Body, Lock & Security System: Section

BODY
BL
A
B
SECTION
BODY, LOCK & SECURITY SYSTEM C
E
CONTENTS
SERVICE INFORMATION ............................ 2 Wiring Diagram - D/LOCK - .....................................18 F
Combination Meter Harness Connector Terminal
PRECAUTIONS ................................................... 2 Layout ......................................................................20
Precaution for Supplemental Restraint System Terminal and Reference Value for Combination G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Meter .......................................................................20
SIONER" ................................................................... 2 Work Flow ................................................................21
Service Notice ........................................................... 2 Trouble Diagnosis Symptom Chart ..........................21
H
Combination Meter Power Supply and Ground
PREPARATION ................................................... 3 Circuit Inspection .....................................................22
Special Service Tool ................................................. 3 Door Lock and Unlock Switch Check ......................23
Commercial Service Tool .......................................... 3 Lock Knob Switch Check .........................................24 BL
SQUEAK AND RATTLE TROUBLE DIAGNO- Door Lock Relay Check ...........................................25
Front Door Lock Actuator (Passenger Side) Check
SIS ....................................................................... 4
....28 J
Squeak and Rattle Trouble Diagnosis ....................... 4
Rear Door Lock Actuator LH/RH Check (Double
Generic Squeak and Rattle Troubleshooting ............ 6
Cab) .........................................................................28
Diagnostic Work Sheet .............................................. 8
DOOR ................................................................ 29 K
HOOD .................................................................10
Front Door ...............................................................29
Fitting Adjustment ................................................... 10
Rear Door ................................................................30
Removal and Installation of Hood Assembly ........... 11
L
Removal and Installation of Hood Lock Control ...... 13 FRONT DOOR LOCK ....................................... 31
Hood Lock Control Inspection ................................. 14 Exploded View .........................................................31
FRONT FENDER ................................................15 REAR DOOR LOCK .......................................... 32 M
Exploded View ........................................................ 15 Exploded View .........................................................32
Removal and Installation ......................................... 15
TAIL GATE ........................................................ 33 N
POWER DOOR LOCK SYSTEM ........................16 Removal and Installation .........................................33
Component Parts and Harness Connector Loca-
tion .......................................................................... 16 BODY (ALIGNMENT) ........................................ 34
System Description ................................................. 16 Alignment .................................................................34 O
Revision: March 2008 BL-1 2009 D22 LCV

PRECAUTIONS
< SERVICE INFORMATION >
SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000003492153
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
The vehicle may be equipped with a passenger air bag deactivation switch. Because no rear seat exists where
a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a
rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the
instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is
enabled and could inflate for certain types of collision. When the switch is turned to the OFF position, the pas-
senger air bag is disabled and will not inflate. A passenger air bag OFF indicator on the instrument panel lights
up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected
by the passenger air bag deactivation switch.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SRS section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
Service Notice INFOID:0000000003492154
• When removing or installing various parts, place a cloth or padding on the vehicle body to prevent scratches.
• Handle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to soil or
damage them.
• Apply sealing compound where necessary when installing parts.
• When applying sealing compound, be careful that the sealing compound does not protrude from parts.
• When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust preven-
tion measures.

PREPARATION
PREPARATION
A
Special Service Tool INFOID:0000000003492155
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. B
Tool number
(Kent-Moore No.) Description
Tool name
C
— Locating the noise
(J-39570)
Chassis Ear
D
E
ABT465
— Locating the noise

(J-43980)
Nissan Squeak and Rattle Kit F
ABT474
Commercial Service Tool INFOID:0000000003492156

H
Tool name BL
Description
(Kent-Moore No.)
Engine Ear Locating the noise
(J-39565)
J
ABT466

SQUEAK AND RATTLE TROUBLE DIAGNOSIS
Squeak and Rattle Trouble Diagnosis INFOID:0000000003492157
WORK FLOW
ABT488
Customer Interview
Interview the customer, if possible, to determine the conditions that exist when the noise occurs. Use the Diag-
nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any
customers comments; refer to BL-8, "Diagnostic Work Sheet". This information is necessary to duplicate the
conditions that exist when the noise occurs
• The customer may not be able to provide a detail description or location of the noise. Attempt to obtain all
the facts and conditions that exist when the noise occurs (or does not occur).
• If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the costumer is
concerned about. This can be accomplished by test driving the vehicle with the costumer.
• After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics
are provided so the customer, service adviser and technician are all speaking the same language when
defining the noise.
- Squeak-(Like tennis shoes on a clean floor)
• Squeak characteristics include the light contact / fast movement / brought on by road conditions / hard sur-
faces = higher pitch noise / softer surfaces = lower pitch noises / edge to surface = chirping.
- Creak-(Like walking on an old wooden floor)
• Creak characteristics include firm contact / slow movement / twisting with a rotational movement / pitch
dependent on materials / often brought on by activity.
- Rattle-(Like shaking a baby rattle)
• Rattle characteristics include the fast repeated contact / vibration or similar movement / loose parts / missing
clip or fastener / incorrect clearance.
- Knock-(Like a knock on a door)
• Knock characteristics include hollow sound / something repeating / often brought on by driver action.
- Tick-(Like a clock second hand)
• Tick characteristics include light contact of light material / loose components / can be caused by driver action
on road conditions.
- Thump-(Heavy, muffled knock noise)
• Thump characteristics include softer knock / dead sound often brought on by activity.
- Buzz-(Like a bumble bee)
• Buzz characteristics include high frequency rattle / firm contact
• Often the degree of acceptable noise level will vary depending upon the person. A noise that you may judge
as acceptable may be very irritating to the customer.
• Weather conditions, especially humidity and temperature, may have a great effect on noise level.
Duplicate the Noise and Test Drive

If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or locations of the noise. This information can be used to A
duplicate the same conditions when you confirm the repair.
If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-
cate the noise with the vehicle stopped by doing one or all of the following:
B
1. Close a door.
2. Tap or push / pull around the area where the noise appears to be coming from.
3. Rev the engine.
4. Use a floor jack to recreate vehicle “twist”. C
5. At idle, apply engine load (electric load, half-clutch on M/T model, drive position on A/T model).
6. Raise the vehicle on a hoist and hit a tire with rubber hammer.
• Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs. D
• If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
vehicle body.
Check Related Service Bulletins E
After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related
to that concern or symptom.
If a TSB relates to the symptom, follow the procedure to repair the noise.
F
Locate the Noise and Identify the Root Cause
1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool
(Chassis Ear: J-39570, Engine Ear: J-39565 and mechanics stethoscope). G
2. Narrow down the noise to a more specific area and identify the cause of the noise by:
• Removing the components in the area that you suspect the noise is coming from.
- Do not use too much force when removing clips and fasteners, otherwise clips and fasteners can be broken H
or lost during the repair, resulting in the creation of new noise.
• Tapping or pushing/pulling the component that you suspect is causing the noise.
- Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only tem-
porarily. BL
• Feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the
noise.
• Placing a piece of paper between components that you suspect are causing the noise. J
• Looking for loose components and contact marks.
Refer to BL-6, "Generic Squeak and Rattle Troubleshooting".
Repair the Cause K
• If the cause is a loose component, tighten the component securely.
• If the cause is insufficient clearance between components:
- Separate components by repositioning or loosening and retightening the component, if possible.
L
- Insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or ure-
thane tape. A Nissan Squeak and Rattle Kit (J-43980) is available through your authorized Nissan Parts
Department.
CAUTION: M
Do not use excessive force as many components are constructed of plastic and may be damaged.
Always check with the Parts Department for the latest parts information.
• The following materials are contained in the Nissan Squeak and Rattle Kit (J-43980) Each item can be
N
ordered separately as needed.
• URETHANE PADS (1.5 mm thick)
- insulates connectors, harness, etc.
• 76268–9E005: 100 x 135 mm / 76884–71L01: 60 x 85 mm / 76884–71L02: 15 x 25 mm O
• INSULATOR (foam blocks)
- Insulates components from contact. Can be used to fill space behind a panel.
• 73982–9E000: 45 mm thick, 50 x 50 mm / 73982–50Y00: 10 mm thick, 50 x 50 mm P
• INSULATOR (Light foam block)
- 80845–71L00: 30 mm thick, 30 x 50 mm
• FELT CLOTH TAPE
- Used to insulate where movement does not occur. Ideal for instrument panel applications.
• 68370–4B000: 15 x 25 mm pad / 68239–13E00: 5 mm wide tape roll
• The following materials, not found in the kit, can also be used to repair squeaks and rattles.
• UHMW (TEFLON) TAPE
- Insulates where slight movement is present. Ideal for instrument panel applications.

• SILICONE GREASE
- Used in place of UHMW tape that will be visible or not fit.
- Note: Will only last a few months.
• SILICONE SPRAY
- Use when grease cannot be applied.
• DUCT TAPE
- Use to eliminate movement.
Confirm the Repair
Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same
conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.
Generic Squeak and Rattle Troubleshooting INFOID:0000000004064950
Refer to Table of Contents for specific component removal and installation information.
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1. The cluster lid A and instrument panel
2. Acrylic lens and combination meter housing
3. Instrument panel to front pillar garnish
4. Instrument panel to windshield
5. Instrument panel mounting pins
6. Wiring harnesses behind the combination meter
7. A/C defroster duct and duct joint
These incidents can usually be located by tapping or moving the components to duplicate the noise or by
pressing on the components while driving to stop the noise. Most of these incidents can be repaired by apply-
ing felt cloth tape or silicone spray (in hard to reach areas). Urethane pads can be used to insulate wiring har-
ness.
CAUTION:
Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you will
not be able to recheck the repair.
CENTER CONSOLE
Components to pay attention to include:
1. Shifter assembly cover to finisher
2. A/C control unit and cluster lid C
3. Wiring harnesses behind audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console.
DOORS
Pay attention to the:
1. Finisher and inner panel making a slapping noise
2. Inside handle escutcheon to door finisher
3. Wiring harnesses tapping
4. Door striker out of alignment causing a popping noise on starts and stops
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks from
the NISSAN Squeak and Rattle Kit (J-43980) to repair the noise.
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid bumpers out of adjustment
2. Trunk lid striker out of adjustment
3. The trunk lid torsion bars knocking together
4. A loose license plate or bracket

Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise. A
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise B
2. Sun visor shaft shaking in the holder
3. Front or rear windshield touching headliner and squeaking
C
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
OVERHEAD CONSOLE (FRONT AND REAR) D
Overhead console noises are often caused by the console panel clips not being engaged correctly. Most of
these incidents are repaired by pushing up on the console at the clip locations until the clips engage.
In addition look for: E
1. Loose harness or harness connectors.
2. Front console map/reading lamp lense loose.
3. Loose screws at console attachment points. F
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the G
noise.
Cause of seat noise include:
1. Headrest rods and holder H
2. A squeak between the seat pad cushion and frame
3. The rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con- BL
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD J
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include: K
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors L
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
M
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
N
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.

Diagnostic Work Sheet INFOID:0000000004064500
LAIA0072E

BL
O
LAIA0071E

HOOD
HOOD
Fitting Adjustment INFOID:0000000003857753
ALKIA1447ZZ
1. Hood assembly 2. Front fender 3. Hood bolts 13 N·m (1.3 kg-m, 10 lb-ft)
4. Hood lock bolts 23 N·m (2.3 kg-m, 17 lb-ft) 5. Front grille 6. Hood lock assemmbly
D. 9.3 mm (0.3 in) E. 4.5 (0.18 in) F. 0.0 mm (0.0 in)
G. 8.7 mm (0.3 in)
CLEARANCE AND SURFACE HEIGHT ADJUSTMENT

1. Remove the front grille. Refer to EI-15, "Removal and Installation".
2. Loosen the hood lock assembly and adjust the rubber bumpers until the surface height of the hood
becomes 1 mm (0.04 in) lower than the fender.
3. Engage the hood striker and temporarily tighten.
4. Check the hood lock assembly and striker for looseness.
5. Tighten the bolts to specification.

HOOD
6. Adjust the surface height of the hood according to the fitting standard dimension by rotating right and left
rubber bumpers. A
7. Install the front grille. Refer to EI-15, "Removal and Installation".
HOOD LOCK ADJUSTMENT
B
2. Move the hood lock to the left or right so that striker center is vertically aligned with hood lock center
(when viewed from vehicle front).
C
3. Make sure the secondary latch is properly engaged with the sec-
ondary striker with hood's own weight by dropping it from
approx. 200 mm (7.87 in) height or by pressing it lightly approx.
3 kg (29 N, 7lb). D
CAUTION:
Do not drop the hood from 300 mm (11.81 in) height or
higher. E
F
LIIA1696E
4. After adjusting hood lock, tighten the lock bolts.

G
BL
ALKIA1448ZZ
J
Removal and Installation of Hood Assembly INFOID:0000000003857754
K
REMOVAL
L

HOOD
ALKIA1445ZZ
1 Hood assembly (KA24DE) 2. Radiator core seal assembly 3. Hood assembly

4. Hood bumper 5. Hood support rod 6. Hood hinge assembly
7. Air intake guide assembly, lower 8. Hood assembly (YD25DDTI) 9. Air intake guide assembly, upper
(YD25DDTI) (YD25DDTI)
1. Support the hood striker with suitable tool to prevent it from falling.
2. Remove the hinge nuts from the hood to remove the hood assembly.
CAUTION:
Operate with two workers, because of its heavy weight.
INSTALLATION
Installation is in the reverse order of removal.

HOOD
Removal and Installation of Hood Lock Control INFOID:0000000003857755
ALKIA1446ZZ
BL
1. Hood lock release handle 2. Hood lock cable 3. Hood lock assembly
A. 23 N·m (2.3 kg-m, 17 lb-ft)
J
REMOVAL
2. Remove the front fender protector (LH). Refer to EI-17, "Removal and Installation of Front Fender Protec- K
tor".
3. Disconnect the hood lock cable from the hood lock, and unclip it from the radiator core support upper and
hoodledge. L
4. Remove the bolts, and the hood release handle.
5. Separate the grommet from the lower dash panel. Pull the hood lock cable out through the passenger
compartment. M
CAUTION:
While pulling, be careful not to damage the outside of the hood lock cable.
N
INSTALLATION
1. Pull the hood lock cable through the lower dash panel hole into the engine room.
CAUTION:

HOOD
Be careful not to bend the cable too much, keep the radius
100mm (3.94 in) or more.
2. Make sure the cable is not offset from the grommet, and push
the grommet into the lower dash panel hole securely.
3. Apply sealant around the grommet at * mark.
LIIA1698E
4. Install the cable securely to the lock and attach the clips to the
hoodledge and the radiator core support.
5. Adjust the hood lock. Refer to BL-13, "Removal and Installation
of Hood Lock Control".
LIIA1699E
6. Install the front fender protector LH. Refer to EI-17, "Removal and Installation of Front Fender Protector".
Hood Lock Control Inspection INFOID:0000000003857756
CAUTION:
If the hood lock cable is bent or deformed, replace it.
2. Make sure the secondary latch is properly engaged with the sec-
ondary striker with hood's own weight by dropping it from
approx. 200 mm (7.87 in) height.
3. While operating the hood opener, carefully make sure the front
end of the hood is raised by approx. 20 mm (0.79 in). Also make
sure the hood opener returns to the original position.
PIIA1086E
4. Check the hood lock lubrication condition. If necessary, apply

“body grease” to the points shown.
PIIA0176E

FRONT FENDER
FRONT FENDER
A
Exploded View INFOID:0000000003885969
BL
ALKIA1464ZZ
1. Front fender baffle assembly RH,LH 2. Front fender RH,LH 3. Front fender bracket assembly RH,LH J
4. Front fender bracket assembly RH,LH
Removal and Installation INFOID:0000000003885681

K
REMOVAL
1. Remove the headlamp assembly. Refer to LT-11, "Removal and Installation". L
2. Remove the front fender protector. Refer to EI-17, "Removal and Installation of Front Fender Protector".
3. Remove the front bumper. Refer to EI-13, "Removal and Installation".
4. Remove the bolts and the front fender. M
INSTALLATION
Installation is in the reverse order of removal.
N

POWER DOOR LOCK SYSTEM
Component Parts and Harness Connector Location INFOID:0000000003492158
ALKIA1486ZZ
1. Combination meter M206, M207 2. Power window main switch (door lock 3. Lock knob
and unlock switch) D6 (Double Cab)
(Double Cab)
4. Power window main switch (door lock 5. Lock knob 6. Lock knob switch D9
and unlock switch) D6 (Single Cab) (view with front door panel LH removed)
(Single Cab)
7. Front door lock actuator (passenger side) 8. Rear door lock actuator (Double Cab) 9. Door lock relay M52
D108 LH D207 (view with cluster lid C removed)
(view with front door panel RH removed) RH D307
(view with rear door panel LH removed,
RH similar)
System Description INFOID:0000000003492159
Power is supplied at all times

• through 40A fusible link letter c (located in the fusible link and fuse box)
• to circuit breaker–1 terminal 5 (located in the fuse block) A
• through circuit breaker–1 terminal 7
• to door lock relay terminal 3 and
• through 10A fuse (No. 6, located in the fuse block)
B
• to combination meter terminal 24.
Ground is supplied
• to combination meter terminals 25 and 75 and
• to door lock relay terminal 2 C
• through body grounds M57 and M61.
INPUT
With the door lock and unlock switch pressed to LOCK, ground is supplied D
• to combination meter terminal 10
• through door lock and unlock switch terminal 18
• through door lock and unlock switch terminal 19 E
With the door lock and unlock switch pressed to UNLOCK, ground is supplied
• through door lock and unlock switch terminal 17 F
• through door lock and unlock switch terminal 19
When the driver door lock knob switch is moved to UNLOCK, ground is supplied G
• through lock knob switch terminal 2
• through lock knob switch terminal 1
H
When the driver door lock knob switch is moved to LOCK, ground supply is removed.
OUTPUT BL
Unlock
Ground is supplied
• to front door lock actuator (passenger side) terminal 1 and J
• to rear door lock actuator LH and RH (Double Cab) terminal 1
• through door lock relay terminal 1.
FRONT DOOR (PASSENGER SIDE)
Power is supplied K
• to front door lock actuator (passenger side) terminal 2
REAR DOOR LH AND RH (DOUBLE CAB) L
Power is supplied
• to rear door lock actuator LH and RH terminal 2
M
With power and ground applied as described, passenger, LR and RR (Double Cab) doors are unlocked.
Lock
Ground is supplied N
• to front door lock actuator (passenger side) terminal 2 and
• to rear door lock actuator LH and RH (Double Cab) terminal 2
Power is supplied O
• to front door lock actuator (passenger side) terminal 1 and rear door lock actuator LH and RH (Double Cab)
terminal 1
• through door lock relay terminal 1. P
With power and ground applied as described, passenger, LR and RR (Double Cab) doors are locked.
OPERATION
• The door lock and unlock switch can lock and unlock passenger, LR and RR (Double Cab) doors. Unlike all
the other doors, the driver door does not contain a door lock actuator and is controlled mechanically instead.
• With the key inserted in the front door key cylinder LH, turning it to LOCK locks the driver door mechanically
and all the other doors electrically; turning it to UNLOCK unlocks the driver door mechanically and all the
other doors electrically.

Key Reminder
When performing a door locking operation using the door lock and unlock switch, passenger, LR and RR
(Double Cab) doors will lock.
• With the driver door closed, turning the driver door lock knob to LOCK locks all doors, the driver door
mechanically and all other doors electrically; turning the driver door lock knob to UNLOCK unlocks all doors,
the driver door mechanically and all the other doors electrically.
• With the driver door open, the driver door cannot be locked using the door lock knob or the key cylinder LH.
Wiring Diagram - D/LOCK - INFOID:0000000003492161
AAKWA0008GB

BL
AAKWA0009GB

Combination Meter Harness Connector Terminal Layout INFOID:0000000003977519
AWNIA1515ZZ
Terminal and Reference Value for Combination Meter INFOID:0000000003977520
Terminal No.
Measuring condition
(Wire color) Reference value (V)
Item
Ignition (Approx.)
(+) (-) Operation or condition
switch
2*1 Water in fuel filter warning Water in fuel warning lamp ON 0

Ground ON
(O) lamp signal Water in fuel warning lamp OFF Battery voltage
3*2 Malfunction indicator lamp Malfunction indicator lamp ON 0

Ground ON
(R) signal Malfunction indicator lamp OFF Battery voltage
21 Engine running Battery voltage

Ground Oil pressure switch signal ON
(V) Engine stopped 0
22 Charge warning lamp ON 0

Ground Alternator signal ON
(Y) Charge warning lamp OFF Battery voltage
23
Ground Ignition signal ON — Battery voltage
(GR)
24
Ground Battery power supply OFF — Battery voltage
(SB)
25
Ground Ground ON — 0
(B)
Speedometer operated [When

vehicle speed is approx. 20 km/
27 26 Vehicle speed sensor input h (12.5 MPH)] [When vehicle
ON
(R) (W) signal speed is approx. 40 km/h (25
MPH)] [When vehicle speed is
approx. 60 km/h (37.5 MPH)]
PKIA0501E
28*2 Ground Engine speed signal ON Engine running (idling)

(P)
SKIA7283J
29*1 — Oil level sensor signal — —

Refer to DI-34, "Electrical Component
(SB) Inspection".
30*1 Ground Oil level sensor signal ground ON — 0

(BR)
31 Fuel level sensor signal
Ground ON — 0
(B) ground

Terminal No.
Measuring condition
(Wire color) Reference value (V) A
Item
Ignition (Approx.)
(+) (-) Operation or condition
switch
32 Refer to DI-34, "Electrical Component B
Ground Fuel level sensor signal — —
(P) Inspection".
33*2 Ground Thermal transmitter signal — —

Refer to DI-34, "Electrical Component
(BR) Inspection". C
39*1 — CAN-L — — —
(P)
D
40*1 — CAN-H — — —
(L)
44 Air bag warning lamp ON 4

Ground Air bag warning lamp signal ON E
(BR) Air bag warning lamp OFF 0
54 ABS warning lamp ON 8

Ground ABS warning lamp signal ON
(G) ABS warning lamp OFF 1 F
G
Speedometer operated [When
61 Vehicle speed signal output
Ground ON vehicle speed is approx. 40 km/
(GR) (2-Pulse)
h (25 MPH)]
H
ELF1080D
67 Parking brake ON 0
Ground Parking brake switch signal OFF BL
(LG) Parking brake OFF Battery voltage
70 Brake warning lamp ON 0

Ground Brake fluid level switch signal ON
(BR) Brake warning lamp OFF Battery voltage J
75
Ground Ground ON — 0
(B)
*1: YD25DDTi models K
*2: KA24DE models
Work Flow INFOID:0000000003950094

L
1. Check the symptom and customer's requests.

2. Understand the outline of system. Refer to BL-16, "System Description". M
3. According to the trouble diagnosis chart, repair or replace the cause of the malfunction. Refer to BL-21,
"Trouble Diagnosis Symptom Chart".
4. Does power door lock system operate normally? OK: GO TO 5, NG: GO TO 3. N
5. Inspection End.
Trouble Diagnosis Symptom Chart INFOID:0000000003950095
Symptom Repair order Refer to page

1. Door lock and unlock switch check BL-23 P
All power door lock actuators (RF, LR, RR) do not
operate with door lock and unlock switch or lock 2. Door lock relay check BL-25
knob switch.
3. Replace combination meter. DI-35
All power door lock actuators (RF, LR, RR) do not 1. Door lock and unlock switch check BL-23
operate with door lock and unlock switch (door
locks operate with lock knob switch). 2. Replace combination meter. DI-35

Symptom Repair order Refer to page
All power door lock actuators (RF, LR, RR) do not 1. Lock knob switch check BL-24
operate with lock knob switch (door locks operate
with door lock and unlock switch). 2. Replace combination meter. DI-35
1. Front door lock actuator (passenger side) check BL-28

Specific door lock actuator does not operate.
2. Rear door lock actuator LH/RH check BL-28
Combination Meter Power Supply and Ground Circuit Inspection INFOID:0000000003970733
1.CHECK FUSE
Check for blown combination meter fuse.
Power source Fuse No.

Battery 6
Is the inspection result normal?
YES >> GO TO 2.
NO >> Be sure to eliminate cause of malfunction before installing new fuse. Refer to PG-3, "Circuit Dia-
gram".
2.CHECK POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect combination meter.
3. Check voltage between combination meter harness connector
M206 terminal 24 and ground.
Voltage (V)
Connector Terminals
(Approx.)
(+) (–)
M206 Battery Voltage
24 Ground
YES >> GO TO 3.
NO >> Repair harness or connector. ALKIA1498ZZ
3.CHECK GROUND CIRCUIT

Check continuity between combination meter harness connector
M206 (A) terminal 25, connector M207 (B) terminal 75 and ground. A
Combination meter connector Terminal Continuity

A: M206 25 Ground B
Yes
B: M207 75
G
ALKIA1499ZZ

H
YES >> Combination meter power and ground circuits are OK.
NO >> Repair harness or connector.
Door Lock and Unlock Switch Check INFOID:0000000003950097 BL
1.CHECK DOOR LOCK AND UNLOCK SWITCH GROUND HARNESS

1. Turn ignition switch OFF. J
2. Check continuity between door lock and unlock switch connec-
tor D6 terminal 19 and ground.
K
19 - Ground : Continuity should exist.
M
ALKIA1489ZZ
Is the inspection result normal? N

YES >> GO TO 2.
NO >> Repair or replace harness.
2.CHECK DOOR LOCK AND UNLOCK SWITCH INPUT UNLOCK SIGNAL O

Check continuity between door lock and unlock switch connector D6
terminal 17 and ground.
Terminals
Connector Condition Continuity
(+) (–)
Door lock and unlock switch is
Yes
turned to UNLOCK position.
D6 17 Ground
No
in neutral or LOCK position.
Is the inspection result normal? ALKIA1490ZZ
YES >> GO TO 3.
NO >> Replace door lock and unlock switch.
3.CHECK DOOR LOCK AND UNLOCK SWITCH INPUT LOCK SIGNAL
Check continuity between door lock and unlock switch connector D6
Terminals
(+) (–)
Yes
turned to LOCK position.
D6 18 Ground
No
in neutral or UNLOCK position.
Is the inspection result normal? ALKIA1491ZZ
YES >> GO TO 4.
NO >> Replace door lock and unlock switch.
4.CHECK DOOR LOCK AND UNLOCK SWITCH INPUT SIGNAL
2. Check continuity between combination meter connector M206
terminals 9, 10 and ground.
Terminals
(+) (–)
Yes
9 Ground
No
in neutral or LOCK position.
M206
Door lock and unlock switch is ALKIA1492ZZ
Yes
10 Ground
No
in neutral or UNLOCK position.

YES >> Door lock and unlock switch circuit is OK.
NO >> Repair or replace harness between door lock switch and combination meter.
Lock Knob Switch Check INFOID:0000000003950101
1.CHECK LOCK KNOB SWITCH INPUT SIGNAL

3. Close driver door to enable lock knob movement.

terminal 11 and ground. A
Terminals
(+) (–) B
Driver door lock knob switch is
Yes
M206 11 Ground C
Driver door lock knob switch is
No
ALKIA1495ZZ
D
YES >> Driver door lock knob switch circuit is OK.
NO >> GO TO 2. E
2.CHECK LOCK KNOB SWITCH GROUND HARNESS
1. Disconnect driver door lock knob switch.
2. Check continuity between driver door lock knob switch connec- F
tor D9 terminal 1 and ground.
1 - Ground : Continuity should exist. G
BL
ALKIA1496ZZ

J
YES >> GO TO 3.
3.CHECK LOCK KNOB SWITCH SIGNAL HARNESS K
terminal 11 and door lock knob switch connector D9 terminal 2.
L
11 - 2 : Continuity should exist.
terminal 11 and ground. M
11 - Ground : Continuity should not exist.

N
ALKIA1497ZZ
Is the inspection result normal? O

YES >> Replace driver door lock knob switch.
Door Lock Relay Check INFOID:0000000003950098 P
1.CHECK POWER SUPPLY CIRCUIT


2. Check voltage between door lock relay harness connector M52
Door lock relay Voltage (V)

Terminals
connector (Approx.)
(+) (–)
M52 Battery Voltage
3 Ground
YES >> GO TO 2
NO >> Be sure to eliminate cause of malfunction before install- ALKIA1502ZZ
ing new fuse or circuit breaker. Refer to PG-3, "Circuit

Diagram".
2.CHECK GROUND CIRCUIT
Check continuity between door lock relay harness connector M52
Door lock relay

Terminals Continuity
connector
(+) (–)
M52 Yes
2 Ground
YES >> GO TO 3
NO >> Repair harness or connector. ALKIA1503ZZ
3.CHECK DOOR LOCK RELAY SIGNALS

2. Momentarily connect a jumper wire between door lock relay con-
nector M52 terminal 5 and ground.
Connector Terminals Condition Result

Door locks LOCK
5 Momentay jumper
(except driver)
M52 Ground
Door locks UNLOCK
6 Momentary jumper
(except driver)
ALKIA1500ZZ

YES >> GO TO 4
NO >> GO TO 5
4.CHECK DOOR LOCK RELAY CONTROL SIGNALS FOR OPEN
1. Disconnect combination meter and door lock relay.
(A) terminals 78, 79 and door lock relay connector M52 (B) ter-
minals 5, 6.
Connector Terminals Connector Terminals Continuity

78 6 Yes
A: M207 B: M52
79 5 Yes
ALKIA1501ZZ

YES >> Door lock relay control circuits are OK. A
5.CHECK DOOR LOCK RELAY CONTROL SIGNALS INPUT
B
1. Disconnect combination meter and door lock relay.
(A) terminals 78, 79 and door lock relay connector M52 (B) ter-
minals 5, 6. C

D
78 6 Yes
A: M207 B: M52
79 5 Yes
3. Check continuity between combination meter connector M207 E
(A) terminals 78, 79 and ground.
ALKIA1504ZZ
Connector Terminals Continuity F

78 No
A: M207 Ground
79 No
G
YES >> GO TO 6
NO >> Repair or replace harness. H
6.CHECK DOOR LOCK RELAY OUTPUT

1. Turn ignition switch OFF. BL
2. Momentarily connect a fused jumper wire between door lock
relay connector M52 terminals 5, 6 and battery ground.
J
Door lock relay
Terminals Condition Result
connector
Door locks LOCK
1(+) 4(-) K
(except driver)
M52 Momentary jumper
Door locks UNLOCK
4(+) 1(-)
(except driver)
L
ALKIA1505ZZ
Is the inspection result normal? M

YES >> Replace door lock relay.
NO >> GO TO 7
7.CHECK DOOR LOCK RELAY OUTPUT CIRCUITS N
1. Disconnect all inoperative door lock actuators.
2. Check continuity between door lock relay connector M52 (A) ter-
minals 1, 4 and inoperative door lock actuator connector D108 O
(passenger side), D207 (rear LH)(with double cab), D307 (rear
RH)(with double cab) terminals 1, 2.
P
1 B: D108, 1
A: M52 D207, Yes
4 D307 2
3. Check continuity between door lock relay connector M52 (A) ter- ALKIA1506ZZ
minals 1, 4 and ground.

Connector Terminals Continuity

1
A: M52 Ground No
4

YES >> Replace door lock actuator.
Front Door Lock Actuator (Passenger Side) Check INFOID:0000000003950099
1.CHECK FRONT DOOR LOCK ACTUATOR RH SIGNAL

2. Disconnect passenger door lock actuator.
3. Using an oscilloscope, check voltage between front door lock
actuator (passenger side) connector M52 terminals 1 and 2.
Terminals Voltage (V)

Connector Condition
(+) (-) (Approx.)
Door lock/unlock switch is 0 → Battery voltage

1 2
turned to LOCK (300 msec)
D108
2 1
turned to UNLOCK (300 msec)
ALKIA1507ZZ

YES >> Replace front door lock actuator (passenger side). Refer to BL-31, "Exploded View".
NO >> Repair or replace harness beween door lock relay and front door lock actuator (passenger side).
Rear Door Lock Actuator LH/RH Check (Double Cab) INFOID:0000000003950100
1.CHECK REAR DOOR LOCK ACTUATOR RH/LH SIGNAL

2. Disconnect inoperative rear door lock actuator.
3. Using an oscilloscope, check voltage between rear door lock
actuator connector D207 (rear LH), D307 (rear RH) terminals 1
and 2.
Terminals Voltage (V)

Connector Condition
(+) (-) (Approx.)

1 2
D207 (LH) turned to LOCK (300 msec)
D307 (RH) Door lock/unlock switch is 0 → Battery voltage
2 1
turned to UNLOCK (300 msec) ALKIA1507ZZ

YES >> Replace inoperative rear door lock actuator. Refer to BL-32, "Exploded View".
NO >> Repair or replace harness beween door lock relay and rear door lock actuator.

DOOR
DOOR
A
Front Door INFOID:0000000003492163
• For removal of door trim, refer to EI-23, "Removal and Installation". B

• After adjusting door or door lock, check door lock operation.
BL
WBT109
P

DOOR
Rear Door INFOID:0000000003492164
WBT110

FRONT DOOR LOCK
FRONT DOOR LOCK
A
BL
ALKIA1458ZZ
1. Front door outside handle rod 2. Front door outside handle 3. Front door bell crank assembly J
4. Inside handle seal 5. Front door inside handle 6. Inside handle escutcheon
7. Inside lock knob rod 8. Front door lock assembly 9. Front door lock auto acutator (if
equipped)
K
10. Striker 11. Key cylinder lock rod 12. Front door outside handle reinforce-
ment

REAR DOOR LOCK
REAR DOOR LOCK
ALKIA1459ZZ
1. Rear door outside handle rod 2. Rear door outside handle 3. Rear door bell crank assembly
4. Inside handle seal 5. Rear door inside handle assembly 6. Inside handle escutcheon
7. Rear door lock auto actuator (if 8. Rear door latch assembly 9. Striker
equipped)

TAIL GATE
TAIL GATE
A
Removal and Installation INFOID:0000000003857762
BL
J
ALKIA1457ZZ
1. Tailgate bumper 2. Tail gate inner panel 3. Tail gate chain assembly (RH/ LH) K
4. Tail gate chain hook (RH/LH) 5. Tail gate assembly 6. Tail gate latch assembly (RH/ LH)

BODY (ALIGNMENT)
BODY (ALIGNMENT)
Alignment INFOID:0000000003492176
• All dimensions indicated in the figures are actual.

• When using a tracking gauge, adjust both pointers to equal length, then check pointers and the gauge to
make sure there is no free play.
• When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
• Measurements should be taken at the center of the mounting holes.
• An asterisk (*) following the value at the measuring point indicates that the measuring point on the other side
is symmetrically the same value.
• The coordinates of the measurement points are the distances measured from the standard line of “X”, “Y”
and “Z”.
WIIA0065E
ENGINE COMPARTMENT

BODY (ALIGNMENT)
Measurement
A
BL
WIIA0067E
Figure marked with * indicates symmetrically identical dimensions on both right-hand and left-hand sides of
the vehicle.
J

BODY (ALIGNMENT)
Measurement Points
WIIA0122E
UNDERBODY

BODY (ALIGNMENT)
Measurement — Frame
A
BL
AWKIA1317GB

BODY (ALIGNMENT)
Measurement Points
AWKIA1318GB
PASSENGER COMPARTMENT

BODY (ALIGNMENT)
Measurement- Single Cab
A
BL
WIIA0074E

BODY (ALIGNMENT)
Measurement Points- Single Cab
WIIA0075E

BODY (ALIGNMENT)
BL
O
WIIA0076E

BODY (ALIGNMENT)
WIIA0077E

BODY (ALIGNMENT)
Measurement - Double Cab
A
BL
WIIA0078E

BODY (ALIGNMENT)
Measurement Points - Double Cab
WIIA0079E

BODY (ALIGNMENT)
BL
O
WIIA0080E

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BODY

Revision: March 2008 BL-1 2009 D22 LCV

Revision: March 2008 BL-2 2009 D22 LCV

— Locating the noise

Commercial Service Tool INFOID:0000000003492156

Revision: March 2008 BL-3 2009 D22 LCV

Revision: March 2008 BL-4 2009 D22 LCV

Revision: March 2008 BL-5 2009 D22 LCV

Revision: March 2008 BL-6 2009 D22 LCV

Revision: March 2008 BL-7 2009 D22 LCV

Revision: March 2008 BL-8 2009 D22 LCV

Revision: March 2008 BL-9 2009 D22 LCV

CLEARANCE AND SURFACE HEIGHT ADJUSTMENT

Revision: March 2008 BL-10 2009 D22 LCV

4. After adjusting hood lock, tighten the lock bolts.

Revision: March 2008 BL-11 2009 D22 LCV

1 Hood assembly (KA24DE) 2. Radiator core seal assembly 3. Hood assembly

Revision: March 2008 BL-12 2009 D22 LCV

Revision: March 2008 BL-13 2009 D22 LCV

4. Check the hood lock lubrication condition. If necessary, apply

5. Install the front grille. Refer to EI-15, "Removal and Installation".

Revision: March 2008 BL-14 2009 D22 LCV

Removal and Installation INFOID:0000000003885681

Revision: March 2008 BL-15 2009 D22 LCV

System Description INFOID:0000000003492159

Power is supplied at all times

Revision: March 2008 BL-16 2009 D22 LCV

Revision: March 2008 BL-17 2009 D22 LCV

Revision: March 2008 BL-18 2009 D22 LCV

Revision: March 2008 BL-19 2009 D22 LCV

Terminal and Reference Value for Combination Meter INFOID:0000000003977520

2*1 Water in fuel filter warning Water in fuel warning lamp ON 0

3*2 Malfunction indicator lamp Malfunction indicator lamp ON 0

21 Engine running Battery voltage

22 Charge warning lamp ON 0

Speedometer operated [When

28*2 Ground Engine speed signal ON Engine running (idling)

29*1 — Oil level sensor signal — —

30*1 Ground Oil level sensor signal ground ON — 0

Revision: March 2008 BL-20 2009 D22 LCV

33*2 Ground Thermal transmitter signal — —

44 Air bag warning lamp ON 4

54 ABS warning lamp ON 8

70 Brake warning lamp ON 0

Work Flow INFOID:0000000003950094

1. Check the symptom and customer's requests.

Symptom Repair order Refer to page

Revision: March 2008 BL-21 2009 D22 LCV

1. Front door lock actuator (passenger side) check BL-28

Combination Meter Power Supply and Ground Circuit Inspection INFOID:0000000003970733

Power source Fuse No.

3.CHECK GROUND CIRCUIT

Revision: March 2008 BL-22 2009 D22 LCV

Combination meter connector Terminal Continuity

Is the inspection result normal?

1.CHECK DOOR LOCK AND UNLOCK SWITCH GROUND HARNESS

Is the inspection result normal? N

Revision: March 2008 BL-23 2009 D22 LCV

Is the inspection result normal?