abnormality is found in a fuse such as wire- Between the BCM and the door switch.
melting, inspect and repair the cause of the melting first, Between the room light switch and GND.
and then replace the fuse. Between the door switch and GND.
clean.
the operation.
Note：
Inspect the slow blow fuse.
If any abnormality is found in a slow blow fuse, inspect
and repair the cause for the meltdown first, and then
replace the fuse.
Inspect the room light switch.
Operate the door switch and check that the circuit
operates normally in the continuity test. If a problem is
found, replace the switch.
Inspect the door switch.
Operate the door switch and check that the circuit
Replace the BCM.
If any defects are found in BCM, repair or replace it. If
the circuit and the switch are normal, replace the BCM.
When BCM is replaced, programming such as idling stop
start system and the MIMAMORI function is required.
Check that the bulbs of the room light are normal.
If any defects are found, repair or replace such defected
bulbs of the room light.
Operation abnormality of the taillight/stoplight function

1. Operation abnormality of the taillight/stoplight Note：
function diagnostics ・ Inspection of the circuit
Note： Check the following circuits for an open circuit, short
・ Prior confirmation and visual inspection circuit (power supply and GND), and high resistance. If
Between the slow blow fuse and the starter switch.
battery.
Between the slow blow fuse and the tail relay.
Check that the fuses are in normal condition. Between the slow blow fuse and the stop light relay.
If any abnormality is found in a fuse such as wire- Between the starter switch and the fuse.
melting, inspect and repair the cause of the melting first, Between the fuse and the tail relay.
and then replace the fuse. Between the tail relay and the fuse.
Between the tail relay and the lighting switch.
Between the fuse and the tail light.
Between the tail light and GND.
clean.
Between the stop light relay and the stop light switch.
Check that the harnesses and connectors are normal. Between the stop light switch and GND.
Check the connector for connection failures and the Between the stop light relay and the stop light.
harness for abnormalities such as abrasion or bends. Between the stop light and GND.
the operation.
Note：
replace the fuse.
Inspect the lighting switch.
Operate the lighting switch and check that the circuit
Inspect the stop light switch.
Operate the stop light switch and check that the circuit
Inspect the function of the tail relay.
Check whether an abnormality exists on the relay.
Inspect the function of the stop light relay.
Check that the bulbs of the combination light (taillight,
stoplight) are normal.
If the fluorescent light is defective, repair or replace it.
Operation abnormality of the license plate light function

1. Operation abnormality of the license plate light Between the slow blow fuse and the tail relay.
function diagnostics Between the starter switch and the fuse.
Between fuse and the tail relay.
Note：
Between the tail relay and the fuse.
・ Prior confirmation and visual inspection Between the tail relay and the lighting switch.
Check that the battery voltage is normal. Between the fuse and the license plate light.
If the battery voltage is not normal, charge or replace the Between the license plate light and GND.
battery. Between the lighting switch and GND.
clean.
the operation.
Note：
replace the fuse.
Check that the license plate light bulbs are normal.
bulbs.
Note：
Check the following circuits for an open circuit, short
circuit (power supply and GND), and high resistance. If
Operation abnormality of the illumination light function without instrument panel

cluster assembly
1. Operation abnormality of the illumination light abnormality is found in the circuit, repair or replace the
function without instrument panel cluster assembly relevant circuit.
diagnostics Between the slow blow fuse and the starter switch.
Note：
Between the starter switch and the fuse.
・ Prior confirmation and visual inspection Between fuse and the tail relay.
Check that the battery voltage is normal. Between the tail relay and the fuse.
If the battery voltage is not normal, charge or replace the Between the tail relay and the lighting switch.
battery. Between the fuse and the illumination light.
Between the illumination light and GND.
Check that the fuses are in normal condition. Between the lighting switch and GND.
clean.
the operation.
Note：
replace the fuse.
Check that the bulbs of the illumination light are normal.
If an abnormality is found in a bulb, repair or replace the
bulb or the switch.
Note：
{power supply and GND}, and high resistance. If any
Operation abnormality of the instrument panel cluster illumination function

1. Operation abnormality of the instrument panel cluster Instrument panel cluster illumination control system
illumination function diagnostics
Note：
Only for models with MID, check whether the lighting ・ Model: Without MID
control is "AUTO" or "MANUAL", and confirm that it is
operating properly in the currently set mode.
It is possible to release the automatic dimming control temperature gauge may be difficult to see
through the special operation, and it can be switched to when driving with the headlights on.
the light switch linked operation.
When the light switch is turned 3 times and "ON ⇔OFF"
Note： is detected within the specified time, the conditions are
・ How to release the LCD display automatic satisfied, and the day and night determination is cancelled
dimming control immediately.
When the cancellation conditions are satisfied, a beep
Caution：
indicating completion sounds after the conditions is met.
・ When the automatic dimming control is turned For the cases below, it is assumed that the conditions are
off, the fuel gauge and engine coolant not satisfied, and the day and night determination cancel
mode is released until the ignition switch is turned ON Through the operation below, the automatic dimming
again and then turned OFF. control (= day and night determination) is released, and
> "Light switch ON ⇔ Light switch OFF" cannot be the brightness can be dimmed for 1 level with the light
detected by turning the light switch 3 times within the switch linked operation in the same way as for the dial
specified time. (Less than 3 times) plate and pointer illuminations.
> "Light switch ON ⇔ Light switch OFF" is detected by
To recover the day and night determination, it should be
turning the light switch 4 or more times within the
switched when the same conditions as the above
specified time.
cancellation are satisfied again after the ignition switch is
LCD display illumination automatic dimming control turned ON and then turned OFF.
release procedure
Note：
・ Model: With MID
Note： Check the effect of the post-mounted electrical

・ Prior confirmation and visual inspection components such as wireless devices and lights.
Check that the battery voltage is normal. components, so that they do not affect the inspection or
If the battery voltage is not normal, charge or replace the the operation.
battery.
Note：
melting, inspect and repair the cause of the melting first, Inspect the lighting switch.
and then replace the fuse. Operate the lighting switch and check that the circuit
clean.
Check whether an abnormality exists in the relay.
Check that the harnesses and connectors are normal. Replace it if any abnormality is found.
Note：
setting.
Operation abnormality of the backup light function

1. Operation abnormality of the backup light function
diagnostics
Note：
battery.
clean.
the operation.
Note：
replace the fuse.
Inspect the backup light switch.
Operate the backup light switch and check that the circuit
found, replace the switch. Inspect the mechanical parts of
the transmission. Check that the bulbs of the backup light
are normal. If any defects are found, repair or replace
such defective bulbs.
Note：
relevant circuit.
Between the slow blow fuse and starter switch.
Between the fuse and the backup light switch.
Between the backup light switch and the backup light.
Between the backup light and GND.
Operation abnormality of the headlight function

1. Operation abnormality of the headlight function Between the slow blow fuse and the headlight relay Hi,
diagnostics Lo.
Note：
Between the fuse and the headlight relay Hi, Lo.
・ Prior confirmation and visual inspection Between the headlight relay Lo and the fuse.
Check that the battery voltage is normal. Between the headlight relay Hi and the fuse.
If the battery voltage is not normal, charge or replace the Between the headlight relay Hi, Lo and the combination
battery. switch (lighting switch).
Between the fuse and the headlight Hi, Lo.
Check that the fuses are in normal condition. Between the headlight Hi, Lo and GND.
clean.
the operation.
Note：
replace the fuse.
Check the function of the headlight relay.
Check whether an abnormality exists on the headlight
Check that the headlight bulbs are normal.
bulbs.
Note：
Operation abnormality of the clearance light function

1. Operation abnormality of the clearance light function Between the slow blow fuse and the tail relay.
diagnostics Between the starter switch and the fuse.
Between fuse and the tail relay.
Note：
Between the tail relay and the fuse.
・ Prior confirmation and visual inspection Between the tail relay and the lighting switch.
Check that the battery voltage is normal. Between the fuse and the clearance light.
If the battery voltage is not normal, charge or replace the Between the clearance light and GND.
battery. Between the lighting switch and GND.
clean.
the operation.
Note：
・ Inspect the slow blow fuse.
If any abnormality is found in a slow blow fuse,
inspect and repair the cause for the meltdown
first, and then replace the fuse.
Check that the bulbs of the clearance light are normal. If
any defects are found, repair or replace such defected
bulbs.
Note：
Operation abnormality of the fog light function

1. Operation abnormality of the fog light function abnormality is found in the circuit, repair or replace the
diagnostics relevant circuit.
Note：
・ Prior confirmation and visual inspection Between the slow blow fuse and the fuse.
Check that the battery voltage is normal. Between the starter switch and the fuse.
If the battery voltage is not normal, charge or replace the Between the fuse and the tail relay.
battery. Between the tail relay and the fuse.
Between the tail relay and the lighting switch.
Check that the fuses are in normal condition. Between the fuse and the fog light switch.
If any abnormality is found in a fuse such as wire- Between the fuse and the fog light relay.
melting, inspect and repair the cause of the melting first, Between the fog light relay and the fog light switch.
and then replace the fuse. Between the fog light relay and the fog light.
Check that the ground connection is normal. Between the fog light and the GND.
If the ground connection has an abnormality, repair and Between the combination switch and GND.
clean. Between the marker relay and GND.
the operation.
Note：
replace the fuse.
Inspect the function of the fog light relay.
Check whether an abnormality exists in the relay.
Check that the bulbs of the fog light are normal. If any
defects are found, repair or replace such defective bulbs.
Note：
Operation abnormality of the turn signal light function

1. Operation abnormality of the turn signal light function Front turn signal light Side turn signal light Rear turn
diagnostics signal light
Note： Note：
・ Prior confirmation and visual inspection ・ Inspection of the circuit
Check that the battery voltage is normal. Check the following circuits for an open circuit, short
If the battery voltage is not normal, charge or replace the circuit (power supply and GND), and high resistance. If
battery. any abnormality is found in the circuit, repair or replace
Between the slow blow fuse and the fuse.
Between the fuse and the flasher unit.
Between the flasher unit and the turn signal switch.
Between the flasher unit and the hazard switch.
Check that the ground connection is normal. Between the turn signal switch and BCM.
If the ground connection has an abnormality, repair and Between the turn signal switch and GND.
clean. Between the hazard switch and GND.
Between the flasher unit and the turn signal light.
Between the turn signal light and GND.
the operation.
Note：
replace the fuse.
Inspect the turn signal switch.
Operate the turn signal switch and check that the circuit
Inspect the hazard switch.
Operate the hazard switch and check that the circuit
Inspect the flasher unit.
If the circuit and the switch are normal, replace the
flasher unit.
Check the answer-back function.
Inspect the keyless entry system, etc. for any abnormality.
Repair or replace it if any abnormality is found.
Check that the bulbs of the turn signal light are normal. If
any defects are found, repair or replace such defected
bulbs.
Lighting Systems (All models) 9A-1
Body, Cab, Accessories

Lighting Systems
(All models)
Table of Contents
Stoplight switch...............................................................9A-2 inspection..................................................................9A-36
removal.......................................................................9A-2 installation................................................................9A-37
inspection....................................................................9A-3 Projector headlight high beam bulb..............................9A-39
installation..................................................................9A-4 removal.....................................................................9A-39
Headlight assembly.........................................................9A-5 installation................................................................9A-40
removal.......................................................................9A-5 Projector headlight low beam bulb...............................9A-41
inspection....................................................................9A-6 removal.....................................................................9A-41
installation..................................................................9A-8 installation................................................................9A-42
Fog light bulb..................................................................9A-9 Front turn signal light bulb............................................9A-43
removal.......................................................................9A-9 removal.....................................................................9A-43
inspection..................................................................9A-10 installation................................................................9A-44
installation................................................................9A-11 Map light bulb...............................................................9A-45
Side turn signal light bulb.............................................9A-12 removal.....................................................................9A-45
removal.....................................................................9A-12 installation................................................................9A-46
installation................................................................9A-13 High mounted stop light bulb........................................9A-47
Combination switch assembly.......................................9A-14 removal.....................................................................9A-47
inspection..................................................................9A-14 installation................................................................9A-48
Door switch...................................................................9A-19
removal.....................................................................9A-19
inspection..................................................................9A-20
installation................................................................9A-21
Halogen headlight bulb.................................................9A-22
removal.....................................................................9A-22
installation................................................................9A-23
Clearance light bulb......................................................9A-24
removal.....................................................................9A-24
installation................................................................9A-25
Tail stoplight bulb.........................................................9A-26
removal.....................................................................9A-26
installation................................................................9A-27
License plate light bulb.................................................9A-28
removal.....................................................................9A-28
installation................................................................9A-29
Backup light bulb..........................................................9A-30
removal.....................................................................9A-30
installation................................................................9A-31
Dome light bulb.............................................................9A-32
removal.....................................................................9A-32
installation................................................................9A-33
Key reminder switch.....................................................9A-34
removal.....................................................................9A-34
9A-2 Lighting Systems (All models)
Stoplight switch
removal
1. Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
2. Stoplight switch removal
1. Remove the stoplight switch from the brake pedal
bracket.
2. Remove the harness connector from the stoplight
switch.
3. Loosen the lock nut using a wrench.
Note：
・ Turn and remove the switch main unit from the
bracket.
1. Stoplight switch
2. Lock nut
inspection
1. Stoplight switch inspection
1. Inspect the stoplight switch using the circuit tester.
Note：
・ Operate the switch to inspect the continuity
between the terminals.
・ Confirm that continuity exists while the switch
is not pressed down.
・ If any abnormality is found in the inspection
result, replace the relevant part with a normal
one.
installation
1. Stoplight switch installation
1. Install the stoplight switch to the brake pedal
bracket.
Note：
・ Screw in the stoplight switch until the tip of its
threaded portion hits the brake pedal.
Caution：
・ Be careful not press the pedal with the tip of
the switch.
Note：
・ Turn the stoplight switch for a 1/2 rotation to
confirm that the gap (L)
between the pedal and the tip of the threaded
portion is 0.2 - 1.2 mm (0.008 - 0.047 in), and
then tighten the lock nut.
・ Connect the connector.
1. Lock nut
2. Brake pedal
3. Stoplight switch
2. Battery ground cable connect

1. Connect the battery ground cable to the battery.
Headlight assembly
removal
2. Radiator grille removal
1. Remove the radiator grille from vehicle.
Note：
・ Remove the screws.
・ Remove the 4 clips.
4. Headlight assembly removal

1. Remove the headlight assembly from vehicle.
Note：
・ Remove the 4 screws.
2. Remove the connector from the headlight assembly.
1. Screw
2. Clip
3. Front bumper assembly removal

1. Remove the front bumper assembly from vehicle.
Note：
1. Headlight assembly
inspection 3. Center line
1. Headlight assembly adjustment Note：

1. Inspect the headlight assembly with the headlight ・ Place the vehicle 1 m (3.28 ft) away from the
tester. screen.
・ Draw a line on the screen that is at the same
Note： height as the center point of the headlight.
・ After inspecting the headlight assembly using
the headlight tester, make adjustments.
・ To adjust the optical axis, it should be
performed after initializing the vehicle height
value in the auto leveling control unit.
・ Inspect the tire air pressure and contamination
on the headlight lens.
・ Set the vehicle to the vehicle conditions at the
time of inspection.
・ Project the center points (bulb center marks)
(A) and (B) of the left and right headlights on
the screen and draw vertical lines.
1. Screen
2. Vehicle
Note：
・ Turn on the headlights and set them to the low
beam.
・ Cover the other headlight which is not being
adjusted with a black cloth, etc.
・ Align the bending point with the vertical line in
the horizontal adjustment, and set the light-
dark boundary line from the horizontal line to
the value in the following table in the vertical
1. Screen adjustment.
2. Vehicle
Leftward/
Downward
Rightward
Bending point
Bending point
alignment
alignment
Height of the light
L = 12mm
is less than 1 m 0
(0.47in)
(3.28 ft)
Note：
・ Vertical adjustment
Turn the adjusting screw using a screwdriver
to adjust the vertical direction of the optical
axis.
Note：
・ Horizontal adjustment
Turn the adjusting screw using a screwdriver
to adjust the horizontal direction of the optical
axis.
installation 1. Install the radiator grille to vehicle.

Note：
1. Headlight assembly installation
・ Put the claw of the radiator grille in the
1. Install the headlight assembly to vehicle. installation hole of the front bumper shown in
Note： the diagram.
・ Install the clip of the headlight assembly.
Install one more connector if the vehicle has
the leveling function.
・ Fix the headlight assembly with 4 bolts.
Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in }
1. Radiator grille
Note：
・ Install the 4 clips.
・ Install the screws.
1. Headlight assembly
2. Front bumper assembly installation

1. Install the front bumper assembly to vehicle.
Note：
1. Screw
2. Clip

Note：
・ Confirm that the light turns on.
3. Radiator grille installation
Fog light bulb
removal
Note：
4. Fog light bulb removal

1. Remove the fog light bulb from the fog light.
Caution：
・ Do not touch the glass part of the fog light bulb
directly by hand.
1. Screw
2. Clip

Note：
1. Connector
2. Fog light assembly
3. Fog light bulb
inspection
1. Fog light bulb adjustment
Note：
・ Make adjustments in the vertical direction.
Rotate the screw to adjust with a screwdriver,
and adjust the fog light in the vertical direction.
installation Note：
1. Fog light bulb installation installation hole of the front bumper shown in
1. Install the fog light bulb to the fog light. the diagram.
2. Install the harness connector to the fog light.
1. Radiator grille
1. Harness connector Note：
2. Fog light assembly ・ Install the 4 clips.
3. Fog light bulb
Note：
1. Screw
2. Clip

3. Radiator grille installation Note：
1. Install the radiator grille to vehicle. ・ Confirm that the light turns on.
Side turn signal light bulb
removal
2. Side turn signal light bulb removal
1. Remove the side turn signal light bulb from the bulb
socket.
Note：
・ Turn the side turn signal light bulb socket to
remove it, and then remove the bulb from the
socket.
installation
1. Side turn signal light bulb installation
1. Install the side turn signal light bulb to the bulb
socket.
Note：
・ Install the bulb to the socket, and then install
the side turn signal light bulb socket by rotating
it.
2. Side turn signal light assembly installation

1. Install the side turn signal light assembly to the door
assembly.
Note：
Combination switch assembly
inspection Note：
・ Operate each switch to inspect the continuity
1. Combination switch assembly inspection between the terminals.
1. Inspect the combination switch assembly using the
circuit tester.
Note：
・ INT (Connector A)
Note：
・ V/INT (Connector A)
Note：
・ Connector A
Note：
・ Connector D
Door switch
removal
2. Door switch removal
1. Remove the door switch from vehicle.
Note：
・ Open the cover with a flat-blade screwdriver,
etc. and remove the screw.
・ Pull out the door switch and remove the
harness connector.
1. Door switch
2. Screw
inspection Note：
1. Door switch inspection between the terminals.
1. Inspect the door switch using the circuit tester.
Switch operation Terminal (1) Ground

When pressed ― ―
When released ○ ○
Note：
・ Confirm that continuity exists while the switch
is not pressed down.
one.
installation
1. Door switch installation
1. Install the door switch to vehicle.
Note：
・ Install the harness connector to the door
switch.
・ Install the screw and close the cover.
1. Door switch
2. Screw

Note：
・ Confirm that the door open warning light in the
meter turns off when the door is closed.
Halogen headlight bulb
removal
2. Halogen headlight bulb removal
1. Remove the headlight assembly from vehicle.
2. Remove the dust cover from the headlight assembly.
3. Remove the clip from the headlight assembly.
4. Remove the headlight bulb from the headlight
assembly.
1. Clip
2. Headlight bulb
3. Dust cover
installation
1. Halogen headlight bulb installation
1. Install the headlight bulb to the headlight assembly.
Note：
・ Set the headlight bulb.
・ Hook the clip to fix the headlight bulb.
2. Install the dust cover to the headlight assembly.
Caution：
・ Do not touch the glass part of the headlight
bulb directly by hand.
1. Clip
2. Headlight bulb
3. Dust cover

Note：
Clearance light bulb
removal
2. Clearance light bulb removal
1. Remove the clearance light bulb from the bulb
socket.
Note：
・ Remove the clearance light bulb from the
headlight assembly.
・ Vehicles equipped with halogen headlights
1. Connector
2. Clearance light bulb
3. Clearance light bulb socket
1. Connector
Note：
・ Vehicles equipped with projector headlights
installation 1. Connect the battery ground cable to the battery.

Note：
1. Clearance light bulb installation
1. Install the clearance light bulb to the bulb socket.
Note：
・ Install the clearance light bulb to the headlight
assembly.
1. Connector
Note：
1. Connector

Tail stoplight bulb
removal
2. Tail stoplight bulb removal
1. Remove the tail stoplight bulb from the rear
combination light assembly.
Note：
・ Remove the screw to remove the lens.
・ Remove the tail stoplight bulb by turning it to
the left while pressing it down.
・ Without cargo bed specification
1. Tail stoplight bulb (LED specification)

2. Turn signal light bulb
3. Backup light bulb
1. Tail stoplight bulb

4. Lens
Note：
・ Deluxe specification
installation 2. Turn signal light bulb

1. Tail stoplight bulb installation
1. Install the tail stoplight bulb to the rear combination
light assembly. 1. Connect the battery ground cable to the battery.
Note： Note：
・ Install the tail stoplight bulb by turning it to the ・ Confirm that the light turns on.
right while pressing it down.
・ Install the lens with the screw.

4. Lens
Note：

License plate light bulb
removal
2. License plate light bulb removal
1. Remove the license plate light bulb from the license
plate light assembly.
Note：
・ Remove the cover.
・ Turn the socket, and remove the lens.
・ Remove the bulb by turning it to the left while
pressing it down.
installation
1. License plate light bulb installation
1. Install the license plate light bulb to the license plate
light assembly.
Note：
・ Install the bulb by turning it to the right while
pressing it down.
・ Turn the socket, and install the lens.
・ Install the cover.

Note：
Backup light bulb
removal
2. Backup light bulb removal
1. Remove the backup light bulb from the rear
combination light assembly.
Note：
・ Remove the backup light bulb by turning it to
the left while pressing it down.
・ Remove the screw to remove the lens.


Note：
installation 3. Backup light bulb
1. Backup light bulb installation 2. Battery ground cable connect

1. Install the backup light bulb to the rear combination 1. Connect the battery ground cable to the battery.
light assembly. Note：
Note：・ Confirm that the light turns on.
・ Install the backup light bulb by turning it to the
right while pressing it down.
・ Install the lens with the screw.

Note：

Dome light bulb
removal
2. Dome light bulb removal
1. Remove the dome light bulb from vehicle.
2. Remove the lens from the dome light.
3. Remove the dome light bulb from the dome light.
1. Dome light bulb

2. Lens
installation
1. Dome light bulb installation
1. Install the dome light bulb to vehicle.
2. Install the dome light bulb to the dome light.
3. Install the lens to the dome light.
1. Dome light bulb

2. Lens

Note：
Key reminder switch
removal
2. Driver air bag assembly removal
Note：
・ Confirm the holes on the both sides of the
steering cover.
1. Remove the driver air bag assembly from the

steering wheel.
2. Disconnect the connector from the driver air bag
assembly.
Note：
・ Disconnect the airbag connector.
・ Disconnect the horn connector.
Note：
・ Confirm the lever position in the hole in the
following illustration.
1. Airbag connector
2. Horn connector
Warning：
・ Keep the airbag assembly away from your
Note： body when carrying it.
・ Insert a bar of diameter 6 mm {0.24 in} to ・ When putting down an undeployed airbag
remove the driver airbag assembly from the assembly, make sure to face the trim cover
lever. upward.
・ Place the trim cover upward on a flat surface.

・ Failure to follow this procedure may result in
personal injury.
1. Key cylinder
2. Steering lock assembly
3. Steering lock bracket
4. Shear bolt
3. Steering cowl removal
Caution：
1. Remove the steering cowl from the steering column.
・ Be careful not to touch and damage the
antenna coil portion of the ICU.
5. Key reminder switch removal
1. Remove the key reminder switch from the steering
lock assembly.
1. Steering cowl upper

2. Steering cowl lower
4. Steering lock assembly removal

1. Remove the steering lock assembly from the steering
shaft assembly. 1. Key reminder switch
Note：
・ As a shear bolt (of a type with a head that can
be twisted off after it is tightened) is used
as the tightening bolt, use an extractor,
reverse tap, etc. to remove it.
inspection
1. Key reminder switch inspection
1. Inspect the key reminder switch using the circuit
tester.
Note：
・ Inspect whether continuity exists when the key
is inserted with the key cylinder placed in the
"LOCK" position.
one.
installation Caution：
・ The shear bolt should be tightened until the
1. Key reminder switch installation head is twisted off.
1. Install the key reminder switch to the steering lock 3. Steering cowl installation
assembly.
1. Install the steering cowl to the steering column.
Caution：
・ When installing the steering cowl, be careful
not to pinch the harness by the cowl.
1. Key reminder switch
Caution：
antenna coil area of the immobilizer control
unit.
2. Steering lock assembly installation
4. Driver air bag assembly installation
1. Install the steering lock assembly to the steering
shaft assembly. 1. Install the connector to the driver air bag assembly.
Note：
・ Connect the airbag connector.
・ Connect the horn connector.
1. Key cylinder
3. Steering lock assembly bracket
4. Shear bolt
1. Airbag connector
2. Horn connector
2. Install the driver air bag assembly to the steering

wheel.
Projector headlight high beam bulb
removal
2. Projector headlight high beam bulb removal
1. Remove the projector headlight high beam bulb from
the headlight assembly.
Note：
・ Press the tab, and remove the connector.
1. Projector headlight high beam bulb

2. Connector
3. Tab
installation
1. Projector headlight high beam bulb installation
1. Install the projector headlight high beam bulb to the
headlight assembly.
Note：
・ Set the projector headlight high beam bulb.
2. Install the projector headlight high beam bulb to the
connector.
Caution：
1. Projector headlight high beam bulb

2. Connector
3. Tab

Note：
Projector headlight low beam bulb
removal
2. Projector headlight low beam bulb removal
1. Remove the projector headlight low beam bulb from
the headlight assembly.
Note：
・ Press the tab, and remove the connector.
1. Projector headlight low beam bulb

2. Connector
3. Tab
installation
1. Projector headlight low beam bulb installation
1. Install the projector headlight low beam bulb to the
headlight assembly.
Note：
・ Set the projector headlight low beam bulb.
2. Install the projector headlight low beam bulb to the
connector.
Caution：
1. Projector headlight low beam bulb

2. Connector
3. Tab

Note：
Front turn signal light bulb
removal 1. Front turn signal light bulb socket

2. Front turn signal light bulb socket
1. Battery ground cable disconnect 3. Front turn signal light bulb
2. Front turn signal light bulb removal
1. Remove the front turn signal light bulb from the bulb
socket.
Note：

3. Front turn signal light bulb
Note：
installation 2. Battery ground cable connect

1. Front turn signal light bulb installation
Note：
1. Install the front turn signal light bulb to the socket.
2. Install the front turn signal light bulb soket to the
connector.
Note：

Note：

Map light bulb
removal
2. Map light bulb removal
1. Remove the map light bulb from vehicle.
2. Remove the lens from the map light.
3. Remove the map light bulb from the socket.
1. Map light bulb

2. Lens
installation
1. Map light bulb installation
1. Install the map light bulb to vehicle.
2. Install the map light bulb to the socket.
3. Install the lens to the map light.
1. Map light bulb

2. Lens

Note：
High mounted stop light bulb
removal
2. High mounted stop light bulb removal
1. Remove the high mounted stop light bulb from
vehicle.
2. Remove the screw from the lens.
Note：
・ Pull up the high-mount stoplight to remove it.
3. Remove the high mounted stop light bulb from the
high mounted stop light bulb.
1. Screw
installation
1. High mounted stop light bulb installation
1. Install the high mounted stop light bulb to the high
mounted stop light bulb.
2. Install the high mounted stop light bulb to the case.
3. Install the high mounted stop light bulb to vehicle.
4. Install the screw to the lens.
1. Screw

Note：
Wiper, Washer Systems (All models) 9B-1

Wiper, Washer Systems
(All models)
Table of Contents
Wiper arm........................................................................9B-2
removal.......................................................................9B-2
installation...................................................................9B-3
Wiper blade rubber..........................................................9B-4
removal.......................................................................9B-4
installation...................................................................9B-5
Washer motor..................................................................9B-6
removal.......................................................................9B-6
inspection....................................................................9B-8
installation...................................................................9B-9
Washer nozzle...............................................................9B-11
removal.....................................................................9B-11
inspection..................................................................9B-12
installation.................................................................9B-13
Wiper motor..................................................................9B-14
removal.....................................................................9B-14
installation.................................................................9B-15
Wiper linkage................................................................9B-16
removal.....................................................................9B-16
installation.................................................................9B-17
9B-2 Wiper, Washer Systems (All models)
Wiper arm
removal
2. Wiper arm cover removal
1. Remove the wiper arm cover from the wiper arm.
3. Wiper arm removal
1. Remove the wiper arm from vehicle.
Note：
・ Remove the nut to remove the wiper arm and
the blade.
1. Wiper arm cover

2. Nut
3. Wiper arm, blade
installation
1. Wiper arm installation
1. Install the wiper arm to vehicle.
Caution：
・ Confirm that the wiper motor is stopped
at the auto stop position.
1. 29 mm (1.14 in)
2. 36.5 - 51.5 mm (1.44 - 2.03 in)
3. 18 mm (0.71 in)
Tightening torque： 31.0 N・m { 3.2 kgf・m / 22.9 lb・

ft }
2. Wiper arm cover installation
1. Install the wiper arm cover to the wiper arm.
Wiper blade rubber
removal Caution：
・ When the wiper blade is removed, cover the
1. Wiper blade removal tip of the wiper arm with a cloth to prevent the
1. Remove the wiper blade from the wiper arm. glass from being damaged.
Note： 2. Wiper blade rubber removal
・ Set the wiper arm vertically. 1. Remove the wiper blade rubber from the wiper
・ Remove the wiper blade downward direction blade.
toward the wiper arm (toward the root of the Note：
arm), while pressing the hook.
・ Pull the wiper rubber in the direction of the
arrow, and remove it from the wiper blade.
1. Wiper blade
2. Hook
3. Wiper arm
1. First
2. Second
installation
1. Wiper blade rubber installation
1. Install the wiper blade rubber to the wiper blade.
Note：
・ Press the wiper rubber until the hook of the
wiper blade fits into the hole of the wiper
rubber.
・ Confirm that the wiper blade is securely fitted
into the wiper rubber.
2. Wiper blade installation
1. Install the wiper blade to the wiper arm.
Note：
・ Place the wiper arm upright to install the wiper
blade.
・ Inspect that the wiper blade lock is secure.
Washer motor
removal
2. Washer hose disconnect
1. Disconnect the washer hose from the wiper motor.
Caution：
・ Drain the washer fluid from the washer tank.
Note：
・ Remove the connector from the washer motor.
4. Mudguard removal
1. Remove the mud guard from the front fender panel.
5. Inner liner removal
1. Remove the inner liner from the front fender panel.
Note：
・ Remove the fixing screw.
1. Washer motor
2. Washer tank
3. Washer motor connector

Note：
6. Tank joint horse disconnect

1. Remove the bolt from the tank joint horse.
2. Disconnect the tank joint horse from the washer
tank.
Note：
・ Turn the tank joint hose in the direction of the
arrow.
Note：
・ Remove the clip band, and then remove the
washer motor.
1. Tank joint hose

2. Bolt
7. Washer tank removal

1. Washer motor
1. Remove the bolt from the washer tank.
2. Remove the washer tank from vehicle.
Note：
・ Remove the top and bottom tabs by tilting the
washer tank, and remove the washer tank
from the vehicle.
1. Upper side tab

2. Washer tank
3. Bolt
4. Lower side tab
8. Washer motor removal

1. Remove the washer motor from the washer tank.
inspection
1. Washer motor inspection
1. Inspect the washer motor using the battery.
Note：
・ Connect the battery to the terminal of the
washer motor.
・ Inspect whether the washer fluid is injected.
・ If a problem is found, repair or replace as
necessary.
1. Positive terminal
2. Negative terminal
installation
1. Washer motor installation
1. Install the washer motor to the washer tank.
Note：
・ Replace the grommet with a new one, and set
it to the washer tank side.
・ Insert the water supply port of the motor into
the grommet.
・ Secure the washer motor to the washer tank
with a clip band.
1. Upper side tab

2. Washer tank
3. Bolt
4. Lower side tab
3. Tank joint horse connect

1. Connect the tank joint horse to the washer tank.
Note：
・ Install the bolt to the tank joint hose.
Tightening torque： 5.9 N・m { 0.6 kgf・m / 52 lb・in }
1. Washer motor
2. Washer tank installation

1. Install the washer tank to vehicle.
Note：
・ Connect the connector to the washer motor.
1. Tank joint hose

2. Bolt
4. Inner liner installation

1. Install the inner liner to the front fender panel.
Note：
・ Install the fixing screw.
5. Mudguard installation 1. Washer motor

2. Washer tank
1. Install the mud guard to the front fender panel.
3. Washer motor connector
1. Install the radiator grille to vehicle.
Note：
installation hole of the front bumper shown in
the diagram.
7. Washer hose connect

1. Connect the washer hose to the washer motor.
Note：
・ Firmly insert and connect the washer hose to
the water supply port of the washer motor.
・ Connect the connector to the washer motor.
Washer nozzle
removal
1. Washer nozzle removal
1. Remove the washer nozzle from the cowl cover.
1. Washer nozzle
2. Cowl cover
inspection
1. Washer nozzle inspection
1. Inspect the washer nozzle.
Note：
・ Check if the washer nozzle port is not clogged.
・ If a problem is found, repair or replace as
necessary.
installation
1. Washer nozzle installation
1. Install the washer nozzle to the cowl cover.
Note：
・ Check the spray position of the washer fluid.
1. 190 mm (7.48 in）

2. 380 mm (14.96 in）
3. 115 mm (4.53 in）
4. 235 mm (9.25 in）
Wiper motor
removal
Note：
the blade.
1. Nut
2. Bolt
6. Wiper motor removal

1. Remove the wiper motor from the wiper linkage.
1. Wiper arm cover

2. Nut
3. Wiper arm, blade
4. Cowl cover removal

1. Remove the cowl cover from the body.
5. Wiper linkage disconnect
1. Disconnect the wiper linkage from vehicle.
Note： 1. Bolt
2. Wiper motor
・ Remove the bolt and the nut from the wiper
linkage.
・ Remove the connector from the wiper motor.
installation 4. Wiper arm installation

1. Wiper motor installation
Caution：
1. Install the wiper motor to the wiper linkage.
1. Bolt
2. Wiper motor
1. 29 mm (1.14 in)
2. Wiper linkage connect 2. 36.5 - 51.5 mm (1.44 - 2.03 in)
3. 18 mm (0.71 in)
1. Connect the wiper linkage to vehicle.
ft }
1. Nut
2. Bolt

Note：
・ Connect the connector to the wiper motor.
3. Cowl cover installation
1. Install the cowl cover to the body.
Wiper linkage
removal
Note：
the blade.
1. Nut
2. Bolt
1. Wiper arm cover

2. Nut
3. Wiper arm, blade

5. Wiper linkage disconnect
1. Disconnect the wiper linkage from vehicle.
Note：
・ Remove the bolt and the nut from the wiper
linkage.
・ Remove the connector from the wiper motor.
installation 1. 29 mm (1.14 in)

2. 36.5 - 51.5 mm (1.44 - 2.03 in)
1. Wiper linkage connect 3. 18 mm (0.71 in)
1. Connect the wiper linkage to vehicle. Tightening torque： 31.0 N・m { 3.2 kgf・m / 22.9 lb・
ft }
1. Nut
2. Bolt

Note：
・ Connect the connector to the wiper motor.
3. Wiper arm installation
Caution：
Electrical Control, Entertainment (All models) 9C-1

Electrical Control, Entertainment
(All models)
Table of Contents
Cigarette lighter assembly...............................................9C-2 installation.................................................................9C-35
removal.......................................................................9C-2 Rear door speaker..........................................................9C-36
installation...................................................................9C-3 removal.....................................................................9C-36
Door speaker....................................................................9C-4 inspection..................................................................9C-38
removal.......................................................................9C-4 installation.................................................................9C-39
inspection....................................................................9C-6 Accessory socket ..........................................................9C-41
installation...................................................................9C-7 removal.....................................................................9C-41
Antenna...........................................................................9C-9 installation.................................................................9C-42
removal.......................................................................9C-9 CD/DVD tuner..............................................................9C-43
inspection..................................................................9C-10 removal.....................................................................9C-43
installation.................................................................9C-11 installation.................................................................9C-44
Hazard switch................................................................9C-12 Remote control mirror switch........................................9C-45
removal.....................................................................9C-12 removal.....................................................................9C-45
inspection..................................................................9C-13 inspection..................................................................9C-47
Radio.............................................................................9C-15 Parking brake switch.....................................................9C-50
installation.................................................................9C-16 inspection..................................................................9C-51
Horn switch...................................................................9C-17 installation.................................................................9C-52
removal.....................................................................9C-17 Ignition switch...............................................................9C-53
inspection..................................................................9C-18 removal.....................................................................9C-53
Horn(HIGH)..................................................................9C-20 Combination switch assembly.......................................9C-61
inspection..................................................................9C-21 installation.................................................................9C-65
installation.................................................................9C-22 ESC off switch...............................................................9C-67
Horn(LOW)...................................................................9C-23 removal.....................................................................9C-67
removal.....................................................................9C-23 inspection..................................................................9C-68
inspection..................................................................9C-24 installation.................................................................9C-69
installation.................................................................9C-25
Front door power window switch..................................9C-26
removal.....................................................................9C-26
inspection..................................................................9C-27
installation.................................................................9C-29
4WD switch...................................................................9C-30
removal.....................................................................9C-30
inspection..................................................................9C-31
installation.................................................................9C-32
Tweeter..........................................................................9C-33
removal.....................................................................9C-33
inspection..................................................................9C-34
9C-2 Electrical Control, Entertainment (All models)
Cigarette lighter assembly
removal
2. Shift console cover removal
1. Remove the shift console cover from the instrument
panel.
Note：
・ Remove the clips at 6 locations, and pull the
shift console cover toward you to remove it.
1. Clip
2. Shift console panel
3. Cigarette lighter assembly
3. Cigarette lighter assembly removal

1. Remove the cigarette lighter assembly from the 1. Mount ring
console cover. 2. Cigarette lighter socket
4. Bezel
5. Rib
installation
1. Cigarette lighter assembly installation
1. Install the cigarette lighter assembly to the shift
console cover.
1. Clip
2. Shift console cover

1. Mount ring
2. Cigarette lighter socket
4. Bezel
5. Rib
2. Shift console cover installation

1. Install the shift console cover to the instrument
panel.
Note：
・ Install the shift console cover to the instrument
panel using the clips at 6 locations.
Door speaker
removal
2. Window regulator handle removal
Note：
・ The following applies to the models without the
power window.
1. Remove the window regulator handle from the front
door.
Note：
・ To remove the window regulator handle,
remove the clip located at the root of the
handle using a wire.
1. Door pull case

2. Screw
5. Front door trim panel removal

1. Remove the front door trim panel from the front
door.
Note：
・ Open the cover and remove the screw.
・ Pull out the clips at 9 locations on the front
door trim panel.
1. Regulator handle
2. Clip
3. Washer
3. Power window switch removal

Note：
・ The following applies to the models with the
power window.
1. Disconnect the harness connector from the power
window switch.
4. Door pull case removal
1. Clip positions
1. Remove the door pull case from the front door.
2. Screw
Note：
6. Door mirror assembly removal
1. Remove the door mirror assembly from the front
door.
Note：
・ Remove the 3 fixing bolts, and disconnect the
connector.
1. Bolt
2. Connector
7. Outer waist seal removal

1. Remove the outer waist seal from the front door.
8. Bracket removal
1. Remove the bracket from the front door.
Note：
9. Door speaker removal
1. Remove the door speaker from the door assembly.
1. Door speaker
2. Screw
3. Clip
inspection
1. Door speaker inspection
1. Inspect the door speaker using the circuit tester.
Note：
・ Confirm that the resistance value is 4 Ω.
2. Inspect the door speaker.
Note：
・ Confirm that the cone paper has no
abnormality such as breakage.
installation
1. Door speaker installation
1. Install the door speaker to the door assembly.
1. Bolt
2. Connector
5. Front door trim panel installation

1. Install the front door trim panel to the front door.
1. Door speaker
2. Screw Note：
3. Clip ・ Install the clips on 9 locations on the front door
trim panel.
2. Bracket installation
・ Install the screws and close the cover.
1. Install the bracket to the front door.
Note：
・ Install the 2 screws.
3. Outer waist seal installation
1. Install the outer waist seal to the front door.
4. Door mirror assembly installation
1. Install the door mirror assembly to the front door.
Note：
・ Connect the connector, and install the 3 fixing
bolts.
1. Clip positions
2. Screw
6. Door pull case installation

1. Install the door pull case to the front door.
Note：
1. Door pull case 1. 45°

2. Screw
7. Power window switch installation
Note：
power window.
1. Connect the harness connector to the power window
switch.
8. Window regulator handle installation
Note：
power window.
1. Install the window regulator handle to the front door.
Note：
・ When closing the front door glass, install the
window regulator handle as shown in the
diagram.
Antenna
removal
2. Antenna removal
1. Remove the antenna from the front pillar.
Note：
・ Remove the 2 screws and the feeder cable
connector.
・ Remove the antenna by shifting toward the
lower side.
1. Antenna
2. Nut
1. Antenna
2. Screw
3. Feeder cable connector
Note：
・ Remove the nut and the feeder cable
connector.
inspection ・ When there is continuity or no continuity, some

of the antenna and the relay feeder
1. Antenna inspection connections have capacitors in them, so it
1. Inspect the antenna using the circuit tester. cannot be inspected by measuring the
resistance. Check the sound by temporarily
Note： connecting it to a radio.
・ Set the circuit tester to the 1 Ω resistance ・ The antenna pole generally has a few sections
range, and measure the following 3 points on that expand and contract. If the connection of
the antenna. the power receiving metal gets rusted,
・ The metal in the section 1 is connected to the continuity will be impaired and so will be the
pole section 3 at the tip of the antenna through sensitivity. Care should be taken to protect
the core wire of the feed line. these sections from rust.
・ For the metal portion in the section 2, the core
wire is shielded inside the feed line and
grounded to the body with the screw 4 in the
bracket section to prevent noises on the core
wire.
1. Core wire metal

2. Winding metal
3. Antenna pole
4. Antenna body
Note：
・ Between 1 and 2
・ When there is no continuity or the meter gauge
needle does not move, there is nothing wrong.
・ When there is continuity, the feed line is
pinched and the core wire is shorted to the
ground, the sensitivity is reduced.
・ Between 2 and 4
・ When continuity exists or the meter reads "0
Ω", there is no abnormality.
・ When there is no continuity, the shielded part
of the core wire is open or improper body
ground exists in the screw section, noise is
mixed.
・ Between 1 and 3
installation
1. Antenna installation
1. Install the antenna to the center pillar.
Note：
・ The pulling work can be easily done by using
the lead wire run through in the removal
procedure.
Hazard switch
removal
2. Center cluster removal
1. Remove the center cluster from the instrument panel.
Note：
・ Pull out the center cluster, and then remove it.
・ Remove the 2 screws, and remove the center
lid cover or the tray.
3. Hazard switch removal
1. Remove the hazard switch from the center cluster.
Note：
・ Disconnect the connector.
inspection
1. Hazard switch inspection
1. Inspect the hazard switch using the circuit tester.
Note：
installation
1. Hazard switch installation
1. Install the hazard switch to the center cluster.
Note：
・ Connect the connector.
2. Center cluster installation
1. Install the center cluster to the instrument panel.
Note：
・ Install the 2 screws and install the center lid
cover or the tray.
・ Put the center cluster in and install it.
Radio
removal Note：
1. Disconnect the battery ground cable from the battery. lid cover or the tray.
2. Center cluster removal 3. Radio removal
1. Remove the center cluster from the instrument panel. 1. Remove the radio from the instrument panel.
1. Radio 3. Screw
2. Screw
Note：
・ Remove the connector.
・ Remove the antenna feeder plug.
installation 1. Install the radio to the instrument panel.
1. Radio installation
1. Radio 3. Screw
2. Screw

Note：
cover or the tray.
Horn switch
removal
2. Horn switch removal
Note：
・ Confirm the holes located on the both sides of
the steering cover.
1. Remove the horn switch from the steering wheel.

2. Disconnect the connector from the horn switch.
Note：
Note：
・ Confirm the lever position in the hole with the
illustration below.
Note：
・ Insert a bar with 6 mm {0.24 in} diameter to
remove the horn switch form the lever.
inspection
1. Horn switch inspection
1. Inspect the horn switch using the circuit tester.
Note：
・ Confirm that there is continuity between the
horn switch terminal and contact plate when
the contact plate is depressed.
1. Horn switch terminal

2. Contact plate
installation
1. Horn switch installation
1. Install the connector to the horn switch.
Note：
2. Install the horn switch to the steering wheel.
Note：
・ Check whether the horn sounds.
Horn(HIGH)
removal
Note：
1. Screw
2. Clip
3. Horn(HIGH) removal
1. Remove the horn from the cross member.
1. Horn, high
inspection
1. Horn(HIGH) inspection
1. Inspect the horn using the battery.
Note：
・ Confirm that the horn sounds when the battery
positive terminal is connected to the horn
terminal, the battery negative terminal is
connected to the bracket, and then the battery
voltage is applied.
・ The battery voltage is 12 V.
installation
1. Horn(HIGH) installation
1. Install the horn to the cross member.
1. Screw
2. Clip

1. Horn, high

Note：
the diagram.
1. Radiator grille
Note：
Horn(LOW)
removal
Note：
1. Screw
2. Clip
3. Horn(LOW) removal
1. Remove the horn from the cross member.
1. Horn, low
inspection
1. Horn(LOW) inspection
1. Inspect the horn using the battery.
Note：
・ Confirm that the horn sounds when the battery
positive terminal is connected to the horn
terminal, the battery negative terminal is
connected to the bracket, and then the battery
voltage is applied.
installation
1. Horn(LOW) installation
1. Install the horn to the cross member.
1. Screw
2. Clip

1. Horn, low

Note：
the diagram.
1. Radiator grille
Note：
Front door power window switch
removal
2. Front door power window switch removal
1. Remove the front door power window switch from
the front door trim pad.
Note：
・ Release the claws at 2 locations by lifting up
the front part of the switch.
inspection Note：
・ Operate the switch to measure the voltage
1. Front door power window switch inspection between the terminals.
1. Inspect the front door power window switch using ・ Crew cab
the circuit tester.
Note： Extend cab

・ Regular cab
installation
1. Front door power window switch installation
1. Install the front door power window switch to the
front door trim pad.
Note：
・ Check the operation of the switch.
4WD switch
removal
2. 4WD switch removal
1. Remove the 4WD switch from the center cluster.
Note：
・ Remove the 4 clips, and pull the 4WD switch
toward you to remove it.
・ Disconnect the connector.
Caution：
・ When removing the center cluster, do not
remove it holding the 4WD switch.
Note：
・ Center console specification 1. 4WD switch
1. 4WD switch
Note：
・ Excluding center console specification
inspection
1. 4WD switch inspection
1. Inspect the 4WD switch using the circuit tester.
Note：
installation
1. 4WD switch installation
1. Install the 4WD switch to the center cluster.
Note：
・ Install the clips at 4 locations.
・ Center console specification
1. 4WD switch
Note：
・ Excluding center console specification
1. 4WD switch

Note：
Tweeter
removal
2. Tweeter removal
1. Remove the tweeter from the instrument panel.
Note：
・ Remove the 2 clips, and pull the speaker grill
toward you to remove it.
1. Speaker grille
2. Screw
3. Tweeter
inspection
1. Tweeter inspection
1. Inspect the tweeter using the circuit tester.
Note：
installation
1. Tweeter installation
1. Install the tweeter to the instrument panel.
Note：
・ Install the speaker grille to the instrument
panel using the clip.
1. Speaker grille
2. Screw
3. Tweeter

Rear door speaker
removal
Note：
power window.
1. Remove the window regulator handle from the rear
door.
Note：
4. Rear door trim panel removal

1. Remove the rear door trim panel from the rear door.
Note：
・ Pull out the clips at 7 locations on the rear
door trim panel.
・ Open the cover with a small-sized flat-blade
screwdriver, etc., taking care not to damage
the rear door trim panel, and remove the
screws.
・ Remove the clip on the rear top of the rear
door trim panel.
1. Regulator handle
2. Clip
3. Washer

Note：
power window.
1. Remove the power window switch from the rear
door.
Note：
・ Remove the power window switch, and 1. Screw
disconnect the connector. 2. Clip
3. Clip positions
5. Bracket removal
1. Remove the bracket from the rear door.
Note：
6. Rear door speaker removal
1. Remove the rear door speaker from the door
assembly.
1. Door speaker
2. Screw
inspection
1. Rear door speaker inspection
1. Inspect the door speaker using the circuit tester.
Note：
2. Inspect the door speaker.
Note：
・ Confirm that the cone paper has no
abnormality such as breakage.
installation
1. Rear door speaker installation
1. Install the rear door speaker to the door assembly.
1. Screw
2. Clip
3. Clip positions

1. Door speaker Note：
2. Screw
2. Bracket installation power window.
1. Install the bracket to the rear door. 1. Install the power window switch to the rear door.
Note： Note：
・ Install the 2 screws. ・ Connect the connector, and install the power
window switch.
3. Rear door trim panel installation
1. Install the rear door trim panel to the rear door.
Note：
・ Install the clips on 7 locations on the rear door
trim panel.
・ Install the clip on the rear top of the rear door
trim panel.

Note：
power window.
1. Install the window regulator handle to the rear door.
Note：
・ When closing the rear door glass, install the
diagram.
1. 45°

Accessory socket
removal
2. Accessory socket removal
1. Remove the accessory socket from the instrument
panel.
1. Cover
2. Accessory socket
3. Instrument panel
installation
1. Accessory socket installation
1. Install the accessory socket to the instrument panel.
1. Cover
2. Accessory socket
3. Instrument panel

CD/DVD tuner
removal ・ Remove the 2 screws, and remove the center

3. CD/DVD tuner removal
1. Remove the CD/DVD tuner from the instrument
2. Center cluster removal panel.
Note：
1. Clip 3. Screw
2. CD/DVD tuner
installation 1. Install the CD/DVD tuner to the instrument panel.
1. CD/DVD tuner installation
1. Clip 3. Screw
2. CD/DVD tuner

Note：
cover or the tray.
Note：
Remote control mirror switch
removal
2. Meter cluster removal
1. Remove the meter cluster from the instrument panel.
Note：
・ Pull out 4 clips from the instrument panel.
・ Disconnect the switch connector.
1. Hood lock control lever

2. Control cable
3. Screw
2. Remove the fuel filler lid opener lever from the

instrument panel driver-side lower cover.
Note：
・ Remove the 2 fixing screws.
1. Clip
3. Instrument panel driver-side lower cover removal

1. Remove the hood lock control lever from the
Note：
1. Fuel filler rid opener lever

2. Fuel filler rid cable
3. Screw
3. Remove the instrument panel driver-side lower cover

from the instrument panel.
Note：
・ Pull out the instrument panel driver side lower
cover.

・ Remove the DLC.
1. Instrument panel driver side lower cover

2. DLC
4. Remote control mirror switch removal

1. Remove the remote control mirror switch from the
inspection Note：
1. Remote control mirror switch inspection between the terminals.
1. Inspect the remote control mirror switch using the
circuit tester.
installation
1. Remote control mirror switch installation
1. Install the remote control switch to the instrument
panel driver-side lower cover.
2. Instrument panel driver-side lower cover installation
1. Install the instrument panel driver-side lower cover
to the instrument panel.
Note：
・ Connect the switch connector.
・ Install the DLC.

3. Screw
3. Install the hood lock control lever to the instrument

Note：
・ Install the 2 fixing screws.

2. DLC

Note：

2. Control cable
3. Screw
3. Meter cluster installation

1. Install the meter cluster to the instrument panel.
Note：
1. Clip

Note：
Parking brake switch
removal
2. Parking brake switch removal
1. Loosen the adjust nut using a wrench.
2. Remove the screw from the parking brake lever
assembly.
3. Remove the parking brake switch from the parking
brake lever assembly.
inspection
1. Parking brake switch inspection
1. Inspect the parking brake switch using the circuit
tester.
Note：
・ Check whether there is continuity between the
parking brake switch connector terminals.
・ When the parking brake lever is engaged:
Continuity exists
・ When the parking brake lever is released: No
continuity
・ If any abnormalities are found in the inspection
results, repair or replace it with a normal one.
1. Harness connector
1. Switch terminal
2. Turn ON the ignition switch.

Note：
・ Confirm that the brake warning light illuminates
when the connector terminals at the harness
side are shorted.
・ If an abnormality is found, inspect the harness.
installation
1. Parking brake switch installation
1. Install the parking brake switch to the parking brake
lever assembly.
1. Parking brake assembly

2. Bolt
3. Equalizer
4. T-end
5. Parking brake cable
6. Adjust screw
7. Parking brake switch
8. Screw

Note：
Ignition switch
removal ・ Failure to follow the previously mentioned

precautions may make the center position of
1. Air bag assembly safety information the SRS coil assembly uncertain, which may
Note： result in damage on the SRS coil assembly.
・ Handling of a deployed airbag assembly 3. SRS control unit preparation
Warning： 1. Deactivate the SRS function.
・ When handling the airbag, the safety Note：
precautions must be observed.
・ Turn the ignition switch to LOCK and remove
・ A small amount of sodium hydroxide may be the key.
contained on the surface of a deployed airbag.
・ Remove the SRS fuse from the fuse relay box
・ This is a by-product of the deployment reaction or disconnect the battery ground cable from
and may cause irritation when it contacts with the battery.
skin or eye.
Caution：
・ To handle activated airbag, wear gloves and
safety glasses. ・ Leave it for approximately 15 seconds or
longer.
・ After handling, wash your hands with soap.
Note：
・ Handling of an undeployed airbag assembly Note：
Warning：
steering cover.
・ When carrying an undeployed airbag, make
sure that the trim cover faces the opposite
direction of your body.
・ When carrying the airbag, never hang the
connector or harness on your hand.
・ When putting down an undeployed airbag,
make sure to face the trim cover upward.
・ Do not place any other item on the steering
wheel with the airbag surface facing
downward.
・ Not following this procedure will result in a fire
or injuries.
Caution：
・ After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
・ If the SRS coil assembly is damaged, replace
it. Note：
2. Driver air bag assembly preparation ・ Confirm the lever position in the hole in the
Note：
・ Set the steering wheel so the vehicle tires are
pointing straight forward before removing the
steering wheel.
Caution：
・ Rotate the steering wheel so that the vehicle
wheels are straight, then lock the steering
wheel.
Note： 1. Airbag connector

・ Insert a bar of diameter 6 mm {0.24 in} to 2. Horn connector
remove the driver airbag assembly from the
Warning：
lever.
body when carrying it.
・ When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
personal injury.

steering wheel.
assembly.
Note：
5. Steering wheel removal
Note：
・ Reconfirm that the steering wheel is set to the
position for advancing straight forward.
・ Make setting marks on the steering wheel and
shaft.
・ They are used for reassembly of parts. 6. Meter cluster removal

Note：
1. Remove the nut from the steering shaft.

2. Remove the steering wheel from the steering shaft
using special tool.
1. Clip

Note：
SST: 5-8521-0016-0 - steering wheel remover
Caution：
・ Never apply an impact to the steering wheel
2. Control cable
with a hammer, etc. to remove it.
3. Screw
・ The steering shaft is designed to absorb
shocks. 2. Remove the fuel filler lid opener lever from the
Note：

1. Fuel filler rid opener lever 9. Combination switch assembly removal

1. Disconnect the harness connector from the
3. Screw
combination switch assembly.
3. Remove the instrument panel driver-side lower cover 2. Remove the combination switch assembly from the
from the instrument panel. steering column.
Note：
cover.
・ Remove the DLC.
10. Steering lock assembly removal

1. Remove the steering lock assembly from the steering
shaft assembly.
Note：
・ As a shear bolt (of a type with a head that can
1. Instrument panel driver side lower cover be twisted off after it is tightened) is used
2. DLC as the tightening bolt, use an extractor,
reverse tap, etc. to remove it.
1. Key cylinder
3. Steering lock bracket
4. Shear bolt
Caution：
antenna coil portion of the ICU.
11. Ignition switch removal
1. Remove the ignition switch from the steering lock
assembly.
1. Ignition switch
installation Caution：
・ The shear bolt should be tightened until the
1. Ignition switch installation head is twisted off.
1. Install the ignition switch to the steering lock 3. Combination switch assembly installation
assembly.
1. Install the combination switch assembly to the
steering column.
1. Ignition switch
Caution： 2. Connect the harness connector to the combination

・ Be careful not to touch and damage the switch assembly.
antenna coil area of the immobilizer control 4. Steering cowl installation
unit.
2. Steering lock assembly installation
Caution：
1. Install the steering lock assembly to the steering
shaft assembly.
1. Key cylinder
3. Steering lock assembly bracket
4. Shear bolt 5. Instrument panel driver-side lower cover installation
1. Install the instrument panel driver-side lower cover Note：
to the instrument panel. ・ Install the 2 fixing screws.
Note：

2. Control cable
3. Screw
1. Instrument panel driver side lower cover 6. Meter cluster installation

2. DLC
2. Remove the fuel filler lid opener lever from the Note：
Note：
1. Clip
7. Steering wheel installation

2. Fuel filler rid cable 1. Install the steering wheel to the steering shaft.
3. Screw
Note：
3. Install the hood lock control lever to the instrument ・ Line up the setting applied during removal, and
panel driver-side lower cover. install the steering wheel.
Caution：
with a hammer, etc. to install it.
shocks.
2. Install the nut to the steering shaft.
Tightening torque： 35 N・m { 3.6 kgf・m / 26 lb・ft }
1. Install the connector to the driver air bag assembly.
Note：
1. Airbag connector
2. Horn connector

wheel.
Combination switch assembly
removal ・ Failure to follow the previously mentioned

precautions may make the center position of
1. Air bag assembly safety information the SRS coil assembly uncertain, which may
Note： result in damage on the SRS coil assembly.
・ Handling of a deployed airbag assembly 3. SRS control unit preparation
Warning： 1. Deactivate the SRS function.
・ When handling the airbag, the safety Note：
・ Turn the ignition switch to LOCK and remove
・ A small amount of sodium hydroxide may be the key.
・ Remove the SRS fuse from the fuse relay box
・ This is a by-product of the deployment reaction or disconnect the battery ground cable from
and may cause irritation when it contacts with the battery.
skin or eye.
Caution：
safety glasses. ・ Leave it for approximately 15 seconds or
longer.
Note：
・ Handling of an undeployed airbag assembly Note：
Warning：
steering cover.
downward.
or injuries.
Caution：
problems.
it. Note：
2. Driver air bag assembly preparation ・ Confirm the lever position in the hole in the
Note：
・ Set the steering wheel so the vehicle tires are
pointing straight forward before removing the
steering wheel.
Caution：
・ Rotate the steering wheel so that the vehicle
wheels are straight, then lock the steering
wheel.
Note： 1. Airbag connector

・ Insert a bar of diameter 6 mm {0.24 in} to 2. Horn connector
Warning：
lever.
upward.
personal injury.

steering wheel.
assembly.
Note：
Note：
shaft.
・ They are used for reassembly of parts. 6. Meter cluster removal

Note：

using special tool.
1. Clip

Note：
Caution：
2. Control cable
3. Screw
shocks. 2. Remove the fuel filler lid opener lever from the
Note：

1. Fuel filler rid opener lever 9. Combination switch assembly removal

1. Disconnect the harness connector from the
3. Screw
combination switch assembly.
3. Remove the instrument panel driver-side lower cover 2. Remove the combination switch assembly from the
from the instrument panel. steering column.
Note：
cover.
・ Remove the DLC.

2. DLC

installation 1. Install the instrument panel driver-side lower cover

1. Combination switch assembly installation
Note：
1. Install the combination switch assembly to the ・ Connect the switch connector.
steering column.
2. Connect the harness connector to the combination

switch assembly.
2. DLC
2. Steering cowl installation
1. Install the steering cowl to the steering column. instrument panel driver-side lower cover.
Caution： Note：
・ When installing the steering cowl, be careful ・ Install the 2 fixing screws.

1. Steering cowl upper 2. Fuel filler rid cable
2. Steering cowl lower 3. Screw
3. Instrument panel driver-side lower cover installation 3. Install the hood lock control lever to the instrument
Note：
Caution：
2. Control cable ・ The steering shaft is designed to absorb
3. Screw shocks.
Note：
・ Connect the switch connector. 1. Install the connector to the driver air bag assembly.
Note：
1. Clip

1. Install the steering wheel to the steering shaft.
1. Airbag connector
Note： 2. Horn connector
・ Line up the setting applied during removal, and
install the steering wheel.
wheel.
ESC off switch
removal
Note：
1. Clip
3. ESC off switch removal

1. Remove the TCS/ESC off switch from the meter
cluster.
inspection
1. ESC off switch inspection
1. Inspect the ESC off switch using the circuit tester.
Note：
installation
1. ESC off switch installation
1. Install the TCS/ESC off switch to the meter cluster.
Note：
1. Clip

Note：
Instrumentation, Driver Info. (All models) 9E-1

Instrumentation, Driver Info.
(All models)
Table of Contents
Vehicle speed sensor.......................................................9E-2
removal........................................................................9E-2
inspection....................................................................9E-3
installation...................................................................9E-4
BCM................................................................................9E-5
removal........................................................................9E-5
installation...................................................................9E-6
setting..........................................................................9E-7
DRM................................................................................9E-9
removal........................................................................9E-9
installation.................................................................9E-10
Instrument panel cluster.................................................9E-11
removal......................................................................9E-11
installation.................................................................9E-13
setting........................................................................9E-14
Keyless entry receiver assembly....................................9E-17
removal......................................................................9E-17
installation.................................................................9E-28
9E-2 Instrumentation, Driver Info. (All models)
Vehicle speed sensor
removal
2. Vehicle speed sensor removal
Note：
・ The following applies to 2WD, without ABS.
1. Remove the vehicle speed sensor from the
transmission.
inspection
1. Vehicle speed sensor inspection
1. Connect the battery to the vehicle speed sensor.
Note：
・ Connect the battery positive (+) terminal to the
vehicle speed sensor terminal No. 1 and the
battery negative (-) terminal to the vehicle
acceleration sensor terminal No. 2.
・ Do not connect the vehicle speed sensor
terminal No. 3 to the battery positive (+)
terminal.
2. Inspect the vehicle speed sensor using the circuit
tester.
Note：
・ Slowly rotate the vehicle speed sensor shaft
and measure the terminal No. 3 and terminal
No. 2 voltage with a circuit tester.
1. Terminal 1
2. Terminal 2
3. Terminal 3
4. Vehicle Speed Sensor
5. Battery
6. Circuit tester
Note：
・ 1.5V and 12V repeat 4 times per rotation of the
vehicle speed sensor shaft.
installation
1. Vehicle speed sensor installation
Note：
・ The following applies to 2WD, without ABS.
1. Install the vehicle speed sensor to the speedometer
bushing.
BCM
removal
1. BCM safety information
Caution：
・ When replacing the BCM make sure to write
the vehicle information to the new BCM.
・ When replacing BCM, before removal upload
the old BCM data to a scan tool, referring to
the following.
・ However, if communication with a scan tool is
not possible, remove the cluster as is.
・ When replacing the BCM, use only one scan
tool from start to end of the replacement
operation. Correct information cannot be
written if the scan tool is changed　during
replacement.
1. Check specification of vehicle. 1. Dash side trim pad
Note： 2. Retainer
・ The following procedure is required when 5. BCM removal
replacing the BCM.
1. Disconnect the harness connector from the BCM.
2. BCM upload
Note：
Note：
・ Remove it together with the bracket installed
・ The following procedure is required when onto the dash panel.
replacing the BCM.
2. Remove the BCM from the dash panel.
・ When communication between the BCM and a
scan tool cannot be carried out, do not perform
the above-mentioned operation.
3. Select the Diagnostics.
4. Select the body.
5. Select the BCM.
6. Select Programming & Resetting.
7. Select BCM Data Upload.
Note：
・ Follow the directions on the screen to upload
the vehicle data to a scan tool.
1. Disconnect the battery ground cable from the battery. 1. BCM
2. Bolt
4. Dash side trim pad removal
1. Remove the dash side trim pad from the body.
installation
1. BCM installation
1. Install the BCM to vehicle.
2. Install the harness connector to the BCM.
1. BCM
2. Bolt
2. Dash side trim pad installation

1. Install the dash side trim pad to the body.
1. Dash side trim pad

2. Retainer

Caution：
the vehicle information to the new BCM.
setting ・ Perform the Setting/Change after installing the

new BCM in the vehicle.
1. BCM safety information
Caution：
the vehicle information to the new BCM. 3. Select the Diagnostics.
・ When replacing BCM, before removal upload 4. Select the body.
the old BCM data to a scan tool, referring to
the following. 5. Select the BCM.
・ When replacing the BCM, use only one scan 6. Select Programming & Resetting.
tool from start to end of the replacement
7. Select BCM Data Setting/Change.
operation. Correct information cannot be
written if the scan tool is changed　during Note：
replacement. ・ Follow the directions on the screen to write the
2. BCM download vehicle data to the BCM.
・ Confirm that the written content is correct.
Note：
・ If communication between the BCM and a 4. Remote controller key setting
scan tool is possible before replacement, New registration of ID code
download the vehicle data.
Note：
Caution：・ Clear all of the registered ID code, and then
・ Make sure to check the vehicle specifications register a new ID code.
before performing the download. ・ The following is when using a scan tool
・ Perform the download after installing the new
BCM in the vehicle. 1. Connect a scan tool to the DLC.
1. Connect a scan tool to the DLC. 2. Turn ON the ignition switch.
2. Turn ON the ignition switch. 3. Select the Diagnostics.
3. Select the Diagnostics. 4. Select the Body.
4. Select the body. 5. Select Remote Keyless Entry Transmitter.
5. Select the BCM. 6. Select Remote Keyless Entry Transmitter

Registration Delete.
6. Select Programming & Resetting.
Note：
7. Select BCM Data Download. ・ Follow the directions on the screen and delete
Note： the ID codes.
・ Follow the directions on the screen to ・ Confirm that the value displayed for "The
download the vehicle data to the BCM. number of registered keys" is 0.
8. Select Module Information. 7. Select Remote Keyless Entry Registration Mode
TimeOut Time and ID Reception Setting.
Note：
・ Confirm that the BCM Part Number recorded 8. Check Registration Mode Timeout of a scan tool.
before the BCM replacement has been Note：
downloaded. ・ Follow the directions on the screen and write
3. BCM setting the given values.
Note： 9. Select Remote Keyless Entry Transmitter
・ If communication between the BCM and a Registration.
scan tool is not possible before replacement, Note：
setting the vehicle data is required. ・ Follow the directions on the screen and
Caution： confirm that the "Registration Complete"
・ Make sure to check the vehicle specifications message displays.
before performing the Setting/Change.
10. Operate the remote controller key.
Note：
・ With the remote control key inserted into the
ignition switch, press the Lock button or
Unlock button 5 times.
Caution：
・ This procedure must be completed within the
given time written in step 8.
・ Confirm that the value displayed for "The
number of registered keys" has been added.
Note：
・ Remove the remote control key from the
ignition switch and confirm if the Lock and
Unlock buttons operate properly.
・ The following is when not using a scan tool
Caution：
・ Close the all doors, and unlock the doors.
・ Pull out the ignition key from the ignition
switch.
Note：
・ Open the driver side front door, and insert the
ignition key to the ignition switch.
・ Repeatedly turn the ignition switch to ON and
OFF 3 times within 5 seconds.
・ After turning the ignition switch to ON and
OFF, repeat closing and then opening the
driver side front door 2 times within 5 seconds.
・ After opening and closing the doors,
repeatedly turn the ignition switch to ON and
・ Operate the LOCK/UNLOCK button of the
transmitter to check the operation.
Caution：
・ Confirm the operation sound of the actuator.
DRM
removal
2. Remove the nut from the dash side trim pad.
Note：
・ Remove the trim cover clip from the body
panel.
3. DRM removal
1. Remove the DRM from the dash panel.
Note：
・ Remove the DRM together with the bracket
installed onto the dash panel.
2. Remove the harness connector from the DRM.
1. DRM
3. Remove the bracket from the DRM.

installation
1. DRM installation
1. Install the DRM to the bracket.
Note：
・ After installing the DRM onto the bracket,
install it onto the dash panel.
2. Install the harness connector to the DRM.
1. DRM

2. Install the nut to the dash side trim pad.
Instrument panel cluster
removal 7. Select Upload Vehicle Configuration Data.

Note：
1. Instrument panel cluster safety information
・ Follow the directions on the screen to upload
Caution： the vehicle data to a scan tool.
・ When replacing the instrument panel cluster,
make sure to write the vehicle information to
the new instrument panel cluster. 1. Disconnect the battery ground cable from the battery.
・ When replacing the instrument panel cluster, 4. Meter cluster removal
before removal upload the old instrument
panel cluster data to a scan tool, referring to 1. Remove the meter cluster from the instrument panel.
the following. Note：
・ However, if communication with a scan tool is ・ Pull out 4 clips from the instrument panel.
not possible, remove the cluster as is.
use only one scan tool from start to end of the
replacement operation. Correct information
cannot be written if the scan tool is changed
during replacement.
1. Check specification of vehicle.
Note：
・ The following procedure is required when
replacing the instrument panel cluster.
Caution：
・ Make sure to check the following specifications
before replacement.
Note：
・ Isuzu Genuine Audio System
ESC Indicator Light
ABS Indicator Light
Cruise Control Indicator Light 1. Clip
4WD Indicator Light
Key Remind Warning 5. Instrument panel cluster removal
2. Instrument panel cluster upload 1. Remove the instrument panel cluster from the
instrument panel.
Note：
・ The following procedure is required when
replacing the instrument panel cluster.
・ When communication between the new
instrument panel cluster and a scan tool
cannot be carried out, do not perform the
above-mentioned operation.
3. Select the Diagnostics.
4. Select the body.
5. Select the meter.
6. Select the programming.
1. Instrument panel cluster

1. Instrument panel cluster installation the vehicle information must be written into the
1. Install the instrument panel cluster to the instrument new instrument panel cluster.
panel.

Note：
1. Clip

setting ・ Perform the download after installing the new

instrument panel cluster in the vehicle.
1. Instrument panel cluster safety information
Caution：
2. Turn ON a scan tool.
make sure to write the vehicle information to 3. Select the Diagnostics.
the new instrument panel cluster.
4. Select the body.
before removal upload the old instrument 5. Select the meter.
panel cluster data to a scan tool, referring to 6. Select the programming.
the following.
7. Select Download Vehicle Configuration Data.
download the data from the old instrument Note：
panel cluster to the new instrument panel ・ Follow the directions on the screen to
cluster, referring to the following. download the vehicle data to the instrument
2. Instrument panel cluster download panel cluster.
Note： 8. Select Module Information.

・ If communication between the old instrument Caution：
panel cluster and a scan tool is possible before ・ Refer to the following list to confirm the
replacement, download the vehicle data. download setting value.
Caution： Note：
・ Make sure to check the vehicle specifications ・ Fixed Settings
before performing the download.
Setting Item Setting Value

1 Language Setting Available
2 GLOW PLUG Indicator Light Not Available
3 SVS Indicator Light Not Available
4 Seat belt reminder function Not Available
5 DPD Indicator Light Not Available
6 Over Speed warning function Not Available
7 PESS Information Display Not Available
8 Back Shift Warning Not Available
Note：
・ Optional Settings
Setting Value
Setting Item Setting Standard
Available Not Available
With Clock Without Clock Select Available in models without Isuzu
Clock Display
Display Display genuine audio system.
With ESC Without ESC
ESC Indicator Light Select Available in models with ESC options.
Indicator Light Indicator Light
With ABS Without ABS
ABS Indicator Light Select Available in models with ABS options.
With Cruise Without Cruise
Cruise Control Select Available in models with Cruise Control
Control Indicator Control Indicator
Indicator Light options.
Light Light
With 4WD Without 4WD
4WD Indicator Light Select Available in models with 4WD.
With Key Remind Without Key Select Available in models with Key Remind
Key Remind Warning
Warning Remind Warning options.
9. Turn OFF the ignition switch. 3. Instrument panel cluster setting
Note： Note：
・ Turn OFF the ignition switch for 30 seconds ・ Vehicle Configuration Data Setting
10. Turn ON the ignition switch. ・ When communication between the old
instrument panel cluster and a scan tool is not
11. Check display of the meter. possible to carried out, program the confirmed
Note： vehicle data above individually.
・ When the data is not written to the instrument 1. Turn ON the ignition switch.
panel cluster, the instrument panel cluster will
2. Turn ON a scan tool.
flash the following displays when the ignition
switch is ON. 3. Select the Diagnostics.
・ When these displays flash, the instrument 4. Select the body.
panel cluster will not function. Make sure that
the displays do not flash after the data is 5. Select the meter.
written. 6. Select the programming.
7. Select Vehicle Configuration Data Setting.
Note：
・ Follow the directions on the screen to program
the data in the instrument panel cluster.
Caution：
・ Refer to the following list to confirm the
selected setting value, perform the “Write”
function.
Note：
・ Fixed Settings
Setting Item Setting Value

1 Language Setting Available
2 GLOW PLUG Indicator Light Not Available
3 SVS Indicator Light Not Available
4 Seat belt reminder function Not Available
5 DPD Indicator Light Not Available
6 Over Speed warning function Not Available
7 PESS Information Display Not Available
8 Back Shift Warning Not Available
Note：
・ Fixed Settings
Setting Value
Setting Item Setting Standard
Available Not Available
Without Clock Select Available in models without Isuzu

Clock Display With Clock Display
Display genuine audio system.
With ESC Indicator Without Indicator
ESC Indicator Light Select Available in models with ESC options.
Light Light
With ABS Indicator Without ABS
ABS Indicator Light Select Available in models with ABS options.
Light Indicator Light
Without Cruise
Cruise Control With Cruise Control Select Available in models with Cruise Control
Control Indicator
Indicator Light Indicator Light options.
Light
With 4WD Indicator Without 4WD
4WD Indicator Light Select Available in models with 4WD.
Light Indicator Light
With Key Remind Without Key Select Available in models with Key Remind
Key Remind Warning
Warning Remind Warning options.
8. Turn OFF the ignition switch.
Note：
・ Turn OFF the ignition switch for 30 seconds
10. Check display of the meter.
Note：
・ When the data is not written to the instrument
panel cluster, the instrument panel cluster will
flash the following displays when the ignition
switch is ON.
・ When these displays flash, the instrument
panel cluster will not function. Make sure that
the displays do not flash after the data is
written.
Keyless entry receiver assembly
removal 8. Remove the bracket from the floor.

3. Glove box removal
1. Remove the glove box from the instrument panel.
2. Console box removal
Note：
・ Below is for the center console type manual
transmission.
1. Remove the shift lever knob from the shift lever.
Note：
・ Below is for the center console type.
2. Remove the shift console cover from the console
box.
Note：
・ Disconnect the cigarette lighter connector.
・ Below is for the 2WD center console type.
3. Remove the cover from the console box.
Note： 1. Glove box
・ Below is for the 4WD center console type. 2. Instrument panel assist side lower cover
4. Remove the 4WD switch from the console box. 4. Instrument panel assist-side lower cover removal
Note： 1. Remove the instrument panel assist-side lower cover
・ Below is for the center console type. from the instrument panel.
5. Remove the console box from the floor. Note：
Note：・ Remove the 4 screws.
・ Open the console box cover and remove 2
screws.
・ Remove the control box backward.
・ Below is for the tray type, excluding the front
bench seat.
・ Open the cover and remove the 2 screws.
・ Pull up the console tray and remove the 2 clips
at the front.
・ Below except for the center console type.
6. Remove the console cover from the instrument
panel.
Note：
・ Below is for 4WD except for the center console 1. Glove box
type. 2. Instrument panel assist side lower cover
・ Disconnect the connector of the 4WD switch.
5. Side cover removal
7. Remove the cup holder cover from the floor.
1. Remove the side cover from the instrument panel. 2. Control cable
3. Screw
Note：
・ Remove the left and right side covers. 2. Remove the fuel filler lid opener lever from the
Note：
Note：

3. Screw
1. Clip
7. Instrument panel driver-side lower cover removal from the instrument panel.
1. Remove the hood lock control lever from the Note：
instrument panel driver-side lower cover. ・ Pull out the instrument panel driver side lower
Note： cover.
・ Remove the 2 fixing screws. ・ Disconnect the switch connector.
・ Remove the DLC.

2. DLC
8. Air bag assembly safety information

Note：
・ Handling of a deployed airbag assembly
Warning：
・ When handling the airbag, the safety
・ A small amount of sodium hydroxide may be
・ This is a by-product of the deployment reaction
and may cause irritation when it contacts with
skin or eye.
safety glasses.
Note：
Note：
・ Handling of an undeployed airbag assembly following illustration.
Warning：
downward.
or injuries.
Caution：
problems.
Note：
・ Insert a bar of diameter 6 mm {0.24 in} to
it.
9. Driver air bag assembly removal lever.
Note：
steering cover.

personal injury.

steering wheel.
2. Disconnect the connector from the driver air bag 10. Steering wheel removal
assembly.
Note：
Note：
・ Disconnect the airbag connector. position for advancing straight forward.
・ Disconnect the horn connector. ・ Make setting marks on the steering wheel and
shaft.
・ They are used for reassembly of parts.
1. Airbag connector
2. Horn connector
Warning： 1. Remove the nut from the steering shaft.

・ Keep the airbag assembly away from your 2. Remove the steering wheel from the steering shaft
body when carrying it. using special tool.
upward.
12. Assist side lid cover removal
1. Remove the assist side lid cover from the instrument
panel.
13. Cover removal
Note：
・ The following applies to models without
SST: 5-8521-0016-0 - steering wheel remover passenger airbag.
1. Remove the cover from the instrument panel.
14. Passenger air bag assembly removal
1. Remove the passenger air bag assembly from the
instrument panel.
Note：
・ Remove the 2 bolts.
Caution：
shocks.
1. Passenger airbag mounting bolts
Caution：
・ Remove carefully as claws are attached.

15. Front door finisher removal Note：

Note：・ The following applies to models with assist
grip.
・ The following applies to crew cab.
・ Remove the assist grip.
1. Remove the front door finisher from the body.
16. Door finisher removal ・ Remove the clip from the body panel.
Note：・ Remove the front pillar trim cover by pulling its
・ The following applies to regular cab and lower part upward.
extend cab.
1. Remove the door finisher from the body.
17. Front pillar trim cover removal
1. Remove the front pillar trim cover from the front
pillar.
Note：
・ The following applies to models without assist
grip.
・ Remove the clip from the body panel.
・ Remove the front pillar trim cover by pulling its
lower part upward.
18. Sill plate removal

1. Remove the sill plate from the floor.
Note：
・ Remove clips from the body panel.
・ Regular cab
1. Sill plate 1. Front sill plate

2. Clip 2. Rear sill plate
3. Clip
Note：
・ Extend cab 19. Dash side trim pad removal
Note：
・ Remove the nut.
panel.
1. Sill plate
2. Clip
Note：
・ Crew cab
20. Front cover removal

Note：
・ The following applies except for auto A/C.
1. Remove the front cover from the instrument panel.
21. Sun sensor removal
Note：
・ The following applies to auto A/C.
1. Remove the sun sensor from the instrument panel.
Note：
・ Disconnect the harness connector.
22. Instrument panel removal
1. Remove the speaker grille from the instrument panel.
Note：
・ Remove the left and right speaker grilles.
2. Remove the side cover from the instrument panel.
Note：
・ Remove the left and right side covers.
3. Remove the instrument panel assembly and
reinforcement from vehicle.
Note：
・ Remove the 4 bolts that fix the steering Note：
column to the reinforcement.
・ Disconnect the control cable of the blower unit
and the ventilation unit.
・ Disconnect the dash harness connector.
・ Remove the bolt and nut that secure the
instrument panel and reinforcement assembly.
23. Center cluster removal Note：

1. Remove the center cluster from the instrument panel. ・ Remove the screw to pull out the center
ventilation grille, and then remove it.
Note：
24. Center ventilation grille removal
1. Remove the center ventilation grille from the
instrument panel.
25. Radio removal
1. Remove the radio from the instrument panel.
1. Radio 3. Screw
2. Screw
Note： 1. Remove the instrument panel cluster from the

・ Remove the 4 screws. instrument panel.
・ Remove the antenna feeder plug.
26. Instrument panel cluster removal
27. Reinforcement removal

1. Remove the reinforcement from the instrument
panel.
Note：
・ Remove the bolt.
1. Instrument panel 2. Reinforcement
28. Dash harness removal

1. Remove the dash harness from the reinforcement.
29. Keyless entry receiver assembly removal
1. Remove the harness connector from the keyless
entry receiver assembly.
2. Remove the screw from the keyless entry receiver
assembly.
3. Remove the keyless entry receiver assembly from
vehicle.
2. Keyless entry receiver assembly
3. Screw
installation 1. Harness connector

2. Keyless entry receiver assembly
1. Keyless entry receiver assembly installation 3. Screw
1. Install the keyless entry receiver assembly to vehicle. 2. Dash harness installation
2. Install the screw to the keyless entry receiver 1. Install the dash harness to the reinforcement.
assembly.
3. Reinforcement installation
3. Install the harness connector to the keyless entry
receiver assembly. 1. Install the reinforcement to the instrument panel.
4. Instrument panel cluster installation

1. Install the instrument panel cluster to the instrument
panel.
1. Radio 3. Screw
2. Screw
6. Center ventilation grille installation

1. Install the center ventilation grille to the instrument
panel.
Note：
・ Put the center ventilation grille in, and install
the screws.
Note：
cover or the tray.
8. Instrument panel installation
1. Install the instrument panel assembly and
reinforcement to vehicle.
Note：
・ Tighten the bolts and nuts that secure the
instrument panel and reinforcement assembly
to the specified torque.
Bolt
Nut
Note：
・ Tighten the 4 bolts that secure the steering
column to the reinforcement to the specified
torque.
Steering column bolt
Note： 12. Sill plate installation

・ Connect the dash harness connector. 1. Install the sill plate to the floor.
・ Connect the control cable of the blower unit
Note：
and ventilation unit.
・ Regular cab
2. Install the side cover to the instrument panel.
Note：
・ Install the left and right side covers.
3. Install the speaker grille to the instrument panel.
Note：
・ Install the left and right speaker grilles.
9. Front cover installation
Note：
1. Install the front cover to the instrument panel.
10. Sun sensor installation
Note：
1. Install the sun sensor to the instrument panel.
1. Sill plate
Note： 2. Clip
・ Connect the harness connector.
Note：
11. Dash side trim pad installation ・ Extend cab
Note：
・ Install the nut.
1. Sill plate Note：

2. Clip ・ The following applies to models with assist
grip.
Note：
・ Insert the lower part of the front pillar trim
・ Crew cab
cover, and install the clip to the body panel.
・ Install the assist grip.
・ Install the 2 fixing screws and close the cover.
1. Front sill plate

2. Rear sill plate
3. Clip
14. Door finisher installation
13. Front pillar trim cover installation
Note：
1. Install the front pillar trim cover to the front pillar.
・ The following applies to regular cab and
Note： extend cab.
・ The following applies to models without assist 1. Install the door finisher to the body.
grip.
15. Front door finisher installation
cover, and install the clip to the body panel. Note：
1. Install the front door finisher to the body.
16. Cover installation 18. Assist side lid cover removal
Note： 1. Remove the assist side lid cover from the instrument
・ The following applies to models without panel.
passenger airbag. 19. Steering cowl installation
1. Install the cover to the instrument panel. 1. Install the steering cowl to the steering column.
17. Passenger air bag assembly installation Caution：
1. Install the passenger air bag assembly to the ・ When installing the steering cowl, be careful
instrument panel. not to pinch the harness by the cowl.
Note：
・ Press the portion indicated by the arrow in the
illustration to install it to the instrument panel.
・ Securely fit the claws.


Note：
Note：
・ Install the 2 bolts.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } install the steering wheel.

Caution： Note：
・ Never apply an impact to the steering wheel ・ Connect the switch connector.
with a hammer, etc. to install it. ・ Install the DLC.
shocks.
Note：

2. DLC

Note：
1. Airbag connector
2. Horn connector

wheel.
23. SRS control unit setting
1. Reactivate the SRS function.
Note：
・ Install the SRS fuse to the fuse relay box or
connect the battery ground cable to the
battery. 1. Fuel filler rid opener lever
・ Turn the ignition switch on, and confirm that
3. Screw
the SRS airbag warning light turns off after
blinking 7 times. 3. Install the hood lock control lever to the instrument
24. Instrument panel driver-side lower cover installation panel driver-side lower cover.
1. Install the instrument panel driver-side lower cover Note：

to the instrument panel. ・ Install the 2 fixing screws.
Note：

2. Control cable
3. Screw
1. Glove box
25. Meter cluster installation 2. Instrument panel assist side lower cover
1. Install the meter cluster to the instrument panel. 28. Glove box installation
Note： 1. Install the glove box to the instrument panel.
1. Glove box
1. Clip 2. Instrument panel assist side lower cover
26. Side cover installation 29. Console box installation

1. Install the side cover to the instrument panel. Note：
Note：・ Below is for the center console type.
・ Install the left and right side covers. 1. Install the console box to the floor.
27. Instrument panel assist-side lower cover installation Note：
1. Install the instrument panel assist-side lower cover to ・ Install the 3 clips.
the instrument panel. ・ Open the console box cover and install 2
screws.

2. Install the cover to the console box.
Note：
3. Install the 4WD switch to the console box.
Note：
4. Install the shift console cover to the console box.
Note：
・ Connect the cigarette lighter connector.
transmission.
5. Install the shift lever knob to the shift lever.
Note：
・ Below is for the tray type.
・ Install the console tray to the floor.
・ Install 2 screws and close the cover.
6. Install the bracket to the floor.
7. Install the cup holder cover to the bracket.
8. Install the console cover to the instrument panel.
Note：
Hood, Fenders, Doors (All models) 9G-1

Hood, Fenders, Doors
(All models)
Table of Contents
Front door assembly........................................................9G-2
removal.......................................................................9G-2
disassembly.................................................................9G-3
reassembly..................................................................9G-6
installation..................................................................9G-9
setting........................................................................9G-10
Engine hood assembly...................................................9G-11
removal.....................................................................9G-11
installation................................................................9G-12
Side step........................................................................9G-14
removal.....................................................................9G-14
installation................................................................9G-15
Rear step bumper...........................................................9G-16
removal.....................................................................9G-16
installation................................................................9G-18
Engine hood lock...........................................................9G-20
removal.....................................................................9G-20
installation................................................................9G-22
Front fender panel.........................................................9G-24
removal.....................................................................9G-24
installation................................................................9G-26
Rear door assembly (crew cab).....................................9G-28
removal.....................................................................9G-28
disassembly...............................................................9G-29
reassembly................................................................9G-31
installation................................................................9G-33
setting........................................................................9G-34
Front under guard..........................................................9G-35
removal.....................................................................9G-35
installation................................................................9G-36
Side access panel assembly (extend cab)......................9G-37
removal.....................................................................9G-37
disassembly...............................................................9G-38
reassembly................................................................9G-40
installation................................................................9G-43
setting........................................................................9G-44
Rear mud guard.............................................................9G-45
removal.....................................................................9G-45
installation................................................................9G-46
Supplementary Information..........................................9G-47
9G-2 Hood, Fenders, Doors (All models)
Front door assembly
removal ・ Place a wooden block under the door for

protection, and support the door assembly by
1. Door harness removal hand.
1. Disconnect the door harness from the dash harness.
Note：
・ Remove the harness bracket, and disconnect
the door harness connector.
1. Wooden block
Note：
・ Remove the upper side hinge bolt.
2. Front door assembly removal 3. Lower the front door assembly.
1. Remove the door check arm from the body.

Note：
・ Remove the check arm screw.
2. Remove the hinge bolt from the front door.

Note：
・ Remove the lower side hinge bolt.
disassembly
Note：
power window.
1. Remove the window regulator handle from the front
door.
Note：
1. Door mirror cover
4. Door pull case removal

1. Remove the door pull case from the front door.
Note：
1. Regulator handle
2. Clip
3. Washer

Note：
power window.
1. Disconnect the harness connector from the power
window switch.
3. Door mirror cover removal 1. Door pull case
2. Screw
1. Remove the door mirror cover from the front door.
5. Front door trim panel removal
Note：
・ Pull out the clip, and remove the cover in the 1. Remove the front door trim panel from the front
upward direction. door.
Note：
・ Pull out the clips at 9 locations on the front
door trim panel.
Note：
9. Speaker assembly removal
1. Remove the speaker assembly from the front door.
Note：
・ Remove the fixing screw, and disconnect the
connector.
10. Weather strip removal
1. Remove the weather strip from the front door.
Note：
・ Remove the clip.
11. Water proof sheet removal
1. Remove the water proof sheet from the front door.
1. Clip positions Note：
2. Screw ・ When removing the sheet, be careful not to
damage it.
6. Door mirror assembly removal
12. Inside handle removal
1. Remove the door mirror assembly from the front
door. 1. Disconnect the inside handle from the door lock
cable.
Note：
・ Remove the 3 fixing bolts, and disconnect the 13. Front door glass removal
connector. 1. Remove the front door glass from the front door.
Note：
・ Remove the 2 bolts that are put through the
access hole, and pull out the front door glass
upward.
1. Bolt
2. Connector

1. Remove the outer waist seal from the front door.
14. Window regulator removal
8. Bracket removal
1. Remove the window regulator from the front door.
1. Remove the bracket from the front door.
Note：
・ Remove the 4 fixing bolts and 2 fixing nuts.

power window.
・ Disconnect the power window motor
connector.
15. Glass run removal
1. Remove the glass-run from the front door.
Note：
・ Pull it out from the door frame of the channel.
16. Glass-run rear channel removal
1. Remove the glass-run rear channel from the front
door.
Note：
17. Door lock assembly removal
1. Cover
1. Remove the door lock assembly from the front door. 2. Screw
Note： 3. Key cylinder
・ Remove the 3 fixing screws and the bolt. 19. Outside handle removal
・ Disconnect the linkage between the outside
1. Remove the outside handle from the front door.
handle and the key cylinder.
・ Disconnect the harness connector. 20. Door harness removal
1. Remove the door harness from the front door.
18. Key cylinder removal

1. Remove the key cylinder from the outside handle.
Note：
・ Remove the cover and remove the fixing
screw.
reassembly
1. Door harness installation
1. Install the door harness to the front door.
2. Outside handle installation
1. Install the outside handle to the front door.
Note：
・ Tighten the fixing bolt to the specified torque.
3. Key cylinder installation
1. Install the key cylinder to the outside handle.
Note：
・ Tighten the fixing screws to the specified
torque.
5. Glass-run rear channel installation
1. Install the glass-run rear channel to the front door.
Note：
・ Install the bolt.
6. Glass run installation
1. Install the glass-run to the front door.
7. Window regulator installation
1. Install the window regulator to the front door.
Note：
・ Install the 4 fixing bolts and 2 fixing nuts.
power window.
・ Connect the power window motor connector.
8. Front door glass installation
1. Install the front door glass to the front door.
1. Cover
Note：
2. Screw
3. Key cylinder ・ Insert the front door glass in the specified
position, by tilting it if necessary, and fit it in
4. Door lock assembly installation the groove of the window regulator.
1. Install the door lock assembly to the front door. ・ Install the front door glass to the window
regulator with the 2 bolts.
Note：
・ Install the 3 fixing screws and the bolt.
・ Connect the linkage of the outside handle and
the key cylinder.
9. Inside handle installation 1. Bolt

2. Connector
1. Connect the inside handle to the door lock cable.
10. Water proof sheet installation 16. Front door trim panel installation
1. Install the water proof sheet to the front door. 1. Install the front door trim panel to the front door.
11. Weather strip installation Note：
・ Install the clips on 9 locations on the front door
1. Install the weather strip to the front door.
trim panel.
Note：・ Install the screws and close the cover.
・ Install the clip.
12. Speaker assembly installation
1. Install the speaker assembly to the front door.
Note：
・ Connect the connector, and install the fixing
screw.
1. Install the bracket to the front door.
Note：
1. Install the outer waist seal to the front door.
15. Door mirror assembly installation
1. Install the door mirror assembly to the front door. 1. Clip positions
Note： 2. Screw
・ Connect the connector, and install the 3 fixing 17. Door pull case installation
bolts.
1. Install the door pull case to the front door.
Note：
1. Install the window regulator handle to the front door.
Note：
・ When closing the front door glass, install the
diagram.
1. Door pull case

2. Screw
18. Door mirror cover installation

1. Install the door mirror cover to the front door.
1. 45°
1. Door mirror cover

Note：
power window.
1. Connect the harness connector to the power window
switch.
Note：
power window.
installation
1. Front door assembly installation
1. Align the front door assembly to the body.
2. Install the hinge bolt to the hinge and the front door.
Note：
・ Install the upper side hinge bolt.
・ Install the lower side hinge bolt.
3. Install the door check arm to the body.
Note：
・ Install the check arm screw.

2. Door harness connect
1. Connect the door harness to the dash harness.
Note：
・ Connect the door harness connector, and
install the harness bracket.
setting
1. Door hinge adjustment
1. Adjust the front door assembly.
Note：
・ The door position can be adjusted by moving
the door hinge.
・ Before making adjustments, remove the
fender, and temporarily fit up the door.
・ When adjusting the clearance between the
door and the body, loosen the hinge of the
door bolt.
・ Loosen the hinge of the body bolt, and adjust
the clearance between the door and the body.
2. Door striker adjustment

1. Adjust the front door assembly.
Note：
・ Loosen the screw of the door striker, and place
a wooden piece over the door striker and tap it
with a hammer to adjust the position of the
door striker.
・ By moving the position of the door striker up
and down to make the bottom surface of the
dovetail in parallel with the door striker, it can
be adjusted properly.
Engine hood assembly
removal
1. Engine hood assembly removal
1. Open the engine hood.
Note：
・ Support the engine hood.
2. Remove the hinge bolt from the engine hood.
Note：
・ Before removing the hinge from the engine
hood, put a marking of the hinge location for
putting the hinge back in place.
1. Clip
2. Hood insulator
3. Engine hood
4. Hood bumper
5. Nut
6. Engine hood garnish
2. Engine hood assembly disassembly

1. Remove the engine hood garnish from the engine
hood.
Note：
・ Remove the 6 nuts.
2. Remove the hood insulator from the engine hood.
Note：
・ Remove the 9 fixing clips, and remove the
hood insulator.
・ Install the hood bumper to the engine hood.
installation
1. Engine hood assembly reassembly
1. Install the hood insulator to the engine hood.
Note：
・ Install the 9 fixing clips.
・ Install the hood bumper to the engine hood.
2. Install the engine hood garnish to the engine hood.
Note：
・ Install the 6 nuts.
1. Clearance: 4.0 mm {0.16 in}

2. Height, level difference: -1.5 mm {-0.06 in}
Note：
・ Turn the hood rest to adjust its height, and
adjust the level difference against the engine
hood.
1. Clip
2. Hood insulator
3. Engine hood
4. Hood bumper
5. Nut
6. Engine hood garnish
2. Engine hood assembly installation

1. Temporarily tighten the hinge bolt to the engine
hood assembly.
Note：
・ Align the hinge with the marking made during
1. Hood rest
removal.
2. Inspect the clearance. 4. Apply the grease to the striker.
Note： Note：
・ Check the engine hood assembly and the ・ Apply a thin layer of grease to the striker.
fender. 5. Install the engine hood garnish to the engine hood.
3. Adjust the clearance to a standard value. Note：
Note：・ Tighten the 6 nuts to the specified torque.
・ Adjust the installation of the engine hood hinge Tightening torque： 6 N・m { 0.6 kgf・m / 53 lb・in }
to adjust the clearance.
6. Securely tighten the hinge bolt to the engine hood
assembly.
Side step
removal
1. Side step removal
1. Remove the side step assembly from the cab.
2. Remove the cover from the side step.
Note：
・ Remove the front and rear covers.
・ Remove the screw, and pull out the cover.
1. Cover
2. Screw
3. Remove the cover bracket from the side step.

Note：
・ Remove the nuts and remove the front and
rear cover brackets.
4. Remove the bracket from the side step.
Note：
・ Remove the bolts and the nuts and remove the
front, center, and rear brackets.
installation
1. Side step installation
1. Install the bracket to the side step.
Note：
・ Put the stud bolt in the slit on the rear surface
of the side step.
・ Temporarily tighten the front, center, and rear
brackets to the stud bolt with the nut.
2. Install the cover bracket to the side step.
Note：
・ Put the stud bolt in the slit on the rear surface
of the side step, and temporarily tighten the
front and rear cover brackets with the nuts.
3. Install the cover to the side step.
Note：
・ Install the front and rear covers with the
screws.
1. Cover
2. Screw
4. Install the side step assembly to the cab.

Note：
・ Tighten the fixing bolt and the nut to the
specified torque.
Rear step bumper
removal
1. Rear step bumper removal
1. Remove the rear step bumper from vehicle.
Note：
・ Disconnect the extension harness connector.
・ Remove the 3 fixing bolts from the frame side.
2. Rear step bumper disassembly
1. Remove the step pad from the reinforcement.
Note：
・ Push out the fixing part of the step pad from
the rear side of the reinforcement.
2. Remove the shell from the reinforcement.
Note：
・ The following applies to the 2WD models. 1. Center pad
・ Remove the 6 clips. 2. Shell
3. Reinforcement
4. Clip
3. Remove the back bar from the reinforcement.

4. Disconnect the connector from the license plate light
assembly.
5. Remove the license plate light assembly from the
reinforcement.
6. Remove the extension harness from the
reinforcement.
7. Disassemble the reinforcement.
Note：
・ The following applies to the 2WD models.
1. Reinforcement
2. Shell
3. Clip, push-lock type
4. Clip
Note：
・ Push the center pad fixing section from the
rear side of the reinforcement to remove it.
・ Remove the bolt and remove the shell.
1. Side bracket
2. Center bar
3. Support bracket
installation
1. Rear step bumper reassembly
1. Assemble the reinforcement.
Note：
1. Reinforcement
2. Shell
3. Clip, push-lock type
4. Clip
Note：
・ Install the bolt and install the shell.
・ Install the center pad to the reinforcement.
1. Side bracket
2. Center bar
3. Support bracket
2. Install the extension harness to the reinforcement.

3. Install the license plate light assembly to the
reinforcement.
4. Connect the connector to the license plate light
assembly.
5. Install the back bar to the reinforcement.
6. Install the shell to the reinforcement.
Note：
1. Center pad
2. Shell
3. Reinforcement
4. Clip
7. Install the step pad to the reinforcement.

2. Rear step bumper installation
1. Align the back bar to the frame.
Note：
・ The surface of the back bar shown as 2 in the
diagram should contact with the top surface of
the frame.
・ The surface of the back bar shown as 3 in the
diagram should contact with the rear end of
the frame.
1. Frame
2. Back bar surface: Contact surface with the frame
top surface
3. Back bar surface: Contact surface with the frame
rear end
2. Install the rear step bumper to vehicle.

Note：
・ Tighten the 3 fixing bolts on the frame side of
the back bar.
Tightening torque： 150 N・m { 15.3 kgf・m / 111 lb・
ft }
Note：
・ Connect the extension harness connector.
Engine hood lock
removal
Note：
1. Marking
Note：
・ Disconnect the engine food lock switch
connector. (Model with anti-theft system)
3. Hood lock control lever removal
1. Screw
2. Clip Note：
2. Engine hood lock assembly removal
2. Disconnect the hood lock control lever from the
1. Remove the engine hood lock assembly from control cable.
vehicle.
Note：
・ Put markings on the hood lock assembly and
the vehicle before removal.

2. Control cable
3. Screw
4. Control cable removal
1. Remove the control cable from vehicle.
Note：
・ Pull off the control cable in the direction toward
the passenger compartment.
installation ・ After tightening the fixing bolt, check the level

difference again. If the value is out of the
1. Control cable installation specified value, adjust the level difference by
1. Install the control cable to vehicle. turning the hood rest.
Note：
・ Route the control cable back again in place.
2. Hood lock control lever installation
1. Connect the hood lock control lever to the control
cable.
1. Engine hood assembly

2. Front fender
3. Hood rest
4. Engine hood lock assembly
5. Specified dimension: (-0.5) - (-2.5) mm {(-0.02) -
(-0.10) in}
3. Securely tighten the engine hood lock assembly to

the body.
1. Hood lock control lever Note：
2. Control cable ・ Tighten the fixing bolt to the specified torque.
3. Screw
Note： 4. Radiator grille installation
・ Confirm that the engine hood lock assembly
and hood lock control lever operate normally. 1. Install the radiator grille to vehicle.
3. Engine hood lock assembly installation Note：

1. Temporarily tighten the engine hood lock assembly installation hole of the front bumper shown in
to the body. the diagram.
Note：
・ Connect the engine food lock switch
connector. (Model with anti-theft system)
・ Install the engine hood lock assembly to the
body, and temporarily tighten the bolt.
2. Close the engine hood assembly.
Note：
・ Position the hood so that the level difference
between the hood and the fender becomes the
specified value.
・ After confirming dimensions, tighten the fixing
bolt of the engine hood assembly.
1. Radiator grille
Note：
1. Screw
2. Clip
Front fender panel
removal
Note：

Note：
1. Screw
2. Clip
2. Mudguard removal
1. Remove the mud guard from the front fender panel.
1. Remove the inner liner from the front fender panel.
Note：
5. Front fender panel removal

1. Remove the front fender panel from vehicle.
Note：
・ Remove the 6 fixing bolts.
1. Front fender panel installation
1. Install the front fender panel to vehicle.
Note：

1. Install the inner liner to the front fender panel.
Note：
2. Inspect the clearance.

Note：
・ Check the front fender panel and the front
door.
4. Mudguard installation
1. Install the mud guard to the front fender panel.
1. Clearance: 5.0 mm {0.2 in} Note：
2. Height, level difference: Same plane ・ Put the claw of the radiator grille in the
the diagram.
1. Radiator grille
Note：
1. Screw
2. Clip
Rear door assembly (crew cab)
removal
1. Door harness disconnect
1. Disconnect the door harness from the rear body
harness.
Note：
・ Remove the center pillar lower trim cover, and
disconnect the door harness connector.
1. Wooden block
Note：
3. Lower the rear door assembly.
2. Rear door assembly (crew cab) removal

Note：
2. Remove the hinge bolt from the rear door.
Note：
・ Place a wooden block under the rear door for
protection, and support the door assembly by
hand.
disassembly
Note：
power window.
1. Remove the power window switch from the rear
door.
Note：
・ Remove the power window switch, and
disconnect the connector.
1. Regulator handle
2. Clip
3. Washer
4. Rear door trim panel removal

1. Remove the rear door trim panel from the rear door.
Note：
・ Pull out the clips at 7 locations on the rear
door trim panel.
・ Open the cover with a small-sized flat-blade
screwdriver, etc., taking care not to damage
the rear door trim panel, and remove the
screws.
2. Door pull case removal ・ Remove the clip on the rear top of the rear
door trim panel.
Note：
power window.
1. Remove the door pull case from the rear door.
Note：
Note：
power window.
1. Remove the window regulator handle from the rear
door.
Note：
handle using a wire. 1. Screw
2. Clip
3. Clip positions
5. Bracket removal
1. Remove the bracket from the rear door.
Note：
6. Speaker assembly removal
1. Remove the speaker assembly from the rear door.
Note：
・ Remove the fixing bolt, and disconnect the
connector.
7. Weather strip removal
1. Remove the weather strip from the rear door.
Note：
8. Water proof sheet removal 13. Rear door window regulator removal
1. Remove the water proof sheet from the rear door. 1. Remove the window regulator from the rear door.
Note： Note：
・ When removing the sheet, be careful not to ・ Remove the 4 fixing bolts.
damage it. ・ The following applies to the models with the
9. Inside lever removal power window.
・ Disconnect the power window motor
1. Disconnect the inside lever from the door lock cable.
connector.
14. Glass run removal
1. Remove the outer waist seal from the rear door.
1. Remove the glass-run from the rear door.
11. Glass run rear channel removal
Note：
1. Remove the glass-run rear channel from the rear ・ Pull it out from the door frame of the channel.
door.
Note：
1. Remove the door lock assembly from the rear door.
Note：
12. Rear door glass removal
・ Remove the 3 fixing screws and the bolt.
1. Remove the rear door glass from the rear door.
・ Disconnect the linkage and the harness
Note： connector.
・ Remove the 2 bolts, and pull out the rear door 16. Outside handle removal
glass upward.
1. Remove the outside handle from the rear door.
Note：
・ Remove the 2 fixing bolts.
17. Door harness removal
1. Remove the door harness from the rear door.
reassembly 7. Glass run rear channel installation

1. Install the glass-run rear channel to the rear door.
Note：
1. Install the door harness to the rear door.
・ Install the bolt.
2. Outside handle installation
1. Install the outside handle to the rear door.
1. Install the outer waist seal to the rear door.
Note：
9. Inside lever installation
1. Connect the inside lever to the door lock cable.
10. Weather strip installation
3. Door lock assembly installation
1. Install the weather strip to the rear door.
1. Install the door lock assembly to the rear door.
Note：
Note：
・ Install the 3 fixing screws and the bolt.
・ Connect the linkage and the harness 11. Water proof sheet installation
connector. 1. Install the water proof sheet to the rear door.
4. Glass run installation 12. Speaker assembly installation
1. Install the glass-run to the rear door. 1. Install the speaker assembly to the rear door.
5. Rear door window regulator installation Note：
1. Install the window regulator to the rear door. ・ Connect the connector, and install the fixing
bolt.
Note：
・ Install the 4 fixing bolts. 13. Bracket installation
・ The following applies to the models with the 1. Install the bracket to the rear door.
power window.
Note：
・ Connect the power window motor connector.
6. Rear door glass installation
14. Rear door trim panel installation
1. Install the rear door glass to the rear door.
1. Install the rear door trim panel to the rear door.
Note：
Note：
・ Install the rear door glass to the window
・ Install the clips on 7 locations on the rear door
regulator using the 2 bolts.
trim panel.
・ Install the clip on the rear top of the rear door
trim panel.
1. Install the door pull case to the rear door.
Note：
Note：
power window.
1. Install the window regulator handle to the rear door.
Note：
・ When closing the rear door glass, install the
diagram.
1. Screw
2. Clip
3. Clip positions

Note：
power window.
1. Install the power window switch to the rear door.
Note：
・ Connect the connector, and install the power
window switch.
1. 45°
16. Door pull case installation

Note：
power window.
installation
1. Rear door assembly (crew cab) installation
1. Align the rear door assembly to the body.
2. Install the hinge bolt to the hinge and the rear door.
Note：
Note：
1. Connect the door harness to the rear body harness.
Note：
install the center pillar lower trim cover.
setting
1. Adjust the rear door assembly.
Note：
the door hinge.
・ Before making adjustments, temporarily fit up
the door.
door bolt.

1. Adjust the rear door assembly.
Note：
door striker.
・ By moving the position of the door striker up
and down to make the bottom surface of the
dovetail in parallel with the door striker, it can
be adjusted properly.
Front under guard
removal
1. Front under guard removal
Note：
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note：
・ Remove the 5 bolts and the clip.
1. Bolt
2. Clip
Note：
2. Remove the front under guard from the frame.
Note：
3. Remove the rear under guard from the frame.
Note：
installation
1. Front under guard installation
Note：
1. Install the front under guard to the frame.
Note：
・ Tighten the clip and the 5 bolts.
1. Bolt
2. Clip
Note：
2. Install the front under guard to the frame.
Note：
・ Tighten the 4 bolts.
3. Install the rear under guard to the frame.
Note：
・ Tighten the 5 bolts.
Side access panel assembly (extend cab)
removal
1. Door harness disconnect
1. Disconnect the door harness from the rear body
harness.
Note：
・ Remove the rear lower trim cover, and
disconnect the door harness connector.
2. Side access panel assembly (extend cab) removal
Note：
2. Remove the hinge bolt from the side access panel.
Note：
・ Place a wooden block under the door for
protection, and support the side access panel
assembly by hand.
1. Wooden block
Note：
3. Lower the side access panel assembly.
disassembly Note：
・ Disconnect the door lock cable.
1. Door trim panel removal
・ Remove the 3 fixing screws and the bolt.
1. Remove the door pull case from the side access ・ Disconnect the linkage and the harness
panel. connector.
Note：
2. Remove the bezel from the side access panel.
3. Remove the seat belt lower anchor bolt from the side
access panel.
4. Remove the door trim panel from the side access
panel.
Note：
・ Pull out the clips at 13 locations on the trim
panel.
1. Linkage clip
2. Remove the upper lock assembly from the side

access panel.
Note：
・ Remove the 3 fixing bolts, and pull out the
linkage and the harness connector upward.
3. Remove the lower lock assembly from the side
access panel.
Note：
・ Remove the 3 fixing bolts, and pull out the
1. Clip positions linkage and the harness connector downward.
2. Rear tongue side seat belt removal 5. Weather strip removal
1. Remove the rear tongue side seat belt from the side 1. Remove the weather strip from the side access panel.
access panel. Note：
Note：・ Remove the clip and double-sided tape.
・ Remove the 2 anchor bolts, and disconnect ・ Clean the weather strip area of the side
the harness connector. access panel so that no double-sided tape
3. Bracket removal remains on it.
・ Wipe off the cement remaining on the side
1. Remove the bracket from the side access panel. access panel with a soft cloth and lead-free
Note： gasoline.
1. Remove the door lock assembly from the side access
panel.
1. Outside weather strip 1. Quarter window glass

2. Side access panel 2. Screw
3. Front-side weather strip 3. Clip
4. Double-sided tape
3. Remove the weather strip from the quarter window
6. Quarter window glass removal glass.
1. Remove the hinge from the quarter window glass. 7. Door harness removal
1. Remove the door harness from the side access panel.
1. Hinge
2. Screw
3. Cap nut
4. Bolt
2. Remove the quarter window glass from the side

access panel.
Note：
・ Remove the 2 screws and 2 clips.
reassembly
1. Install the door harness to the side access panel.
2. Quarter window glass installation
1. Install the weather strip to the quarter window glass.
Note：
・ Install the weather strip by aligning its corner
with the white mark with the upper corner of
the side access panel.
2. Install the quarter window glass to the side access
panel.
Note：
・ Install the 2 screws and 2 clips.
1. Hinge
2. Screw
3. Cap nut
4. Bolt
3. Weather strip installation

1. Install the weather strip to the side access panel.
Note：
・ Install the clip and double-sided tape.
1. Quarter window glass

2. Screw
3. Clip
3. Install the hinge to the quarter window glass.
1. Outside weather strip

2. Side access panel
3. Front-side weather strip
4. Double-sided tape
4. Door lock assembly installation

1. Install the lower lock assembly to the side access
panel.
Note：
1. Upper lock assembly

2. Lock cable
4. Door lock assembly
1. Lower lock assembly
3. Install the door lock assembly to the side access
2. Door lock assembly
panel.
3. Lock cable
4. Harness connector Note：
2. Install the upper lock assembly to the side access
panel. Tightening torque： 11 N・m { 1.1 kgf・m / 97 lb・in }
Note： Note：
・ Tighten the fixing bolt to the specified torque. ・ Connect the linkage and the harness
connector.
1. Install the bracket to the side access panel.
Note：
6. Rear tongue side seat belt installation
1. Install the rear tongue side seat belt to the side access
panel.
Note：
・ Connect the harness connector, and install the
2 anchor bolts.
7. Door trim panel installation
1. Install the door trim panel to the side access panel.
Note：
・ Install the clips on 13 locations on the trim
panel.
1. Clip positions
2. Install the seat belt lower anchor bolt to the side

access panel.
3. Install the bezel to the side access panel.
4. Install the door pull case to the side access panel.
Note：
installation
1. Side access panel assembly (extend cab) installation
1. Align the side access panel assembly to the body.
2. Install the hinge bolt to the hinge and the side access
panel.
Note：
Note：
1. Connect the door harness to the rear body harness.
Note：
install the rear lower trim cover.
setting
1. Adjust the side access panel assembly.
Note：
the door hinge.
・ Before making adjustments, temporarily fit up
the door.
door bolt.
1. Adjust plate
2. Door striker
3. Bolt
Note：
door striker.
・ Adjust the door closing condition properly by
moving the position of the door striker.

1. Adjust the side access panel assembly.
Note：
・ Adjust the door closing condition properly by
moving the position of the door striker up and
down through adjusting the thickness of the
adjust plate.
1. Bolt
2. Door striker
Rear mud guard
removal
1. Front flap removal
Note：
・ The following applies to standard cabs.
1. Remove the front flap from the rear body.
Note：
1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard

1. Remove the inner liner from the rear body.
Note：
・ The following applies to standard cabs with
1. J-type nut front flaps.
2. Inner liner ・ Left side: Remove the 7 clips.
3. Spats ・ Right side: Remove the 6 clips.
4. Screw ・ The following applies to standard cabs without
2. Rear mud guard removal front flaps.
・ Left side: Remove the 10 clips.
Note：
・ Right side: Remove the 9 clips.
・ The following applies to vehicles equipped with
rear mud guards. ・ The following applies to wide cabs.
・ Left side: Remove the 9 clips and the screw.
1. Remove the rear mud guard from the rear body.
・ Right side: Remove the 8 clips and the screw.
Note：
installation 3. Front flap installation

Note：
1. Install the inner liner to the rear body.
1. Install the front flap to the rear body.
Note：
Note：
front flaps. ・ Install the 3 screws.
・ Left side: Install the 7 clips. ・ Securely insert the J-type nut until it hits the
inner end of the panel.
・ Right side: Install the 6 clips.
・ The following applies to standard cabs without
front flaps.
・ Left side: Install the 10 clips.
・ Right side: Install the 9 clips.
・ The following applies to wide cabs.
・ Left side: Install the 9 clips and the screw.
・ Right side: Install the 8 clips and the screw.
2. Rear mud guard installation
Note：
rear mud guards.
1. Install the rear mud guard to the rear body.
Note：
・ Tighten the 3 screws to the specified torque.
Tightening torque： 3 N・m { 0.3 kgf・m / 27 lb・in } 1. J-type nut
2. Inner liner
Note： 3. Spats
・ Securely insert the J-type nut until it hits the 4. Screw
inner end of the panel.
1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard
Supplementary Information
1. Component Views Note：
・ Rear step bumper, 2WD models
1. Shell 5. Extension harness

2. Reinforcement assembly 6. License plate light assembly
3. Back bar
4. Step pad
Note：
・ Rear step bumper, 4WD models
1. Center pad 5. Step pad

2. Shell 6. Extension harness
3. Reinforcement assembly 7. License plate light assembly
4. Back bar
Note：
・ Rear mud guard
1. Inner liner 3. Spats, models with the standard cab spats

2. Rear mud guard, models with the rear mud guard
Note：
・ Front under guard
1. 2WD 4. Front under guard

2. Front under guard 5. Rear under guard
3. 4WD
Note：
・ Side step
1. Side step 6. Rear bracket

2. Front cover 7. Rear cover bracket
3. Front cover bracket 8. Rear cover
4. Front bracket
5. Center bracket
Note：
・ Engine hood assembly
1. Engine hood garnish 4. Bolt

2. Engine hood
3. Nut
Note：
・ Engine hood lock
1. Radiator grille 4. Cable protector

2. Control cable 5. Engine hood lock assembly
Note：
・ Front fender panel
1. Front fender 4. Inner liner

2. Bumper side retainer 5. Front bumper
3. Mud guard
Note：
・ Front door assembly
1. Upper side hinge bolt 4. Front door assembly

2. Lower side hinge bolt 5. Check arm
3. Door harness
1. Front door trim panel 12. Window regulator

2. Power window switch 13. Door lock assembly
3. Door pull case 14. Outside handle
4. Door harness 15. Inside handle
5. Door mirror cover 16. Glass-run rear channel
6. Front door panel 17. Water proof sheet
7. Door mirror assembly 18. Speaker assembly
8. Outer waist seal 19. Bracket
9. Glass-run 20. Check arm
10. Front door weather strip
11. Front door glass
Note：
・ Rear door assembly
1. Rear door assembly 4. Check arm

2. Upper side hinge 5. Lower side hinge
3. Door harness
1. Rear door trim panel 11. Rear door glass

2. Power window switch 12. Rear door window regulator
3. Door harness 13. Outside handle
4. Inside lever 14. Glass-run rear channel
5. Door lock assembly 15. Water proof sheet
6. Rear door upper cover 16. Speaker assembly
7. Rear door panel 17. Bracket
8. Outer waist seal 18. Check arm
9. Glass-run
10. Rear door weather strip
Note：
・ Side access panel assembly
1. Side access panel assembly 4. Lower side hinge

2. Upper side hinge 5. Door harness
3. Check arm
1. Rear tongue side seat belt 8. Quarter window glass weather strip
2. Door trim panel 9. Striker plate
3. Door pull case 10. Check arm
4. Upper lock assembly 11. Lower lock assembly
5. Side access panel 12. Door lock assembly
6. Quarter window glass 13. Bracket
7. Weather strip
Cab Structure (All models) 9H-1

Cab Structure
(All models)
Table of Contents
Radiator grille..................................................................9H-2
removal.......................................................................9H-2
installation..................................................................9H-3
Front air dam...................................................................9H-4
removal.......................................................................9H-4
installation..................................................................9H-5
Air outlet valve................................................................9H-6
removal.......................................................................9H-6
installation..................................................................9H-7
Front bumper...................................................................9H-8
removal.......................................................................9H-8
installation................................................................9H-10
Supplementary Information..........................................9H-12
9H-2 Cab Structure (All models)
Radiator grille
removal
Note：
1. Screw
2. Clip
installation
Note：
the diagram.
1. Radiator grille
Note：
1. Screw
2. Clip
Front air dam
removal
1. Front air dam removal
1. Remove the front air dam from the front bumper.
Note：
・ Remove the bolt and the clip.
・ The following applies to the standard cab.
・ The front air dam can be divided.
installation
1. Front air dam installation
1. Install the front air dam to the front bumper.
Note：
・ Securely insert the J-type clip all the way.
・ Install the clip, and tighten the bolt at the
specified torque.
Bolt
Air outlet valve
removal
1. Air outlet valve removal
1. Install the air outlet valve to the cab.
installation
1. Air outlet valve installation
1. Install the air outlet valve to the cab.
Front bumper
removal 1. Remove the bumper seal from vehicle.

Note：
・ Remove the 6 clips on one side.
Note：
1. Upper bumper seal

2. Lower bumper seal
2. Remove the front bumper support from vehicle.
1. Screw
2. Clip

Note：
3. Remove the front bumper impact bar assembly from

vehicle.
3. Front bumper impact bar assembly removal

4. Bumper frame bracket removal

1. Remove the bumper frame bracket from vehicle.
Note：
・ Remove the fascia support side bracket.
・ Remove the fascia support lower bracket.
1. Fascia support side bracket

2. Fascia support lower bracket
installation
1. Bumper frame bracket installation
1. Install the bumper frame bracket to vehicle.
Note：
・ Install the fascia support lower bracket.
・ Install the fascia support side bracket.
3. Install the bumper seal to vehicle.

Note：
・ Install the 6 clips on one side.
1. Fascia support side bracket

2. Fascia support lower bracket
2. Front bumper impact bar assembly installation

1. Install the front bumper impact bar assembly to
vehicle.
Note：
1. Upper bumper seal

2. Lower bumper seal
3. Fog light installation

Note：
・ The following applies to the models equipped
with the fog light.
1. Install the fog light to the front bumper.
Note：
・ Tighten the fixing nut to the specified torque.
2. Install the front bumper support to vehicle.

1. Nut 1. Radiator grille
Tightening torque： 7 N・m { 0.7 kgf・m / 62 lb・in } Note：

4. Front bumper assembly installation ・ Install the 4 clips.
Note：
1. Screw
2. Clip

Note：
the diagram.
・ Front bumper
1. Radiator grille 5. Fascia support side bracket

2. Front bumper fascia 6. Fascia support lower bracket
3. Front bumper support
4. Front bumper impact bar assembly
Note：・ Standard cab

・ Front air dam
1. Front air dam 4. Clip

2. J-type clip
3. Bolt
Note：
・ Wide cab
1. Left-side front air dam 4. Clip

2. J-type clip 5. Bolt
3. Right-side front air dam
Note：
・ Radiator grille
1. Radiator grille 3. Screw

2. Clip
Note：
・ Air outlet valve
1. Air outlet valve

Seats (All models) 9I-1

Seats
(All models)
Table of Contents
Rear seat ...........................................................................9I-2
removal.........................................................................9I-2
installation....................................................................9I-3
Front seat..........................................................................9I-4
removal.........................................................................9I-4
installation....................................................................9I-7
Supplementary Information............................................9I-11
9I-2 Seats (All models)
Rear seat
removal
1. Rear seat removal
1. Remove the rear seat from vehicle.
Note：
・ Remove the cover.
・ Pull the tip-up strap to throw up the seat
cushion, and remove the 3 bolts.
・ Pull the seat back folding strap to lower the
seat back, and remove the 3 nuts.
・ Pull out the buckle side rear seat belt from the
elastomer band of the seat back.
1. Rear seat cushion, right side

2. Rear seat back
3. Rear seat cushion, right side
4. Hinge bracket, right side
5. Hinge bracket, center
6. Hinge bracket, left side
1. Rear seat
2. Cover
3. Seat back folding strap
4. Nut
5. Bolt
6. Tip-up strap
2. Rear seat back removal

1. Remove the rear seat back from the rear seat
cushion.
Note：
・ Remove the headrest.
・ Remove the bolt and the nut, and remove the
rear seat back and hinge bracket.
installation
1. Rear seat back installation
1. Install the rear seat back to the rear seat cushion.
Note：
・ Tighten the hinge bracket with the screw and
the nut to the specified torque.
1. Rear seat
2. Side cover
3. Folding strap
4. Nut
5. Bolt
6. Tip-up strap
Note：
・ When passing the seat belt through the
elastomer band of the seat cushion, pass the
1. Rear seat cushion, right side belt downward through the band, making the
2. Rear seat back belt cross as shown in the diagram.
3. Rear seat cushion, left side
4. Hinge bracket, right side
5. Hinge bracket, center
6. Hinge bracket, left side
2. Rear seat installation

1. Install the rear seat to vehicle.
Note：
・ Install the side cover.
・ Tighten the bolt and the nut to the specified
torque.
1. Rear seat back

2. Buckle side rear seat belt, left side
3. Buckle side rear seat belt, right side
4. Elastomer band
Front seat
removal
1. Front seat removal
1. Remove the front seat from vehicle.
Note：
・ Except for regular cabs, remove the rear
cover.
1. Seat belt switch harness connector

1. Front seat
2. Rear cover, except for regular cabs 2. Remove the driver seat belt buckle from the driver
seat.
Note：
・ Disconnect the seat belt warning harness Note：
connector. ・ Remove the driver seat belt buckle mounting
・ For vehicles equipped with power seats, bolt.
disconnect the power seat harness.
・ The following applies to the bench seat.
・ Draw out the front buckle side center seat belt
from the seat hole of the bench seat cushion
and drop it on the floor.
・ Remove the front tongue side center seat belt
from the seat band of the bench seat.
2. Buckle side driver seat belt removal
1. Disconnect the harness connector from the driver
seat.
Note：
・ Disconnect the seat belt switch harness
connector.
1. Driver seat belt buckle

3. Buckle side passenger seat belt removal
1. Remove the passenger seat belt buckle from the
passenger seat.
Note：
・ Remove the passenger seat belt buckle
mounting bolt.
1. Side cover, the passenger seat-inside

2. Side cover, the passenger seat-outside
Note：
・ Bench seat
1. Passenger seat belt buckle
4. Front seat back removal

1. Remove the front seat back from the front seat.
Note：
・ Remove the headrest.
・ Remove the lever knob.
・ For bucket seats with a seat lifter mechanism,
remove the cap and lifter lever.
・ Remove the side cover.
・ Bucket seat, bucket seat with a seat lifter
mechanism
1. Side cover, inside

2. Side cover, outside
3. Lever knob
Note：
・ Power seat

3. Switch knob
Note：
・ Remove the J hook of the seat back trim.
・ Remove the 4 bolts, and remove the seat
back.
5. Seat slide adjuster removal
Note：
・ The following applies to the bucket seat.
1. Remove the seat slide adjuster from the front seat.
Note：
・ Remove the 4 fixing nuts inside the slide
adjuster.
・ Remove the 3 fixing nuts outside the slide
adjuster.
installation
1. Seat slide adjuster installation
1. Install the seat slide adjuster to the front seat.
Note：
・ Tighten the 4 fixing nuts inside the slide
adjuster to the specified torque.
・ Tighten the 3 fixing nuts outside the slide
adjuster to the specified torque.
2. Front seat back installation
1. Install the front seat back to the front seat.
Note：
・ Tighten the 4 bolts to the specified torque.
Tightening torque： 46 N・m { 4.7 kgf・m / 34 lb・ft } 1. Side cover, inside
Note： 2. Side cover, outside
3. Lever knob
・ Install the side cover.
・ Bucket seat, bucket seat with a seat lifter Note：
mechanism ・ Power seat
1. Side cover, the passenger seat-inside 1. Side cover, outside

2. Side cover, the passenger seat-outside 2. Side cover, inside
3. Switch knob
Note：
・ Bench seat Note：
・ Install the lever knob.
3. Buckle side driver seat belt installation
1. Install the driver seat belt buckle to the driver seat.
Note：
・ Install the driver seat belt buckle mounting
bolt.
Tightening torque： 40.0 N・m { 4.1 kgf・m / 30 lb・ 4. Buckle side passenger seat belt installation
ft }
1. Install the passenger seat belt buckle to the passenger
seat.
Note：
・ Install the passenger seat belt buckle
mounting bolt.
Tightening torque： 40.0 N・m { 4.1 kgf・m / 30 lb・
ft }
1. Driver seat belt buckle
2. Connect the harness connector to the driver seat.

Note：
・ Connect the seat belt switch harness
connector.
1. Passenger seat belt buckle
5. Front seat installation

1. Install the front seat to the floor panel.
Note：
・ Install the bolt to the specified torque.
Note：
・ The following applies to the driver seat side.
・ Connect the harness connector to the dash
harness.
・ Connect the seat belt warning harness
connector.
1. Seat belt switch harness connector

3. Front tongue side center seat belt
4. Driver seat
5. Seat hole
1. Front seat
2. Rear cover, except for regular cabs
Note：
・ Except for regular cabs, install the rear cover
to the seat slide adjuster.
・ The following applies to the bench seat.
・ The front tongue side center seat belt is
tightened together with the driver seat by using
the driver seat fixing bolt.
・ Cross the center seat belt buckle from the
back side of the passenger seat buckle.
・ Pass the front buckle side center seat belt 1. Center seat belt buckle
through the seat hole of the seat cushion. 2. Passenger seat belt buckle
・ Completely pull out each seat belt buckle of
the front buckle side center seat belt from the Note：
cushion surface. ・ Pass the front tongue side center seat belt
through the seat band of the bench seat, and
attach the webbing loop to the seat band.
1. Front bench seat

2. Front buckle side center seat belt
1. Front tongue side center seat belt
2. Bench seat
3. Seat band
4. Webbing loop
・ Front seat, power seat
1. Seat cushion assembly 5. Headrest

2. Switch knob 6. Buckle side seat belt
3. Side cover, outside 7. Side cover, inside
4. Seat back
Note：
・ Front seat, bucket seat with a seat lifter
mechanism
1. Seat slide adjuster 6. Seat back

2. Seat cushion 7. Headrest
3. Side cover, outside 8. Buckle side seat belt
4. Cap, seat lifter lever 9. Side cover, inside
5. Lever knob
Note：
・ Front seat, bucket seat
1. Seat slide adjuster 6. Headrest

2. Seat cushion 7. Side cover, outside
3. Buckle side seat belt 8. Lever knob
5. Seat back
Note：
・ Front seat, bench seat
1. Seat back 5. Seat cushion

2. Headrest 6. Side cover, inside
4. Lever knob
Note：
・ Rear seat
1. Seat cushion, right side 7. Side cover, left side

2. Hinge bracket, right side 8. Hinge bracket, center
3. Side cover, right side 9. Hinge bracket, left side
4. Seat back 10. Seat cushion, left side
5. Headrest 11. Tip-up strap
6. Folding strap
Security and Locks (All models) 9J-1

Security and Locks
(All models)
Table of Contents
Remote controller key......................................................9J-2
disassembly..................................................................9J-2
reassembly....................................................................9J-3
setting...........................................................................9J-4
ICU...................................................................................9J-6
removal........................................................................9J-6
installation....................................................................9J-7
setting...........................................................................9J-8
Fuel filler lid opener lever..............................................9J-10
removal......................................................................9J-10
installation..................................................................9J-13
Anti theft horn................................................................9J-16
removal......................................................................9J-16
inspection...................................................................9J-17
installation..................................................................9J-18
Supplementary Information............................................9J-19
9J-2 Security and Locks (All models)
Remote controller key
disassembly
1. Remote controller key disassembly
1. Remove the key ring from the remote controller key.
2. Open the key cover using the coin.
3. Remove the transmitter from the remote controller
key.
4. Remove the battery cover from the transmitter.
5. Remove the battery from the transmitter.
1. Key cover
2. Battery cover
3. Transmitter
4. Key
5. Key ring
6. Battery
7. Battery holder
reassembly
1. Remote controller key reassembly
1. Install the battery to the transmitter.
Note：
・ Install a new battery CR1620 with the positive
(+) side up.
2. Install the battery cover to the transmitter.
3. Install the transmitter to the remote controller key.
4. Close the key cover.
5. Install the key ring to the remote controller key.
1. Key cover
2. Battery cover
3. Transmitter
4. Key
5. Key ring
6. Battery
7. Battery holder
setting ・ The following is when not using a scan tool
1. Remote controller key setting Caution：

New registration of ID code
Note： switch.
・ Clear all of the registered ID code, and then
Note：
register a new ID code.
・ The following is when using a scan tool
1. Connect a scan tool to the DLC. ・ Repeatedly turn the ignition switch to ON and
2. Turn ON the ignition switch. OFF 3 times within 5 seconds.
3. Select the Diagnostics. ・ After turning the ignition switch to ON and
OFF, repeat closing and then opening the
4. Select the Body. driver side front door 2 times within 5 seconds.
5. Select Remote Keyless Entry Transmitter. ・ After opening and closing the doors,
repeatedly turn the ignition switch to ON and
6. Select Remote Keyless Entry Transmitter
Registration Delete.
Note： transmitter to check the operation.
・ Follow the directions on the screen and delete
Caution：
the ID codes.
number of registered keys" is 0. 2. Remote controller key setting 2nd
7. Select Remote Keyless Entry Registration Mode Additional registration of ID code
TimeOut Time and ID Reception Setting. Note：
8. Check Registration Mode Timeout of a scan tool. ・ Register the new ID code received to the
Note： registered ID code as additional code.
・ Follow the directions on the screen and write ・ When the total registered and newly registered
the given values. ID codes exceed 5, they will be deleted
starting with the oldest code.
9. Select Remote Keyless Entry Transmitter
・ The following is when using a scan tool
Registration.
Note：
・ Follow the directions on the screen and 2. Turn ON the ignition switch.
confirm that the "Registration Complete" Note：
message displays. ・ Use the newly added remote control key to
10. Operate the remote controller key. turn the ignition switch to the ON position.
Note： 3. Select the Diagnostics.
・ With the remote control key inserted into the 4. Select the Body.
Unlock button 5 times. 5. Select Remote Keyless Entry Transmitter.
Caution： 6. Select Remote Keyless Entry Transmitter

Registration.
given time written in step 8. Note：
・ Confirm that the value displayed for "The ・ Follow the directions on the screen and
number of registered keys" has been added. confirm that the "Do you want to register
another Transmitter?" message displays.
Note：
・ Remove the remote control key from the 7. Operate the remote controller key.
Note：・ The number of blinks of the hazard light is the
・ With the remote control key inserted into the number of registered ID codes.
Unlock button 5 times.
Caution：
given time written in "Registration Mode
Timeout."
number of registered keys" has been added.
Note：
・ Remove the remote control key from the
・ The following is when not using a scan tool
switch.
・ Repeatedly turn the ignition switch to ON and
・ After turning the ignition switch to ON and
OFF, close and then open the driver side front
door within 5 seconds.
・ After the door opening and closing operation,
turn the ignition switch to ON and OFF within
10 seconds.
・ Confirm that the hazard light blinks 3 times.
transmitter to check the operation.
Caution：
ID code check
Note：
・ Confirm the number of registered ID codes
with this mode.
switch.
・ Insert the ignition key into the ignition switch
and then pull it out 2 times, and then leave the
key inserted at the third time.
Caution：
・ This procedure must be completed within 5
seconds.
Note：
・ Count the blinks of hazard light.
ICU
removal 2. Steering lock


3. ICU removal
1. Disconnect the harness connector from the ICU.
2. Remove the ICU from the steering lock.
Note：
1. ICU
installation 3. Battery ground cable connect

1. ICU installation
1. Install the ICU to the steering lock.
Note：
1. ICU
2. Steering lock
2. Connect the harness connector to the ICU.

Caution：

setting Caution：
・ When the ICU and ECM are reset at the same
1. ICU setting time, the transponder key must be replaced.
Transponder key erasure procedure 7. Connect a scan tool to the DLC.
1. Connect a scan tool to the DLC. 8. Turn ON the ignition switch.
2. Turn ON the ignition switch. Note：
Note：・ On a scan tool, select Reset Immobilizer in
・ On a scan tool, select Erase Transponder- Additional Functions.
Keys in Additional Functions. ・ Operate following the on-screen instructions.
・ Operate following the on-screen instructions. Caution：
Caution：・ An incorrect security code input causes a
・ An incorrect security code input causes a security wait time.
security wait time. ・ When turning the ignition switch to ON or OFF,
・ When turning the ignition switch to ON or OFF, wait at least 5 seconds between ON and OFF.
wait at least 5 seconds between ON and OFF. 9. Turn OFF the ignition switch.
3. Turn OFF the ignition switch. Note：
Note：・ After the ICU reset is completed, turn OFF the
・ After the transponder key erasure is ignition switch for 30 seconds.
completed, turn OFF the ignition switch for 30 ・ Confirm that the engine does not start with all
seconds. transponder keys.
・ Confirm that the engine does not start with all ICU programming procedure
transponder keys.
Transponder key programming procedure
Note：
・ On a scan tool, select Program Immobilizer
Note： Function in Programming.
・ On a scan tool, select Program Transponder- ・ Operate following the on-screen instructions.
Keys in Programming.
Caution：
・ Operate following the on-screen instructions.
・ An incorrect security code input causes a
Caution： security wait time.
・ An incorrect security code input causes a ・ When turning the ignition switch to ON or OFF,
security wait time. wait at least 5 seconds between ON and OFF.
・ When turning the ignition switch to ON or OFF, ・ Keep the transponder key to be programmed
wait at least 5 seconds between ON and OFF. away from other keys, other transponder keys,
・ Keep the transponder key to be programmed key number plates, and any other metal items.
away from other keys, other transponder keys, 12. Turn OFF the ignition switch.
key number plates, and any other metal items.
Note：
・ After the ICU programming is completed, turn
Note： OFF the ignition switch for 30 seconds.
・ After the transponder key programming is ・ Confirm that the engine can be started with all
completed, turn OFF the ignition switch for 30 transponder keys.
seconds.
ECM reset procedure
・ Confirm that the engine can be started with all
transponder keys. Caution：
・ When the ICU and ECM are reset at the same
ICU reset procedure
time, the transponder key must be replaced.
14. Turn ON the ignition switch. Note：
Note：・ On a scan tool, select Program Immobilizer
Function in Programming.
・ On a scan tool, select Reset Engine Control
Module in Additional Functions. ・ Operate following the on-screen instructions.
・ Operate following the on-screen instructions. Caution：
Caution：・ An incorrect security code input causes a
security wait time.
security wait time. ・ When turning the ignition switch to ON or OFF,
wait at least 5 seconds between ON and OFF.
・ When turning the ignition switch to ON or OFF,
wait at least 5 seconds between ON and OFF. ・ Keep the transponder key to be programmed
away from other keys, other transponder keys,
15. Turn OFF the ignition switch. key number plates, and any other metal items.
Note： 21. Turn OFF the ignition switch.
・ After the ECM reset is completed, turn OFF
Note：
the ignition switch for 30 seconds.
・ After programmings for the ICU, ECM and all
・ Confirm that the engine does not start with all
transponder keys are completed, turn OFF the
transponder keys.
ignition switch for 30 seconds.
ECM programming procedure ・ Confirm that the engine can be started with all
16. Connect a scan tool to the DLC. transponder keys.
Note：
・ On a scan tool, select Program Immobilizer
Function in Programming.
・ Operate following the on-screen instructions.
Caution：
security wait time.
・ When turning the ignition switch to ON or OFF,
wait at least 5 seconds between ON and OFF.
・ Keep the transponder key to be programmed
away from other keys, other transponder keys,
key number plates, and any other metal items.
Note：
・ After the ECM programming is completed, turn
OFF the ignition switch for 30 seconds.
・ Confirm that the engine can be started with all
transponder keys.
ICU & ECM programming procedure
Caution：
・ When the ICU and ECM are replaced at the
same time, the transponder key must be
replaced.
Fuel filler lid opener lever
removal Note：
・ Crew cab
Note：
・ Regular cab
1. Front sill plate

2. Rear sill plate
3. Clip
2. Front tongue side seat belt removal

Note：
1. Sill plate ・ The following applies to crew cab model.
2. Clip
1. Remove the seat belt lower anchor bolt from the
Note： center pillar.
・ Extend cab
1. Seat belt lower anchor bolt

1. Sill plate
2. Clip 3. Center pillar lower trim cover removal
Note：
・ The following applies to crew cab model.
1. Remove the center pillar lower trim cover from the Note：
center pillar. ・ The following applies to standard cabs.
Note： 1. Remove the front flap from the rear body.
Note：
1. Clip
4. Fuel filler lid opener lever removal 1. J-type nut

2. Inner liner
3. Spats
4. Screw
Note：
6. Rear mud guard removal
・ Remove the 2 screws, and disconnect the
cable. Note：
rear mud guards.
1. Remove the rear mud guard from the rear body.
Note：
1. Fuel filler lid opener lever

2. Fuel filler lid cable
3. Screw
5. Front flap removal

1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard

1. Remove the inner liner from the rear body.
Note：
front flaps.
front flaps.
・ Left side: Remove the 9 clips and the screw.
8. Fuel filler lid cable assembly removal
1. Remove the fuel filler lid cable assembly from
vehicle.
Note：
・ Push out the grommet toward the front of the
vehicle and remove the cable assembly.
・ Remove the fixing clip, and turn the cable
holder counterclockwise by 90° to remove it
from the rear body.
1. Cable holder
・ Tighten the 3 screws to the specified torque.
1. Fuel filler lid cable assembly installation
1. Install the fuel filler lid cable assembly to vehicle.
Note：
Caution：
・ Securely insert the J-type nut until it hits the
・ Do not bend the cable excessively. inner end of the panel.
・ Install the cable from the inside of the cab.
Note：
・ Push the grommet into the back panel.
・ Fasten the clip in the specified position.
・ Insert the cable holder of the fuel filler lid cable
assembly into the rear body, and turn it
clockwise by 90° to install it.
1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard
4. Front flap installation

Note：
1. Cable holder
1. Install the front flap to the rear body.
Note：
1. Install the inner liner to the rear body. ・ Install the 3 screws.
Note：・ Securely insert the J-type nut until it hits the
・ The following applies to standard cabs with inner end of the panel.
front flaps.
front flaps.
・ Left side: Install the 9 clips and the screw.
3. Rear mud guard installation
Note：
rear mud guards.
1. Install the rear mud guard to the rear body.
1. Install the center pillar lower trim cover to the center
pillar.
1. J-type nut
2. Inner liner
3. Spats
1. Clip
4. Screw
7. Front tongue side seat belt installation
5. Fuel filler lid opener lever installation
Note：
1. Install the fuel filler lid opener lever to the
instrument panel driver-side lower cover. ・ The following applies to crew cab model.
Note： 1. Install the seat belt lower anchor bolt to the center
pillar.
・ Connect the cable, and install the 2 screws.
Upper and lower anchor bolt
1. Fuel filler lid opener lever

2. Fuel filler lid cable
3. Screw 1. Seat belt lower anchor bolt
6. Center pillar lower trim cover installation 8. Sill plate installation

Note： 1. Install the sill plate to the floor.
・ The following applies to crew cab model. Note：
・ Regular cab

3. Clip
Note：
・ Extend cab
1. Sill plate
2. Clip
Note：
・ Crew cab
Anti theft horn
removal 1. Remove the anti theft horn from vehicle.

Note：
2. Anti theft horn removal
1. Anti-theft horn
3. Anti theft indicator light removal

1. Remove the anti theft indicator light from the
instrument panel.
Note：
・ Remove the harness connector, and then
remove the right side speaker grille.
・ Remove the anti-theft indicator light from the
right side speaker grille.
inspection
1. Anti theft horn inspection
Note：
・ Inspect the anti-theft horn using battery.
・ Confirm that the horn sounds when the horn
terminal is connected to the battery, and then
the battery voltage is applied.
installation 2. Anti theft horn installation

1. Install the anti theft horn to vehicle.
1. Anti theft indicator light installation
Note：
1. Install the anti theft indicator light to the instrument
panel. ・ Tighten the bolts at the specified torque.
Note： Tightening torque： 8 N・m { 0.8 kgf・m / 6 lb・ft }

・ Install the anti-theft indicator light to the right Note：
side speaker grille. ・ Install the harness connector.
・ Install the harness connector and install the
right side speaker grille.
1. Anti-theft horn

1. Component Views ・ Regular cab
Note：
・ Fuel filler lid opener lever
1. Fuel filler lid opener lever 5. Grommet

2. Clip 6. Clip
3. Fuel filter lid cable assembly 7. Band clip
4. Cab back panel
Note：
・ Extend cab

2. Clip 6. Clip
3. Fuel filter lid cable assembly 7. Band clip
4. Cab back panel
Note：
・ Crew cab

2. Clip 6. Band clip
3. Fuel filter lid cable assembly
4. Cab back panel
Note：
・ ICU
1. Steering cowl lower 3. Steering lock

2. ICU
Note： 1. Key cover

・ Remote controller key 2. Battery cover
3. Transmitter
4. Key
5. Key ring
6. Battery
7. Battery holder
Note：
・ Anti-theft horn
1. Right side speaker grille 3. Anti-theft horn

2. Anti-theft indicator light
Exterior, Interior Trim (All models) 9L-1

Exterior, Interior Trim
(All models)
Table of Contents
Head lining......................................................................9L-2
removal........................................................................9L-2
installation...................................................................9L-9
Instrument panel............................................................9L-17
removal......................................................................9L-17
installation.................................................................9L-26
Pillar trim cover.............................................................9L-33
removal......................................................................9L-33
installation.................................................................9L-40
Console box...................................................................9L-47
removal......................................................................9L-47
installation.................................................................9L-48
Supplementary Information...........................................9L-49
9L-2 Exterior, Interior Trim (All models)
Head lining
removal ・ Remove the clip from the body panel.

1. Door finisher removal
lower part upward.
Note：
extend cab.
2. Front door finisher removal
Note：
3. Rear door finisher removal
Note：
1. Remove the rear door finisher from the body.
pillar. 5. Rear end trim cover removal
Note： 1. Remove the rear end trim cover from the body panel.
・ The following applies to models without assist Note：
grip. ・ Remove the trim cover clip from the body
・ Remove the clip from the body panel. panel and remove the trim cover by sliding it
・ Remove the front pillar trim cover by pulling its upward.
lower part upward. ・ Regular cab, half trim type
Note： 1. Rear end trim cover

・ The following applies to models with assist 2. Rear window
grip. 3. Body panel
4. Clip
Note： 2. Rear window
・ Regular cab, full trim type 3. Body panel
4. Clip
Note：
・ Crew cab
1. Rear end trim cover

2. Rear window
3. Body panel
4. Clip
Note：
・ Extend cab

2. Rear window
3. Body panel
4. Clip

Note：
・ Regular cab


3. Clip
Note：
・ Extend cab 7. Dash side trim pad removal
Note：
・ Remove the nut.
panel.
1. Sill plate
2. Clip
Note：
・ Crew cab
8. Tongue side seat belt removal

Note：
・ The following applies to regular cab.
1. Remove the adjuster cover from the tongue side seat
belt.
2. Remove the seat belt upper anchor bolt from the rear
pillar.
Note：
・ Remove the adjuster cover.
1. Adjuster cover
2. Seat belt upper anchor bolt
1. Adjuster cover 3. Remove the seat belt lower anchor bolt from the
2. Seat belt upper anchor bolt center pillar.
3. Remove the seat belt lower anchor bolt from the rear
pillar.
10. Center pillar lower trim cover removal

Note：
9. Front tongue side seat belt removal ・ The following applies to crew cab model.
Note： 1. Remove the center pillar lower trim cover from the
・ The following applies to crew cab model. center pillar.
1. Remove the adjuster cover from the front tongue side Note：
seat belt. ・ Remove clips from the body panel.
2. Remove the seat belt upper anchor bolt from the
center pillar.
Note：
pillar.
Note：
・ Remove the anchor bolt cover.
1. Clip
11. Center pillar upper trim cover removal

Note：
1. Anchor bolt cover
1. Remove the center pillar upper trim cover from the 2. Seat belt upper anchor bolt
center pillar.
13. Rear lower trim cover removal
Note：
・ Remove the clip from the body panel. 1. Remove the rear lower trim cover from the rear
pillar.
・ Remove the center pillar upper trim cover by
pulling its upper part downward. Note：
panel.
・ Regular cab
1. Clip
12. Rear tongue side seat belt removal

Note： 1. Clip
Note：
・ Extend cab
1. Clip 1. Clip
Note： Note：
・ Crew cab ・ Extend cab
1. Clip 1. Clip
14. Rear upper trim cover removal Note：

1. Remove the rear upper trim cover from the rear ・ Crew cab
pillar.
Note：
panel.
・ Regular cab
1. Clip 1. Striker cover

2. Clip
15. Sun visor removal
19. Head lining removal
1. Remove the sun visor from the head lining.
1. Remove the head lining from vehicle.
Note：
・ Remove the 2 fixing screws. Note：
2. Remove the sun visor holder from the head lining.
Note：
16. Overhead console removal
Note：
・ The following applies to models equipped with
an overhead console.
1. Remove the over head console from the head lining.
17. Assist grip removal
1. Remove the assist grip from the head lining.
Note：
・ Open the cover and remove the 2 fixing
screws.
・ The following applies to crew cab, rear side.
・ Remove the assist grip with coat hook.
Note：
screws.
exciter speaker.
18. Striker cover removal ・ Disconnect the exciter harness.
Note：
・ The following applies to extend cab.
1. Remove the striker cover from the head lining.
Note：
installation 1. Striker cover

2. Clip
1. Head lining installation
3. Assist grip installation
1. Install the head lining to vehicle.
1. Install the assist grip to the head lining.
Note：
・ Install the 2 clips. Note：
・ Install the assist grip with coat hook.
4. Overhead console installation
Note：
1. Install the over head console to the head lining.
5. Sun visor installation
1. Install the sun visor holder to the head lining.
Note：
2. Install the sun visor to the head lining.
Note： Note：
・ The following applies to models equipped with ・ Install the 2 fixing screws.
exciter speaker.
6. Rear upper trim cover installation
・ Connect the exciter harnesses.
2. Striker cover installation 1. Install the rear upper trim cover to the rear pillar.
Note： Note：
・ The following applies to extend cab. ・ Regular cab
1. Install the striker cover to the head lining.

Note：
1. Clip
Note：
・ Extend cab
1. Clip 1. Clip
Note： Note：
1. Clip 1. Clip
7. Rear lower trim cover installation Note：

1. Install the rear lower trim cover to the rear pillar. ・ Crew cab
Note：
・ Regular cab
1. Clip 1. Clip
8. Rear tongue side seat belt installation 10. Center pillar lower trim cover installation
Note： Note：
・ The following applies to crew cab. ・ The following applies to crew cab model.
1. Install the rear tongue side seat belt to the rear pillar. 1. Install the center pillar lower trim cover to the center
pillar.
Note：
・ Install the anchor bolt cover.
1. Clip
11. Tongue side seat belt installation

1. Anchor bolt cover Note：
2. Seat belt upper anchor bolt ・ The following applies to regular cab.
9. Center pillar upper trim cover installation 1. Install the seat belt upper anchor bolt to the center
pillar.
Note：
・ The following applies to crew cab. 2. Install the seat belt lower anchor bolt to the center
pillar.
1. Install the center pillar upper trim cover to the center
pillar.
Tightening torque： 46 N・m { 4.7 kgf・m / 34 lb・ft } 3. Install the adjuster cover to the front tongue side seat
Upper and lower anchor bolts belt.
3. Install the adjuster cover to the tongue side seat belt.
1. Adjuster cover
1. Adjuster cover

1. Seat belt lower anchor bolt 13. Dash side trim pad installation
12. Front tongue side seat belt installation 1. Install the dash side trim pad to the body.
Note： Note：
・ The following applies to crew cab model. ・ Install the nut.
1. Install the seat belt upper anchor bolt to the center
pillar.
2. Install the seat belt lower anchor bolt to the center
pillar.
14. Sill plate installation 1. Sill plate

2. Clip
1. Install the sill plate to the floor.
Note： Note：
・ Regular cab ・ Crew cab

3. Clip
Note：
15. Rear end trim cover installation
・ Extend cab
1. Install the rear end trim cover to the body panel.
Note：
・ Install the back upper hook of the trim cover to
the body panel.
・ Regular cab, half trim type

2. Rear window
3. Body panel
4. Clip
Note：
・ Regular cab, full trim type

2. Rear window
3. Body panel
4. Clip
Note：
・ Crew cab

2. Rear window
3. Body panel
4. Clip
Note：
・ Extend cab
Note：
・ The following applies to models with assist
grip.

2. Rear window
3. Body panel
4. Clip

Note：
grip.

Note：
extend cab.
1. Install the door finisher to the body.
Note：
19. Rear door finisher installation
Note：
1. Install the rear door finisher to the body.
Instrument panel
removal 2. Clip
1. Battery ground cable disconnect Note：

1. Disconnect the battery ground cable from the battery. ・ Crew cab

Note：
・ Regular cab
1. Front sill plate

2. Rear sill plate
3. Clip

Note：
1. Sill plate extend cab.
2. Clip
Note： 4. Front door finisher removal
・ Extend cab
Note：
pillar.
Note：
grip.
lower part upward.
1. Sill plate
Note： 7. Console box removal

・ The following applies to models with assist Note：
grip.
・ Remove the assist grip. transmission.
Note：
lower part upward. ・ Below is for the center console type.
box.
Note：
Note：
4. Remove the 4WD switch from the console box.
Note：
5. Remove the console box from the floor.
Note：
1. Remove the dash side trim pad from the body. screws.
Note：・ Remove the control box backward.
・ Remove the nut. ・ Below except for the center console type.
・ Remove the trim cover clip from the body 6. Remove the console cover from the instrument
panel. panel.
Note：
7. Remove the cup holder cover from the floor. Note：
8. Remove the bracket from the floor. ・ Handling of a deployed airbag assembly
8. Glove box removal Warning：

skin or eye.
safety glasses.
Note：
・ Handling of an undeployed airbag assembly
Warning：
1. Glove box connector or harness on your hand.
2. Instrument panel assist side lower cover ・ When putting down an undeployed airbag,
9. Instrument panel assist-side lower cover removal ・ Do not place any other item on the steering
1. Remove the instrument panel assist-side lower cover wheel with the airbag surface facing
from the instrument panel. downward.
Note：・ Not following this procedure will result in a fire
or injuries.
Caution：
problems.
it.
Note：
steering cover.
1. Glove box
2. Instrument panel assist side lower cover

Note： 1. Remove the driver air bag assembly from the

・ Confirm the lever position in the hole in the steering wheel.
following illustration. 2. Disconnect the connector from the driver air bag
assembly.
Note：
Note：
・ Insert a bar of diameter 6 mm {0.24 in} to
lever.
1. Airbag connector
2. Horn connector
Warning：
upward.

personal injury.

Note：
shaft. Caution：
・ They are used for reassembly of parts. ・ Never apply an impact to the steering wheel
shocks.
Note：

using special tool.
1. Clip 1. Fuel filler rid opener lever

14. Instrument panel driver-side lower cover removal 3. Screw
Note：
Note：
cover.
・ Remove the DLC.

2. Control cable
3. Screw
2. Remove the fuel filler lid opener lever from the 1. Instrument panel driver side lower cover
instrument panel driver-side lower cover. 2. DLC
Note：
1. Steering cowl upper 18. Assist side lid cover removal

1. Remove the assist side lid cover from the instrument
16. Cover removal panel.
Note： 19. Instrument panel cluster removal

・ The following applies to models without 1. Remove the instrument panel cluster from the
passenger airbag. instrument panel.
17. Passenger air bag assembly removal
1. Remove the passenger air bag assembly from the
instrument panel.
Note：

Note：
Note：
Caution：・ The following applies except for auto A/C.
Note：
Note：
Note：
Note：
3. Remove the instrument panel assembly and Note：
reinforcement from vehicle. ・ Disconnect the control cable of the blower unit
Note：
・ Disconnect the dash harness connector.
・ Remove the 4 bolts that fix the steering
column to the reinforcement. ・ Remove the bolt and nut that secure the
instrument panel and reinforcement assembly.
24. Center ventilation grille removal

1. Remove the center ventilation grille from the
instrument panel.
Note：
・ Remove the screw to pull out the center
ventilation grille, and then remove it.
Note：
・ The following applies to models with radio.
1. Remove the radio from the instrument panel.
26. Center cluster removal
Note：
27. Reinforcement removal
1. Remove the reinforcement from the instrument
panel.
Note：
25. Radio removal
28. Dash harness removal

1. Remove the dash harness from the reinforcement.
installation 2. Reinforcement installation

1. Install the reinforcement to the instrument panel.
1. Dash harness installation
1. Install the dash harness to the reinforcement.

Note：
cover or the tray.
Note：
・ The following applies to models with radio.
1. Install the radio to the instrument panel.
Note：
・ Connect the harnesses.
5. Center ventilation grille installation
1. Install the center ventilation grille to the instrument 6. Instrument panel installation
panel.
Note： reinforcement to vehicle.
・ Put the center ventilation grille in, and install
Note：
the screws.
Bolt
Nut
Note： 7. Front cover installation

・ Tighten the 4 bolts that secure the steering Note：
torque.
Steering column bolt 8. Sun sensor installation
Note：
Note：
9. Side cover installation
Note：
panel.
Note：
・ Connect the dash harness connector.
・ Connect the control cable of the blower unit
and ventilation unit.
Note：
3. Install the speaker grille to the instrument panel.
Note：
Note：
11. Assist side lid cover installation

1. Install the assist side lid cover to the instrument
panel. 1. Passenger airbag mounting bolts
12. Cover installation 14. Steering cowl installation
Note： 1. Install the steering cowl to the steering column.
Caution：
passenger airbag.
1. Install the cover to the instrument panel. not to pinch the harness by the cowl.
13. Passenger air bag assembly installation
1. Install the passenger air bag assembly to the
instrument panel.
Note：
・ Press the portion indicated by the arrow in the


1. Install the instrument panel driver-side lower cover
Note：

2. Control cable
3. Screw
1. Instrument panel driver side lower cover 16. Meter cluster installation
2. DLC 1. Install the meter cluster to the instrument panel.
2. Remove the fuel filler lid opener lever from the Note：
instrument panel driver-side lower cover. ・ Connect the switch connector.
Note：
1. Clip

2. Fuel filler rid cable 1. Install the steering wheel to the steering shaft.
3. Screw Note：
3. Install the hood lock control lever to the instrument ・ Line up the setting applied during removal, and
panel driver-side lower cover. install the steering wheel.
Note：
Note：
battery.
blinking 7 times.
21. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Caution： Note：
・ Never apply an impact to the steering wheel ・ Install the 4 screws.
shocks.
Note：
1. Glove box
22. Glove box installation

1. Install the glove box to the instrument panel.
1. Airbag connector
2. Horn connector

wheel.
Note：
grip.
1. Glove box
23. Console box installation

Note：
Note：
3. Install the console cover to the instrument panel. ・ The following applies to models with assist
Note： grip.
・ Connect the cigarette lighter connector. ・ Insert the lower part of the front pillar trim
Note：

Note：
extend cab.
Note：
28. Sill plate installation
Note：
・ Regular cab
1. Sill plate
2. Clip
Note：
・ Crew cab
1. Sill plate
2. Clip
Note：
・ Extend cab
1. Front sill plate

2. Rear sill plate
3. Clip
Pillar trim cover
removal Note：
・ Crew cab
Note：
・ Regular cab
1. Front sill plate

2. Rear sill plate
3. Clip

Note：
1. Sill plate ・ The following applies to regular cab and
2. Clip extend cab.
Note： 1. Remove the door finisher from the body.
・ Extend cab 3. Front door finisher removal
Note：
Note：
pillar.
Note：
grip.
1. Sill plate ・ Remove the clip from the body panel.
2. Clip ・ Remove the front pillar trim cover by pulling its
lower part upward.
Note： 7. Rear end trim cover removal

・ The following applies to models with assist 1. Remove the rear end trim cover from the body panel.
grip.
Note：
panel and remove the trim cover by sliding it
・ Remove the clip from the body panel. upward.
・ Remove the front pillar trim cover by pulling its ・ Regular cab, half trim type
lower part upward.

6. Dash side trim pad removal 2. Rear window
1. Remove the dash side trim pad from the body. 3. Body panel
4. Clip
Note：
・ Remove the nut. Note：
・ Remove the trim cover clip from the body ・ Regular cab, full trim type
panel.
Note：
・ Crew cab

2. Rear window
3. Body panel
4. Clip
Note：
・ Extend cab

2. Rear window
3. Body panel
4. Clip
8. Tongue side seat belt removal

Note：
belt.
pillar.
Note：

2. Rear window
3. Body panel
4. Clip
1. Adjuster cover 1. Adjuster cover

2. Seat belt upper anchor bolt 2. Seat belt upper anchor bolt
3. Remove the seat belt lower anchor bolt from the rear 3. Remove the seat belt lower anchor bolt from the
pillar. center pillar.
1. Seat belt lower anchor bolt 1. Seat belt lower anchor bolt
9. Front tongue side seat belt removal 10. Center pillar lower trim cover removal
Note： Note：
・ The following applies to crew cab model. ・ The following applies to crew cab model.
1. Remove the adjuster cover from the front tongue side 1. Remove the center pillar lower trim cover from the
seat belt. center pillar.
2. Remove the seat belt upper anchor bolt from the Note：
center pillar. ・ Remove clips from the body panel.
Note：
pillar.
Note：
1. Clip

Note：
1. Remove the center pillar upper trim cover from the 2. Seat belt upper anchor bolt
center pillar.
Note：
・ Remove the clip from the body panel. 1. Remove the rear lower trim cover from the rear
pillar.
pulling its upper part downward. Note：
panel.
・ Regular cab
1. Clip

Note： 1. Clip
Note：
・ Extend cab
1. Clip 1. Clip
Note： Note：
1. Clip 1. Clip

pillar.
Note：
panel.
・ Regular cab
1. Clip
installation
1. Install the rear upper trim cover to the rear pillar.
Note：
・ Regular cab
1. Clip
2. Rear lower trim cover installation

1. Install the rear lower trim cover to the rear pillar.
Note：
・ Regular cab
1. Clip
Note：
・ Extend cab
1. Clip
Note：
・ Extend cab
1. Clip
Note：
・ Crew cab
1. Clip 1. Anchor bolt cover

Note：
・ Crew cab 4. Center pillar upper trim cover installation
Note：
pillar.
1. Clip

Note：
1. Clip
1. Install the rear tongue side seat belt to the rear pillar.
5. Center pillar lower trim cover installation
Note：
Note：
pillar.
1. Clip 1. Seat belt lower anchor bolt
6. Tongue side seat belt installation 7. Front tongue side seat belt installation
Note： Note：
・ The following applies to regular cab. ・ The following applies to crew cab model.
1. Install the seat belt upper anchor bolt to the center 1. Install the seat belt upper anchor bolt to the center
pillar. pillar.
2. Install the seat belt lower anchor bolt to the center 2. Install the seat belt lower anchor bolt to the center
pillar. pillar.
Tightening torque： 46 N・m { 4.7 kgf・m / 34 lb・ft } Tightening torque： 46 N・m { 4.7 kgf・m / 34 lb・ft }
Upper and lower anchor bolts Upper and lower anchor bolt
3. Install the adjuster cover to the tongue side seat belt. 3. Install the adjuster cover to the front tongue side seat
belt.
1. Adjuster cover
2. Seat belt upper anchor bolt 1. Adjuster cover
1. Seat belt lower anchor bolt 1. Rear end trim cover

2. Rear window
8. Rear end trim cover installation 3. Body panel
1. Install the rear end trim cover to the body panel. 4. Clip
Note： Note：
・ Install the back upper hook of the trim cover to ・ Extend cab
the body panel.

2. Rear window
3. Body panel
4. Clip
Note：
2. Rear window
3. Body panel
4. Clip
Note：
・ Crew cab

Note：
grip.

2. Rear window
3. Body panel
4. Clip

Note：
Note：
grip.
11. Door finisher installation 1. Sill plate

2. Clip
Note：
・ The following applies to regular cab and Note：
extend cab. ・ Extend cab
Note：
Note：
Note：
・ Regular cab
1. Sill plate
2. Clip
Note：
・ Crew cab
1. Front sill plate

2. Rear sill plate
3. Clip
Console box
removal
Note：
transmission.
Note：
box.
Note：
Note：
4. Remove the 4WD switch from the console box.
Note：
5. Remove the console box from the floor.
Note：
screws.
・ Remove the control box backward.
・ Below is for the tray type, excluding the front
bench seat.
・ Open the cover and remove the 2 screws.
・ Pull up the console tray and remove the 2 clips
at the front.
panel.
Note：
・ Below is for 4WD except for the center console
type.
・ Disconnect the connector of the 4WD switch.
8. Remove the bracket from the floor.
installation
1. Console box installation
Note：
1. Install the console box to the floor.
Note：
・ Open the console box cover and install 2
screws.
2. Install the cover to the console box.
Note：
3. Install the 4WD switch to the console box.
Note：
4. Install the shift console cover to the console box.
Note：
transmission.
5. Install the shift lever knob to the shift lever.
Note：
・ Below is for the tray type.
・ Install the console tray to the floor.
・ Install 2 screws and close the cover.
Note：
・ Instrument panel
1. Reinforcement 12. Front cover, models without auto A/C or sun

2. Ventilation duct assembly and defroster nozzle sensor, models with auto A/C
assembly 13. Center lid cover or tray
3. Dash harness 14. Right side speaker grille
4. Left side cover 15. Speaker
5. Glove box 16. Instrument panel assembly
6. Instrument panel assist lower cover 17. Right side cover
7. Assist side lid cover 18. Steering cowl
8. Left side speaker grille 19. Instrument panel driver lower cover
9. Passenger airbag, models with passenger airbag, 20. Radio
or cover, models without passenger airbag 21. Control lever assembly, models with manual A/C
10. Meter cluster or control panel assembly, models with auto A/C
11. Meter assembly 22. Right side center ventilation grille
23. Center cluster
24. Left side center ventilation grille
Note：・ Center console type, except front bench seat

・ Console box type
1. Shift console cover 5. Parking brake cover

2. Clip 6. 4WD switch, 4WD models
3. Console box 7. Cover, 2WD models
4. Screw
Note：
・ Tray type, except front bench seat type
1. Console cover 4. Screw

2. Clip
3. Console tray
Note：
・ Except the center console
1. Console cover 4. Ashtray holder

2. Clip 5. Bracket
3. Ashtray
Note：・ Regular cab

・ Head lining
1. Assist grip 6. Assist grip, models with assist grip

2. Head lining 7. Sun visor and sun visor holder
3. Rear pillar trim cover 8. Dome light
4. Hole cover
5. Front pillar trim cover
Note：
・ Extend cab
1. Assist grip 7. Assist grip, models with assist grip

2. Striker cover 8. Front pillar trim cover
3. Head lining 9. Sun visor and sun visor holder
4. Rear upper trim cover 10. Spot light or overhead console
5. Dome light
6. Hole cover
Note：
・ Crew cab
1. Assist grip 7. Center pillar upper trim cover

2. Head lining 8. Assist grip, models with assist grip
3. Assist grip with coat hook 9. Front pillar trim cover
4. Rear upper trim cover 10. Sun visor and sun visor holder
5. Dome light 11. Spot light or overhead console
6. Hole cover

・ Pillar trim cover
1. Front pillar trim cover 6. Rear end trim cover, full trim type
2. Door finisher 7. Rear lower trim cover
3. Tongue side seat belt 8. Sill plate
4. Rear upper trim cover 9. Dash side trim pad
5. Rear end trim cover, half trim type
Note：
・ Extend cab
1. Front pillar trim cover 5. Rear end trim cover

2. Door finisher 6. Sill plate
3. Rear upper trim cover 7. Dash side trim pad
4. Rear lower trim cover
Note：
・ Crew cab
1. Front pillar trim cover 8. Rear lower trim cover

2. Front door finisher 9. Rear end trim cover
3. Center pillar upper trim cover 10. Sill plate
4. Front tongue side seat belt 11. Center pillar lower trim cover
5. Rear door finisher 12. Sill plate
6. Rear tongue side seat belt 13. Dash side trim pad
7. Rear upper trim cover
Unibody Sub-frames (All models) 9P-1

Unibody Sub-frames
(All models)
Table of Contents
Body mounting................................................................9P-2
installation...................................................................9P-2
Tail gate...........................................................................9P-9
removal........................................................................9P-9
installation.................................................................9P-10
Rear body.......................................................................9P-12
removal......................................................................9P-12
installation.................................................................9P-15
Supplementary Information...........................................9P-18
9P-2 Unibody Sub-frames (All models)
Body mounting
・ The following applies to the regular cab.
1. Body mounting installation
1. Install the body mounting to the frame and the body. Tightening torque： 50 N・m { 5.1 kgf・m / 37 lb・ft }
Bolt 1 in the diagram
Tightening torque： 66 N・m { 6.7 kgf・m / 49 lb・ft } ・ The installation bolt 3, on the right side of the
Bolts 2 and 3 in the diagram section 2 in the diagram, is not tightened
Tightening torque： 106 N・m { 10.8 kgf・m / 78 lb・ completely and rotates even when it is
ft } Bolts 4, 5, 8, and 9 in the diagram tightened to the specified torque.
・ The following applies to the extend cab.
Note：
・ Use new bolts for the installation bolts 4, 5, 8,
and 9 in the diagram.
Tightening torque： 66 N・m { 6.7 kgf・m / 49 lb・ft } ・ The installation bolt 3, on the right side of the
Bolts 2 and 3 in the diagram section 2 in the diagram, is not tightened
Tightening torque： 106 N・m { 10.8 kgf・m / 78 lb・ completely and rotates even when it is
ft } Bolts 4, 7, and 8 in the diagram tightened to the specified torque.
・ The following applies to the crew cab.
Note：
・ Use new bolts for the installation bolts 4, 7,
Bolts 2, 3, and 4 in the diagram
ft } Bolts 5, 7, and 8 in the diagram
Note：
・ Use new bolts for the installation bolts 5, 7,
・ The installation bolts 3 and 4, on the right side
of the section 2 in the diagram, are not
tightened completely and rotate even when
they are tightened to the specified torque.
Tail gate
removal
1. Tail gate removal
1. Remove the hole cover from the tail gate.
2. Remove the outside handle from the tail gate.
Note：
・ Disconnect the lock link and remove the 2
fixing bolts.
1. Bolt
2. Lock link, left side
3. Lock link, right side
3. Remove the tail gate lock assembly from the tail

gate.
4. Remove the tail gate link from the tail gate and the
rear body.
5. Remove the tail gate from the rear body.
Note：
・ The tailgate removal work requires 2 workers.
・ Remove the tailgate hinge fixing bolt.
6. Remove the tail gate hinge from the tail gate.
7. Remove the tail gate lock striker from the rear body.
installation
1. Tail gate installation
1. Install the tail gate lock striker to the rear body.
Note：
2. Install the tail gate hinge to the tail gate and the rear
body.
Note：
・ The tailgate installation work requires 2
workers.
Bolt A
1. Clearance: 5.0 mm {0.20 in}
Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft } 2. Height, level difference: Same plane
Bolts B and C 3. Height, level difference: Same plane
3. Install the tail gate link to the tail gate and the rear
body.
4. Install the tail gate lock assembly to the tail gate.
Note：
5. Install the outside handle to the tail gate.
Note：
・ Connect the lock link and tighten the 2 fixing
bolts to the specified torque.
1. Bolt A
2. Tailgate hinge
3. Shim
4. Bolt B
5. Bolt C
Note：
・ Check the tailgate and rear body for the points
shown in the diagram below.
1. Bolt
2. Lock link, left side
3. Lock link, right side
6. Install the hole cover to the tail gate.

Rear body
removal Note：
・ Regular cab
Note：
・ Empty the rear body before removing it.
2. Chassis harness disconnect
1. Disconnect the chassis harness from the connector.
Note：
・ Disconnect the rear combination light.
・ Disconnect the license light harness
connector.
3. Fuel filler lid cable assembly disconnect
1. Disconnect the fuel filler lid cable assembly from the
rear body.
Note：
・ Remove the fixing clip, and turn the cable
holder counterclockwise by 90° to remove it
from the rear body.
1. Bolt
2. Washer
3. Clip
4. Cushion
Note：
・ Extend cab
1. Cable holder
4. Filler neck removal

1. Remove the filler neck from the rear body and the
fuel filler hose.
2. Disconnect the evaporator hose from the filler neck.
5. Rear body assembly removal
1. Remove the bolt from the rear body and the frame.
2. Remove the clip from the rear body and the frame.
1. Bolt 1. Bolt
2. Washer 2. Clip
3. Clip 3. Cushion
4. Cushion 4. Washer
Note： 3. Remove rear body assembly from the frame.

・ Crew cab Note：
・ Install the hoisting wire to the hook of the rear
body and hoist the rear body.
Caution：
・ When hoisting the rear body, be careful not to
hit the cab body.
1. Hook
installation
1. Rear body assembly installation
1. Install the wire to the rear body.
Note：
・ Install the hoisting wire to the hook of the rear
body and hoist the rear body.
1. Hook
1. Bolt
2. Install rear body assembly to the frame. 2. Washer
3. Clip
Caution：
4. Cushion
・ When installing the rear body, be careful not to
hit the cab body. Note：
3. Install the bolt to the rear body and the frame. ・ Extend cab
Note：
・ Tighten the bolts to the specified torque.
ft }
4. Install the clip to the rear body and the frame.
Note：
・ Regular cab
1. Bolt 1. Bolt
2. Washer 2. Clip
3. Clip 3. Cushion
4. Cushion 4. Washer
Note： 2. Filler neck installation

・ Crew cab 1. Install the filler neck to the rear body and the fuel
filler hose.
2. Connect the evaporator hose to the filler neck.
3. Fuel filler lid cable assembly connect
1. Connect the fuel filler lid cable assembly to the rear
body.
Caution：
・ Do not bend the cable excessively.
Note：
・ Fasten the clip in the specified position.
・ Insert the cable holder of the fuel filler lid cable
assembly into the rear body, and turn it
clockwise by 90° to install it.
1. Cable holder
4. Chassis harness connect

1. Connect the chassis harness to the connector.
Note：
・ Connect the rear combination light.
・ Connect the license light harness connector.
・ Rear body
1. Hook 3. Fuel filler lid

2. Tailgate

・ Body mounting
Note：
・ Break-front cab
Note：
・ Crew cab
Note：
・ Tailgate
1. Hole cover 6. Tailgate link

2. Tailgate 7. Tailgate hinge
3. Tailgate lock striker 8. Center hinge
4. Tailgate lock assembly
5. Outside handle
Glass, Windows, Mirrors (All models) 9T-1

Glass, Windows, Mirrors
(All models)
Table of Contents
Rear window assembly....................................................9T-2
removal........................................................................9T-2
inspection....................................................................9T-9
installation.................................................................9T-11
Windshield.....................................................................9T-20
removal......................................................................9T-20
installation.................................................................9T-33
Supplementary Information...........................................9T-47
9T-2 Glass, Windows, Mirrors (All models)
Rear window assembly
removal Note：
・ Crew cab
Note：
・ Regular cab
1. Front sill plate

2. Rear sill plate
3. Clip

Note：
2. Clip extend cab.
Note：
Note：
pillar.
Note：
grip.
lower part upward.
Note： 7. Tongue side seat belt removal

grip.
belt.
pillar.
lower part upward.
Note：

1. Adjuster cover
Note： 2. Seat belt upper anchor bolt
・ Remove the nut.
8. Front tongue side seat belt removal
panel. Note：
1. Remove the adjuster cover from the front tongue side
seat belt.
2. Remove the seat belt upper anchor bolt from the
center pillar.
Note：
1. Clip

Note：
1. Adjuster cover
2. Seat belt upper anchor bolt 1. Remove the center pillar upper trim cover from the
center pillar.
Note：
center pillar.
pulling its upper part downward.
9. Center pillar lower trim cover removal

Note： 1. Clip
・ The following applies to crew cab model. 11. Rear tongue side seat belt removal
1. Remove the center pillar lower trim cover from the Note：
center pillar.
Note：
pillar.
Note：
1. Clip
Note：
・ Crew cab


1. Remove the rear lower trim cover from the rear
pillar.
Note：
panel.
・ Regular cab
1. Clip
13. Rear upper trim cover removal

1. Remove the rear upper trim cover from the rear
pillar.
Note：
panel.
・ Regular cab
1. Clip
Note：
・ Extend cab
1. Clip 1. Clip
Note： 14. Rear end trim cover removal

・ Extend cab 1. Remove the rear end trim cover from the body panel.
Note：
panel and remove the trim cover by sliding it
upward.
1. Clip
Note：
・ Crew cab

2. Rear window
3. Body panel
4. Clip
Note：
Note：
・ Crew cab

2. Rear window
3. Body panel
4. Clip
Note：
・ Extend cab

2. Rear window
3. Body panel
4. Clip

Note：
Note：
Note：
1. Rear end trim cover 1. Remove the assist grip from the head lining.
2. Rear window
Note：
3. Body panel
4. Clip ・ Open the cover and remove the 2 fixing
screws.
・ The following applies to crew cab, rear side. ・ Cut open the adhered caulking material with a
・ Remove the assist grip with coat hook. knife.
・ Open the cover and remove the 2 fixing ・ Secure one end of 0.5 mm {0.02 in} diameter
screws. piano steel wire to a piece of wood to use it as
a handle.
18. Striker cover removal
・ Pierce the other end of the piano wire through
Note： the caulking material adhered to the edge of
・ The following applies to extend cab. the front windshield glass using 2 pairs of
needle nose pliers.
・ Secure the other end of the piano wire to
Note： another piece of wood.
・ Remove the clip. ・ Carefully move the piano wire like a saw with
an assistant worker to cut out the caulking
material adhered over the entire edge of the
rear window.
1. Striker cover
2. Clip
19. Head lining removal 1. Piano wire

1. Remove the head lining from vehicle. 2. Cement
3. A rectangular piece of wood, etc. attached to both
Note： ends of the piano wire
・ Remove the 2 clips. 4. Rear window
exciter speaker. Note：
・ Disconnect the exciter harness. ・ Suspend the rear window from the body.
・ Remove the remaining caulking material from
20. Rear window removal
the body portion holding the rear window.
Note：・ Wipe off the caulking material remaining on
・ The following applies to the models with a rear the rear window with a soft cloth and lead-free
defogger. gasoline.
1. Disconnect the rear defogger connector from the rear
window.
2. Remove the rear window from the panel.
Note：
・ Follow the procedures described below to
carefully remove the rear window.
inspection
1. Rear window assembly inspection
Inspection of the rear defogger heat wires
Note：
・ The heat wires are attached to the interior side
of the glass.
・ Use a soft cloth to wash and wipe in a
direction parallel to the wires.
Caution：
・ Do not use glass cleaner, etc.
Note：
・ When measuring the voltage, wrap tinfoil
around the minus probe, and push the foil onto
the wire with your hands as shown in the
diagram. Note：
・ If there is a location where the voltage
suddenly drops to 0V, then there is a location
between that location and the power source
where a wire is damaged.
・ Move the tester probe from the location where
voltage was 0V toward the power source and
measure the location where voltage suddenly
increases.
1. Heat wire
2. Test probe
3. Tin foil

2. Turn ON the rear defogger switch.
3. Measure a voltage using tester.
Note：
Repair of a damaged heat wire
・ Measure the voltage between three points on
the heat wires and the minus (-) terminal with a Note：
voltmeter. ・ Clean the ends of the damaged heat wire with
・ Confirm that the voltage drops as you proceed unleaded gasoline.
from A to B and C in the diagram. ・ Place masking tape parallel to the wire above
and below where it was damaged.
Note：
・ Thoroughly mix repair agent (DuPont paste
No. 4817 or equivalent).
・ Use a fine tip brush to apply a small amount of
repair agent to the wire.
1. Heat wire
2. Tip brush
Note：
・ Remove the masking tape after a few minutes.
・ Let set for 24 hours or more.
installation
1. Rear window installation
1. Clean the rear window using the unleaded gasoline.
2. Clean the body panel using the unleaded gasoline.
Note：
・ Clean the bonding surface of the rear window.
・ Wipe off the caulking material remaining on
the body with a soft cloth and lead-free
gasoline.
3. Install the fastener tape to the body panel flange.
Note：
・ Attach the fastener tape at 0 - 3 mm {0 - 0.12
in} from the mark.
1. Dam seal
2. Application locations of the sealing agent Sunstar
penguinseal #560 or equivalent
3. Application area of primer Sunstar GP-402 or
equivalent
4. 8 mm {0.31 in}
5. 14 mm {0.55 in}
6. 6 mm {0.24 in}
1. Fastener tape 7. 24 mm {0.94 in}
2. Mark 8. 10 mm {0.39 in}
3. 15 mm {0.59 in} 9. 28 mm {1.10 in}
4. Align the fastener edge with the body panel edge.
5. Apply the sealing adhesive to the rear window.
4. Apply the primer to the rear window. Note：
Note：・ When using an air spray gun, air pressure
・ Apply Sunstar GP-402 or equivalent to the must be kept lower than the specified value.
bonding surface on the rear window side. Specified air pressure： 147 to 294 kPa { 1.5 to 3.0 kgf/
・ Apply the primer as described in the figure. cm2 / 21 to 43 psi } or below
Note：
・ After the primer completely dries, apply the
sealing material, Sunstar penguinseal #560 or
equivalent, along the edge of the rear window
so that the sealing material forms the bonding
area of 20 mm {0.79 in} at the right lower
section of the rear window.
Caution：
・ After applying the primer, leave it for at least 1
minute for air drying.
・ Bonding must be accomplished within 5 1. Dam seal

minutes after the sealing material is applied. 2. Rear window support
3. Rear defogger connector, the models with rear
defogger
4. Fastener
5. Application area of sealing agent Sunstar #560 or
equivalent
6. Sealing material bonding surface: 20 mm {0.79
in}
6. Install the rear window to the panel.

Note：
・ Insert the rear window support into the panel,
and push it toward the panel to fix it.
・ Wipe off the sealing material protruding from
the edge.
1. Cement 5. Head lining

2. Panel 6. Fastener
3. Dam seal 7. Rear window
4. Rear window support
Note：・ The following applies to the models with a rear

・ Confirm that there is no water leakage from defogger.
the rear window.
7. Connect the rear defogger connector to the rear 1. Striker cover
window. 2. Clip
2. Head lining installation 4. Assist grip installation
1. Install the head lining to vehicle. 1. Install the assist grip to the head lining.
Note： Note：
・ Install the 2 clips. ・ Install the 2 fixing screws and close the cover.
Note：
1. Install the over head console to the head lining.
1. Install the sun visor holder to the head lining.
Note：
Note： Note：
exciter speaker. 7. Rear end trim cover installation
1. Install the rear end trim cover to the body panel.
3. Striker cover installation
Note：
Note：・ Install the back upper hook of the trim cover to
・ The following applies to extend cab. the body panel.
1. Install the striker cover to the head lining. ・ Regular cab, half trim type
Note：

2. Rear window
3. Body panel
4. Clip
Note：

2. Rear window
3. Body panel
4. Clip
Note： 2. Rear window
・ Extend cab 3. Body panel
4. Clip
Note：
・ Crew cab
Note：
・ Extend cab
1. Clip
Note：
・ Crew cab

2. Rear window
3. Body panel
4. Clip

Note：
・ Regular cab
1. Clip
9. Rear lower trim cover installation

1. Install the rear lower trim cover to the rear pillar.
Note：
・ Regular cab
1. Clip
1. Clip 1. Clip
Note： 10. Rear tongue side seat belt installation

・ Extend cab Note：
1. Install the rear tongue side seat belt to the rear pillar.
Note：
1. Clip
Note：
・ Crew cab

11. Center pillar upper trim cover installation

Note：
pillar.
Upper and lower anchor bolts
1. Clip

Note：
1. Adjuster cover
pillar.
1. Clip 14. Front tongue side seat belt installation
13. Tongue side seat belt installation Note：

Note：
・ The following applies to regular cab. 1. Install the seat belt upper anchor bolt to the center
pillar.
pillar. 2. Install the seat belt lower anchor bolt to the center
pillar.
pillar. Tightening torque： 46 N・m { 4.7 kgf・m / 34 lb・ft }
3. Install the adjuster cover to the front tongue side seat
belt.

1. Adjuster cover

Note：
15. Dash side trim pad installation extend cab.
1. Install the dash side trim pad to the body. 1. Install the door finisher to the body.
Note： 18. Front door finisher installation

・ Install the nut. Note：
Note：
Note：
・ Regular cab
1. Front sill plate

2. Rear sill plate
3. Clip
1. Sill plate
2. Clip
Note：
・ Extend cab
1. Sill plate
2. Clip
Note：
・ Crew cab
Windshield
removal Note：
・ Crew cab
Note：
・ Regular cab
1. Front sill plate

2. Rear sill plate
3. Clip

Note：
2. Clip extend cab.
Note：
Note：
pillar.
Note：
grip.
lower part upward.
Note： 7. Tongue side seat belt removal

grip.
belt.
pillar.
lower part upward.
Note：

1. Adjuster cover
Note： 2. Seat belt upper anchor bolt
・ Remove the nut.
3. Remove the seat belt lower anchor bolt from the rear
pillar.
panel.
8. Front tongue side seat belt removal 9. Center pillar lower trim cover removal
Note： Note：
・ The following applies to crew cab model. ・ The following applies to crew cab model.
1. Remove the adjuster cover from the front tongue side 1. Remove the center pillar lower trim cover from the
seat belt. center pillar.
2. Remove the seat belt upper anchor bolt from the Note：
center pillar. ・ Remove clips from the body panel.
Note：
1. Clip

1. Adjuster cover
2. Seat belt upper anchor bolt Note：
center pillar. 1. Remove the center pillar upper trim cover from the
center pillar.
Note： Note：
・ Remove the clip from the body panel. ・ Remove the trim cover clip from the body
panel.
・ Regular cab
1. Clip

1. Clip
Note：
Note：
・ Extend cab
pillar.
Note：
1. Clip
Note：
・ Crew cab

1. Remove the rear lower trim cover from the rear
pillar.
1. Clip 1. Clip

pillar.
Note：
panel.
・ Regular cab
1. Clip

Note：
1. Clip ・ Remove the 2 fixing screws.
Note：
・ Extend cab Note：
Note：
1. Remove the assist grip from the head lining.
Note：
screws.
・ Remove the assist grip with coat hook.
screws.
17. Striker cover removal
Note：
Note：
Note：
exciter speaker.
・ Disconnect the exciter harness.
Note：
panel.
Note：
3. Remove the bracket from the floor.
20. Glove box removal
1. Striker cover 21. Instrument panel assist-side lower cover removal
2. Clip
1. Remove the instrument panel assist-side lower cover
18. Head lining removal from the instrument panel.
1. Remove the head lining from vehicle. Note：
Note：・ Remove the 4 screws.
Caution：
problems.
it.
Note：
steering cover.
1. Glove box

Note：
・ Handling of a deployed airbag assembly
Warning：
skin or eye.
Note：
safety glasses.
Note：
・ Handling of an undeployed airbag assembly
Warning：
downward.
or injuries.
Note：・ When putting down an undeployed airbag
・ Insert a bar of diameter 6 mm {0.24 in} to assembly, make sure to face the trim cover
remove the driver airbag assembly from the upward.
lever. ・ Place the trim cover upward on a flat surface.
personal injury.

steering wheel.
2. Disconnect the connector from the driver air bag 25. Steering wheel removal
assembly.
Note：
Note：・ Reconfirm that the steering wheel is set to the
・ Disconnect the airbag connector. position for advancing straight forward.
・ Disconnect the horn connector. ・ Make setting marks on the steering wheel and
shaft.
・ They are used for reassembly of parts.
1. Airbag connector
2. Horn connector
Warning：
・ Keep the airbag assembly away from your 2. Remove the steering wheel from the steering shaft
body when carrying it. using special tool.
1. Clip

Note：
Caution：
shocks.
Note：

2. Control cable
3. Screw

Note：
1. Fuel filler rid opener lever 1. Steering cowl upper

2. Fuel filler rid cable 2. Steering cowl lower
3. Screw
29. Cover removal
Note：
Note： passenger airbag.
cover.
・ Disconnect the switch connector. 30. Passenger air bag assembly removal
・ Remove the DLC. 1. Remove the passenger air bag assembly from the
instrument panel.
Note：

2. DLC

Caution：
Note：
Note：
Note：
Note：
31. Assist side lid cover removal ・ Remove the left and right side covers.
1. Remove the assist side lid cover from the instrument 3. Remove the instrument panel assembly and
panel. reinforcement from vehicle.
32. Instrument panel cluster removal Note：
1. Remove the instrument panel cluster from the ・ Remove the 4 bolts that fix the steering
instrument panel. column to the reinforcement.
1. Instrument panel cluster Note：

・ Disconnect the control cable of the blower unit
1. Remove the side cover from the instrument panel. ・ Disconnect the dash harness connector.
Note：・ Remove the bolt and nut that secure the
・ Remove the left and right side covers. instrument panel and reinforcement assembly.

Note：
37. Wiper arm cover removal Note：

1. Remove the wiper arm cover from the wiper arm. ・ Remove the clip.
・ Remove the engine hood rear seal from the
hook of the cowl cover.
Note：
the blade.
1. Engine hood rear seal

2. Hook

1. Wiper arm cover
2. Nut 42. Room mirror removal
3. Wiper arm, blade
1. Remove the room mirror from the front windshield
39. Side cowl cover removal glass.
1. Remove the side cowl cover from the body. Note：

・ Remove the screw and pull out the room
40. Engine hood rear seal removal
mirror upward.
1. Remove the engine hood rear seal from the cowl
cover.
43. Front windshield glass removal 1. Piano wire

2. Cement
1. Remove the front windshield glass from the body.
3. A rectangular piece of wood, etc. attached to both
Note： ends of the piano wire
・ Follow the procedures described below to 4. Front windshield glass
carefully remove the front windshield glass.
Note：
・ Cut open the adhered caulking material with a
・ Suspend the front windshield glass from the
knife.
body.
・ Secure one end of 0.5 mm {0.02 in} diameter
・ Remove the remaining caulking material from
piano steel wire to a piece of wood to use it as
the body portion holding the front windshield
a handle.
glass.
・ Pierce the other end of the piano wire through
the caulking material adhered to the edge of
the front windshield glass with a soft cloth and
the front windshield glass using 2 pairs of
lead-free gasoline.
needle nose pliers.
・ Secure the other end of the piano wire to
another piece of wood.
・ Carefully move the piano wire like a saw with
an assistant worker to cut out the caulking
material adhered over the entire edge of the
front windshield glass.
・ Use a new spacer.
1. Front windshield glass installation
6. Install the molding to the front windshield glass.
1. Clean the front windshield glass using the unleaded
gasoline. Note：
・ Use a new molding.
Note：
・ Clean the bonding surface of the front
windshield glass.
the body with a soft cloth and lead-free
gasoline.
3. Apply the primer to the body.
Note：
・ Apply Sunstar RD-12163 or equivalent to the
bonding surface on the body side.
・ Apply the following primer application width: 23
mm {0.91 in} or longer for the upper section;
20 mm {0.79 in} or longer for side section; 25
mm {0.98 in} or longer for lower section.
4. Install the spacer to the body.
Note： 1. Molding
2. Windshield support
・ Use a new spacer.
3. Spacer
4. 26 mm {1.02 in}
5. Spacer positioning mark
7. Apply the primer to the front windshield glass.

Note：
・ Apply Sunstar penguinseal #560 or equivalent
to the bonding surface on the front windshield
glass side.
・ The width of primer application shall be 16.5
mm {0.65 in} to 25 mm {0.98 in} from the edge
of the front windshield glass.
1. Spacer
2. Application area of primer: 23 mm {0.91 in},
upper section
3. Application area of primer: 20 mm {0.79 in}, side
section
4. Application area of primer: 25 mm {0.98 in},
lower section
5. Install the spacer to the front windshield glass.

forms the bonding area of 20 mm {0.79 in} at

the right lower section of the front windshield
glass.
1. Molding
3. Spacer
4. Sealing agent
5. 20 mm {0.79 in}
1. Sealing agent Caution：
2. Application location of the primer
・ After applying the primer, leave it for at least 1
3. 11 mm {0.43 in}
minute for air drying.
4. 2 mm {0.08 in}
5. 11 mm {0.43 in} ・ Bonding must be accomplished within 5
6. 25 mm {0.98 in} for upper edge area, 20.5 mm minutes after the sealing material is applied.
{0.81 in} for side edge area, 25 mm {0.98 in} for 9. Install the front windshield glass to the body.
lower edge area
7. 11 mm {0.43 in} for center position, 8 mm {0.31 Note：
in} for side position ・ Adjust the front windshield glass position with
8. 15 mm {0.59 in} a suction cup.
9. 27 mm {1.06 in} ・ Install the front windshield glass to the sealing
10. 5 mm {0.20 in} material applied to the entire edge of the body
11. 22 mm {0.87 in} panel.
12. Dam seal ・ Insert the windshield support into the
installation hole of the body panel, and then
8. Apply the sealing adhesive to the front windshield
press the front windshield glass to the panel to
glass.
install it.
Note：
・ When using an air spray gun, air pressure
must be kept lower than the specified value.
Specified air pressure： 147 to 294 kPa { 1.5 to 3.0 kgf/
cm2 / 21 to 43 psi } The following applies.
Note：
・ After the primer completely dries, apply the
sealing material, Sunstar penguinseal #560 or
equivalent, along the edge of the front
windshield glass so that the sealing material
4. Engine hood rear seal installation
1. Install the engine hood rear seal to the cowl cover.
Note：
・ Install the engine hood rear seal to the hook of
the cowl cover.
2. Installation hole

Note：
・ Wipe off the protruded sealing material with
lead-free gasoline and a soft cloth.
・ Keep the bonding surface temperature at the
following temperature for 24 hours.
： 20 to 30 ℃ { 68 to 86 °F }
1. Engine hood rear seal
Note： 2. Hook
・ Confirm that there is no water leakage from
the front windshield glass. 5. Side cowl cover installation
2. Room mirror installation 1. Install the side cowl cover to the body.
1. Install the room mirror to the front windshield glass. 6. Wiper arm installation
Note： 1. Install the wiper arm to vehicle.

・ Install the screws. Caution：

ft }
8. Instrument panel installation
reinforcement to vehicle.
Note：
Bolt
1. 29 mm (1.14 in) Nut
2. 36.5 - 51.5 mm (1.44 - 2.03 in)
3. 18 mm (0.71 in)
Note：
・ Tighten the 4 bolts that secure the steering
torque.
Steering column bolt
Note：
11. Sun sensor installation
Note：
Note：
12. Assist side lid cover installation
1. Install the assist side lid cover to the instrument
panel.
13. Cover installation
Note： Note：
・ Connect the dash harness connector. ・ The following applies to models without
・ Connect the control cable of the blower unit passenger airbag.
and ventilation unit. 1. Install the cover to the instrument panel.
2. Install the side cover to the instrument panel. 14. Passenger air bag assembly installation
Note： 1. Install the passenger air bag assembly to the
・ Install the left and right side covers. instrument panel.
3. Install the speaker grille to the instrument panel. Note：
Note：・ Press the portion indicated by the arrow in the
panel.
Note：
10. Front cover installation

1. Passenger airbag mounting bolts 1. Instrument panel driver side lower cover
2. DLC
Caution：
Note：

3. Screw
1. Install the instrument panel driver-side lower cover panel driver-side lower cover.
Note：
Note：・ Install the 2 fixing screws.
1. Hood lock control lever Caution：

2. Control cable ・ Never apply an impact to the steering wheel
3. Screw with a hammer, etc. to install it.
17. Meter cluster installation ・ The steering shaft is designed to absorb
shocks.
Note：
Note：
1. Clip

Note：
1. Airbag connector
install the steering wheel.
2. Horn connector

wheel.
Note：
battery.
blinking 7 times.
22. Side cover installation
Note：
・ Install the left and right side covers. 1. Glove box
23. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to 25. Console box installation
the instrument panel. Note：
Note：・ Below except for the center console type.
・ Install the 4 screws. 1. Install the bracket to the floor.
Note：
26. Head lining installation
1. Install the head lining to vehicle.
Note：
1. Glove box
24. Glove box installation

1. Install the glove box to the instrument panel.
Note： Note：
exciter speaker.
27. Striker cover installation
Note：
Note：
・ Regular cab
1. Install the striker cover to the head lining.
Note：
1. Clip
Note：
・ Extend cab
1. Striker cover
2. Clip
28. Assist grip installation

1. Install the assist grip to the head lining.
Note：
Note：
1. Install the over head console to the head lining. 1. Clip
Note：
1. Install the sun visor holder to the head lining. ・ Crew cab
Note：
1. Clip 1. Clip
32. Rear lower trim cover installation Note：

1. Install the rear lower trim cover to the rear pillar. ・ Crew cab
Note：
・ Regular cab
1. Clip

1. Clip Note：
Note：・ The following applies to crew cab.
・ Extend cab 1. Install the rear tongue side seat belt to the rear pillar.
Note：
1. Anchor bolt cover 1. Clip

36. Tongue side seat belt installation
34. Center pillar upper trim cover installation
Note：
Note：・ The following applies to regular cab.
1. Install the center pillar upper trim cover to the center pillar.
pillar.
pillar.
Upper and lower anchor bolts
1. Clip

Note：
1. Adjuster cover
pillar.
37. Front tongue side seat belt installation 38. Dash side trim pad installation
Note： 1. Install the dash side trim pad to the body.
・ The following applies to crew cab model. Note：
1. Install the seat belt upper anchor bolt to the center ・ Install the nut.
pillar.
pillar.
3. Install the adjuster cover to the front tongue side seat
belt.

Note：
grip.
1. Adjuster cover
Note：
Note：
・ Regular cab
Note：
grip.
1. Sill plate
2. Clip
Note：
・ Extend cab

Note：
extend cab.
Note： 1. Sill plate
・ The following applies to crew cab. 2. Clip
Note：
・ Crew cab
1. Front sill plate

2. Rear sill plate
3. Clip
・ Windshield
1. Molding 4. Engine hood rear seal

2. Side cowl cover 5. Cowl cover
3. Front windshield glass
Note：
・ Rear window assembly
1. Fastener 4. Rear window

2. Dam seal
3. Rear defogger connector and rear defogger
TFCEL-WE-1211TH_70101_奥付 2011.8.8 9:33 AM ページ 1
Published: Aug., 2011 All rights reserved.

Second Edition
WORKSHOP MANUAL
AND ACCESSORIES
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
TFCEL-WE-1211TH_70101_奥付 2011.8.8 9:33 AM ページ 2
2012MY
WORKSHOP MANUAL

AND ACCESSORIES
No.TFCEL-WE-1211TH

Tfcel-We-1211th 2nd WSMW 120 TF Tis 12tf

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Tfcel-We-1211th 2nd WSMW 120 TF Tis 12tf

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2012MY

BODY, CAB, CHASSIS ELECTRICAL

Section Sub Section

Description Body, Cab, Accessories

Maintenance precautions of body, cab, accessories

Function, structure, operation of body, cab, accessories

License plate light system Wiper intermittent drive

1. Wiper arm RH 7. Washer motor

Note： ・ Model without MID

1. Generator warning light 8. Check 4WD warning light

* To return to the maintenance display, reset the distance

Service (Engine Oil Reminder Distance Setting)

→ The reminder screen is displayed only 3 times for

Note： 1. Backup light switch, M/T

Primary specifications of body, cab, accessories

2. Body size Note：

1： 916 mm { 36.06 in } 2： 490 mm { 19.29 in }

1： 1420 mm { 55.91 in } 2： 1500 mm { 59.06 in }

1： 1392 mm { 54.80 in } 2： 1416 mm { 55.75 in }

1： 1042 mm { 41.02 in } 2： 1705 mm { 67.13 in }

1： 1901 mm { 74.84 in } 9： 1882 mm { 74.09 in }

1： 2059 mm { 81.06 in } 9： 1882 mm { 74.09 in }

1： 1045 mm { 41.14 in } 2： 1020 mm { 40.16 in }

1： 1537 mm { 60.51 in } 2： 1587 mm { 62.48 in }

1： 1029 mm { 40.51 in } 8： 833 mm { 32.80 in }

Introduction to the trouble diagnosis of body, cab, accessories

Description Body, Cab, Accessories

Tachometer representational accuracy check

Speedometer representational accuracy check

inspection ・ If the tire pressure is improper, the display

Tester Meter indicator

Description Body, Cab, Accessories

Driving information is not displayed

Display Check the Parts

Pointer of the speedometer shakes

Indicated error of the speedometer is significantly large

Pointer of the tachometer shakes

Indicated error of the tachometer is significantly large

Segment display of the fuel gauge does not change

Wiper motor does not stop

Washer motor does not operate

Speedometer and odometer do not operate

Odometer does not count up (speedometer is normal)

Speedometer does not operate (odometer is normal)

Right rear window does not operate

Rear left side window does not operate

Wiper does not operate regardless of the switch position

Wiper does not operate at the "INT" position

Wiper does not operate at the "LO" position

Wiper does not operate at the "HI" position

None of the windows operate

Window at the driver side does not operate

Window at the front left side does not operate

Both of the rear windows do not operate

Operation abnormality of the dome light function

Operation abnormality of the taillight/stoplight function

Operation abnormality of the license plate light function

Operation abnormality of the illumination light function without instrument panel

Operation abnormality of the instrument panel cluster illumination function

Note： Check the effect of the post-mounted electrical

Operation abnormality of the backup light function

Operation abnormality of the headlight function

Operation abnormality of the clearance light function

Note：・ Model without MID