42-1

GROUP 42
BODY
DAFTAR ISI
FUEL FILLER LID ....................................................................................................................... 42-2
DOOR ........................................................................................................................................ 42-4
SERVICE PADA KENDARAAN .............................................................................................. 42-4
DOOR ASSEMBLY ................................................................................................................ 42-4
DOOR GLASS & REGULATOR ............................................................................................ 42-6
DOOR HANDLE AND LATCH ............................................................................................... 42-8
WINDOW GLASS RUNCHANNEL & DOOR OPENING WEATHERSTRIP ......................... 42-10
BODY MOUNTING ..................................................................................................................... 42-12
REAR BODY ROPE HOOK ...................................................................................................... 42-14
FUNGSI KUSTOMISASI ............................................................................................................. 42-16

Pebruari 2009 - CWPAS-CR 0209

42-2 BODY - FUEL FILLER LID

FUEL FILLER LID

PELEPASAN DAN PEMASANGAN

<SINGLE CAB>
4

Fuel filler lid height and clearance adjustment

3
2

5 1

AC509874 AB

Urutan pelepasan Fuel filler lid Urutan pelepasan Fuel filler lid lock release
cable
1. Fuel filler lid assembly
· Rear splash shield
2. Fuel filler lid locking clip
Pelepasan Fuel filler lid lock release handle 4. Fuel filler lid hook
· Front scuff plate, rear pillar trim (Refer to
3. Fuel filler lid lock release handle
GROUP 52A, Interior Trim.)
· A/C cooling unit (Refer to GROUP 55A, Heater
Unit and Cooling Unit.)
5. Fuel filler lid lock release cable

CWPAS-CR 0209- Pebruari 2009

 BODY - FUEL FILLER LID 42-3

<DOUBLE CAB>

Fuel filler lid height and clearance adjustment

4 2
3

1
3

6 AC509876 AB

Urutan pelepasan Fuel filler lid Urutan pelepasan Fuel filler lid lock release
cable
1. Fuel filler lid assembly
· Rear splash shield
2. Fuel filler lid locking clip
3. Damper 5. Fuel filler lid hook

Pelepasan Fuel filler lid lock release handle · Front scuff plate, Rear scuff plate, Centre pillar
lower trim, Rear pillar lower trim (Refer to
4. Fuel filler lid lock release handle GROUP 52A, Interior Trim.)
· A/C cooling unit (Refer to GROUP 55A, Heater
Unit and Cooling Unit.)
6. Fuel filler lid lock release cable

Pebruari 2009 - CWPAS-CR 0209

42-4 BODY - DOOR

DOOR
SERVICE PADA KENDARAAN
SHIFT "P" INTERLINK DOOR UNLOCK FUNCTION
CHECK
When the selector is moved to the P (parking) position with the igni-
tion switch on, all the doors will be unlocked.
Carry out troubleshooting if the doors are not unlocked. Refer to .
note
The adjustment function allows you to change the selector "P" posi-
tion-linked door unlocking’s setting from "Inhibit (initial setting)" or
"Operation". Prior to the check, confirm which setting is activated.

DOOR ASSEMBLY
PELEPASAN DAN PEMASANGAN

<SINGLE CAB>

5, 6

8
7
27 ± 5 N·m
11 ± 2 N·m 1 5

22 ± 4 N·m

9 25 ± 7 N·m
1.5 ± 0.5 N·m
4
27 ± 5 N·m
24 ± 4 N·m 3

2 6 25 ± 7 N·m

22 ± 4 N·m
AC509563 AB

CWPAS-CR 0209- Pebruari 2009

 BODY - DOOR 42-5

Pelepasan Damper
1. Damper
Urutan pelepasan Door assembly
· Front Scuff Plate and Cowl Side Trim
(Mengacu keGROUP 52A, Interior Trim.)
2. Wiring harness connector connection
3. Door check connecting bolt
4. Door assembly
5. Door upper hinge
6. Door lower hinge
>>A<< 7. Striker
8. Striker shim
Pelepasan Door switch
9. Door switch

SERVICE POINT PEMASANGAN

>>A<< PEMASANGAN STRIKER
Latch centre Luruskan centre pada striker dan latch dalam ±1.5 mm, dan pasang.
Striker centre

+1.5 mm

-1.5 mm

Striker
Latch
AC006126 AB

Pebruari 2009 - CWPAS-CR 0209

42-6 BODY - DOOR

DOOR GLASS & REGULATOR

PELEPASAN DAN PEMASANGAN

<SINGLE CAB>
Pekerjaan setelah pemasangan
• Penyetelan Door Window Glass.

5.0 ± 1.0 N·m

<Vehicles without <Vehicles with

power window> power window>
4
2
3 7 AC509763 AD

6
1

AC509768 AB

CWPAS-CR 0209- Pebruari 2009

 BODY - DOOR 42-7

Pelepasan Power window Urutan pelepasan Door

switch <Kendaraan dengan window glass assembly
power window>
· Beltline moulding, beltline
1. Power window main switch weatherstrip inner
(driver’s side), power window
· Waterproof film
sub switch (passenger’s side)
(Mengacu ke GROUP 52A, Door 5. Door window glass assembly
Trim.) Urutan pelepasan Door
Urutan pelepasan Regulator window regulator
handle < Kendaraan tanpa · Rear lower sash
power window>
<<B>> 6. Door window regulator assembly
<<A>> >>A<< 2. Clip
7. Power window motor
>>A<< 3. Regulator handle <Kendaraan dengan power
>>A<< 4. Escutcheon window>

SERVICE POINT PELEPASAN

<<A>> PELEPASAN CLIP
Gunakan kain untuk melepaskan clip seperti ditunjukkan pada
gambar.

AC100005
<<B>> PELEPASAN DOOR WINDOW REGULATOR ASSY
1. Lepaskan bolt pemasangan door window glass assy.
2. Angkat door window glass, dan pasang special tool window glass
holder (MB990480) pada glass seperti ditunjukkan pada gambar
MB990480
untuk mencegah glass terjatuh.
3. Lepaskan door window regulator assy.

AC100009AC

SERVICE POINT PEMASANGAN

>>A<< PEMASANGAN RESCUTCHEON/REGULATOR HANDLE/
CLIP
1. Pasang escutcheon dan regulator handle ke clip.
Horizontal line
2. Tutup door window glass sepenuhnya, dan kemudian pasang
regulator handle seperti ditunjukkan pada gambar.
30˚

Front of vehicle

AC100007AB

Pebruari 2009 - CWPAS-CR 0209

42-8 BODY - DOOR

DOOR HANDLE AND LATCH

PELEPASAN DAN PEMASANGAN

<SINGLE CAB>
Pekerjaan sebelum pelepasan Pekerjaan setelah pemasangan
• Pelepasan Door Trim Assembly (Mengacu ke • Pemeriksaan play pada Door Inside Handle Play.
GROUP 52A, Door Trim). • Pemeriksaan play pada Door Outside Handle.
• Pemasangan Door Trim Assembly (Mengacu ke
GROUP 52A, Door Trim).

5.0 ± 1.0 N·m

3
4 5

2 14 6

5.0 ± 1.0 N·m

12
7
10
13
5.0 ± 1.0 N·m

N 8 15

11
2

24 ± 4 N·m
5.0 ± 1.0 N·m
AC509774 AC

AC509773 AB

CWPAS-CR 0209- Pebruari 2009

 BODY - DOOR 42-9

Pelepasan Door inside handle Urutan pelepasan Door latch

assembly
>>B<< 1. Door inside handle
Urutan pelepasan Door lock key · Waterproof film and rear lower sash
cylinder and door outside handle 8. Screw
· Waterproof film and rear lower sash 9. Door latch assembly
2. Plug 10. Door inside lock cable
3. Door outside handle cover 11. Door inside handle cable
4. Door lock key cylinder 12. Door outside handle rod
5. Door outside handle 13. Door outside lock rod
6. Door outside handle gasket 14. Door panel bracket
7. Door outside handle base Urutan pelepasan Door check
· Waterproof film
>>A<< 15. Door check

SERVICE POINT PEMASANGAN

>>A<< PEMASANGAN DOOR CHECK
AC302892 Pasang door check dengan tanda identifikasi menghadap ke atas.

Lokasi Application Tanda identifikasi

Left side 57L
Right side 57R

Identification mark
AC504339 AB

>>B<< PEMASANGAN DOOR INSIDE HANDLE

Ketika menghubungkan inside cable ke door inside handle, pastikan
door latch dan inside handle terbebas (tidak terkunci).

Pebruari 2009 - CWPAS-CR 0209

42-10 BODY - DOOR

WINDOW GLASS RUNCHANNEL & DOOR OPENING WEATHERSTRIP

PELEPASAN DAN PEMASANGAN

<SINGLE CAB>

1
1 N·m MAX

3
2
Sealant: 3M ATD Part No. 8633 or equivalent

7 1
6 4

5
:Sectional view :Sectional view
of clip positions of clip positions
9.0 ± 2.0 N·m

AC502962 AC502964

AC509779 AB

CWPAS-CR 0209- Pebruari 2009

 BODY - DOOR 42-11

Urutan pelepasan Door Urutan pelepasan Rear lower

window glass runchannel sash
· Pull handle bracket (Mengacu ke · Pull handle bracket (Mengacu ke
GROUP 52A, Door Trim.) GROUP 52A, Door Trim.)
>>B<< 1. Waterproof film >>B<< 1. Waterproof film
2. Door beltline weatherstrip inner >>A<< 5. Rear lower sash
3. Door beltline moulding Urutan pelepasan Door
opening weatherstrip inner
4. Door window glass runchannel
Urutan pelepasan Door · Cowl side trim, front scuff plate
beltline weatherstrip inner and rear pillar trim (Mengacu ke
GROUP 52A, Interior Trim.)
· Door trim assembly (Mengacu
ke GROUP 52A, Door Trim.) 6. Door opening weatherstrip inner

2. Door beltline weatherstrip inner Pelepasan Door opening

weatherstrip outer
Urutan pelepasan Door
beltline moulding <<A>> 7. Door opening weatherstrip outer

· Door trim assembly (Mengacu

ke GROUP 52A, Door Trim.)
3. Door beltline moulding

SERVICE POINT PELEPASAN

<<A>> PELEPASAN DOOR OPENING WEATHERSTRIP OUTER
15 mm Fabricated Buatlah fabricated tool seperti ditunjukkan pada gambar untuk
tool melepaskan door opening weatherstrip outer.
4 mm

8 mm

Thickness:
1 mm

ACX00555 AC

SERVICE POINT PEMASANGAN

>>A<< PEMASANGAN REAR LOWER SASH
Pasang rear lower sash dengan window sash (door) dengan baik.

>>B<< PEMASANGAN WATERPROOF FILM

Waterproof film PERHATIAN
Ketika menempelkan waterproof film, pastikan sealant
diberikan dibawah inner panel water drain hole.
Berikan sealant sesuai spesifikasi ke waterproof film seperti
ditunjukkan dan tempelkan film.
Spesifiaksi sealant: 3M ATD Part No.8633 atau setara

Inner panel water drain hole AC509863 AB

Pebruari 2009 - CWPAS-CR 0209

42-12 BODY - BODY MOUNTING

BODY MOUNTING
<Single cab>
AC501255
AC501256
AC407105
PELEPASAN DAN PEMASANGAN
I
H
<SINGLE CAB> G
I
E F
D G H
C
F
D E
C
B

A
B

A B C D E
11 11
6 6 6

7 7 7 10 10
5 5 5
8N 8N

4 4 4
45 ± 5 N·m 45 ± 5 N·m

3 3 3
2 2 2
1N 1N 1N

47 ± 7 N·m 47 ± 7 N·m 47 ± 7 N·m

F G 10 H I
10
11 11
9
9 10 10
8N 8N

45 ± 5 N·m 45 ± 5 N·m

AC505025 AD
Urutan pelepasan Cab body
mounting
1. Cab body mounting nut Urutan pelepasan Rear body
mounting
2. Cab body mounting washer
8. Rear body mounting nut
3. Cab body mounting cushion
9. Rear body mounting screw or bolt
4. Cab body mounting spacer
10. Rear body mounting shim
5. Cab body mounting cushion
11. Rear body mounting bolt
6. Cab body mounting bolt
<<B>> · Rear body
7. Cab body mounting washer
<<A>> · Cab body

CWPAS-CR 0209- Pebruari 2009

BODY - BODY MOUNTING 42-13

SERVICE POINT PELEPASAN

<<A>> PELEPASAN CAB BODY
1. Lepaskan part-part berikut .
• Hood
• Radiator grille
• Headlamp
• Front bumper assembly
• Oil cooler hose <kendaraan dengan oil cooler>
• Radiator assembly
• Air cleaner duct
• Steering shaft joint
• Heater hose
• Power steering reservoir tank
• Brake booster vacuum hose
• Accelerator cable
• Fuel hose
• Brake pipe
• A/C piping
• Clutch release cylinder <M/T>
• Speedometer cable
• Parking brake cable
• Shift lever knob <M/T>
• Select lever knob <A/T>
• Idle up vacuum hose
• Engine harness
• A/C harness
• Frame harness
• Earth strap
• Engine earth
• Door opening weatherstrip inner
• Floor carpet
• Cab body mounting bolt
2. Setelah melepaskan bolt pengencangan cab body dan cab body
washer, masukkan balok kayu ke cab body dan dengan perlahan
angkat body dengan crane.
PERHATIAN
Sebelum mengangkat, periksa kembali semua sambungan
diantara cab body, frame dan engine sudah terpisah.
Hubungkan kawat sling ke bar atau frame, fitting protection
covers seperlunya.

<<B>> PELEPASAN REAR BODY

1. Lepaskan part berikut.
• Fuel filler neck
• Rear body harness
• Bolt pengencangan rear body dan screw
2. Kaitkan kabel pada rope hocks di rear body, dan kemudian
gunakan crane untuk mengangkat rear body.
PERHATIAN
Pastikan rear body tidak mengenai cab body ketika sedang
diangkat.

Pebruari 2009 - CWPAS-CR 0209

42-14 BODY - REAR BODY ROPE HOOK

REAR BODY ROPE HOOK

PELEPASAN DAN PEMASANGAN

<SINGLE CAB>
<Single cab>
8

4 5
10
6
1 9
2 63 ± 7 N·m 6
7

63 ± 7 N·m

3 AC600045 AB

Urutan pelepasan Rear body rope

hook
1. Rear body plug
2. Rear body rope hook
>>A<< 3. Rear body grommet A
>>A<< 4. Rear body grommet B
Urutan pelepasan Rear gate rope
hook
· Rear gate cover
5. Rear gate rope hook
>>B<< 6. Rear body grommet C
>>B<< 7. Rear body grommet D
Pelepasan Rear body guard frame
stopper
8. Rear body guard frame stopper
Urutan pelepasan Rear traction hook
9. Rear traction hook
10. Rear traction hook plate

CWPAS-CR 0209- Pebruari 2009

 BODY - BODY MOUNTING 42-15

SERVICE POINT PEMASANGAN

>>A<< PEMASANGAN REAR BODY GROMMET A DAN B
Nilai ukuran (a): 40 mm <Rear body grommet A>, 33mm <Rear
body grommet B>.
PERHATIAN
Pasang grommet pada lokasi yang benar agar jangan sampai
rusak.
a

Rear body grommet A,B AC509880 AB

>>B<< PEMASANGAN REAR BODY GROMMET C DAN D

Pasang grommet sehingga tanda-tanda pasangan menghadap
Mark keatas.
Ukuran nilai (a): 46,5 mm <Rear body grommet C>, 38,5mm
<Rear body grommet D>
PERHATIAN
a Pasang grommet pada lokasi yang benar agar jangan sampai
rusak.

Rear body grommet C, D AC509879 AB

Pebruari 2009 - CWPAS-CR 0209

42-16 BODY - FUNGSI KUSTOMISASI

FUNGSI KUSTOMISASI
The following functions can be customised using ETACS system of M.U.T.-III.

Fungsi Nama item Konfigurasi

Waktu berkedipnya Hazard lamp pada keyless entry Hazard answer back • Lock 1 Unlock 2 (Initial
hazard lamp answerback function <kendaraan dengan setting)
keyless entry system> • Lock 1 Unlock 0
• Lock 0 Unlock 2
• Lock 2 Unlock 1
• Lock 0 Unlock 1
• Lock 2 Unlock 0
• Lock 0 Unlock 0
Fungsi pengaturan Door unlock (posisi Shift "P") Door unlock (Posisi • Inhibit (Initial setting)
<kendaraan dengan keyless entry system> Shift "P") • Operation
Waktu pengaturan Timer lock Auto-relock time • 30 detik (Initial setting)
Waktu timer lock setelah penggunaan keyless entry • 60 detik
unlock <kendaraan dengan keyless entry system> • 120 detik
• 180 detik

CWPAS-CR 0209- Pebruari 2009