Tài liệu hướng dẫn sửa chữa Hệ thống cabo và cửa trên xe 34 2005 2006 toyota hilux factory service manual engine hood and door cabo va cua. Cung cấp các thông tin cho Kỹ thuật viên tiến hành sửa chữa nhanh chóng, chính xác, hiệu quả
ED–8 ENGINE HOOD / DOOR – HOOD REASSEMBLY INSTALL HOOD LOCK CONTROL CABLE ASSEMBLY ED B088396 (a) Tie the string inside the wire harness grommet to the hood lock control cable assembly (b) Using the string, fit the hood lock control cable assembly into the wire harness grommet B088394 INSTALL HOOD LOCK CONTROL LEVER SUBASSEMBLY (a) Connect the hood lock control cable assembly ENGINE HOOD / DOOR – HOOD ED–9 (b) Engage the claws and install the hood lock control lever sub-assembly B088397E01 INSTALL HOOD LOCK CONTROL CABLE PROTECTOR SUB-ASSEMBLY (a) Install the hood lock control cable protector subassembly with the nuts Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) ED B088393 INSTALL WASHER NOZZLE SUB-ASSEMBLY (a) Connect the washer hose (b) Engage the claws and install the washer nozzle sub-assembly INSTALL HOOD SUPPORT (a) Engage the claws and install the hood stay holder B088392E01 B088391E02 (b) Install the grommet (c) Install the hood support (b) (c) B088390E01 ED–10 ENGINE HOOD / DOOR – HOOD INSTALL HOOD LOCK ASSEMBLY (a) Connect the hood lock control cable assembly B088389 (b) Install the hood lock assembly with the bolts Torque: 12 N*m (122 kgf*cm, ft.*lbf) ED B088162 INSTALL NO HOOD LOCK RELEASE LEVER PROTECTOR (See page ED-5) INSTALL RADIATOR GRILLE (See page ET-11) ENGINE HOOD / DOOR – FRONT DOOR (w/ Power Window) ED–13 DISASSEMBLY HINT: Use the same procedures for both the LH and RH sides DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (a) Disengage the clips and remove the front door lower frame bracket garnish LH NOTICE: Confirm that no clips remain on the door panel when the garnish is removed Transfer any remaining clips to the garnish side before installing REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Double Cab) (a) Using a screwdriver with its tip wrapped in protective tape, disengage the claws and clip, then remove the power window regulator master switch assembly (b) Disconnect the connector REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Access Cab) (a) Using a screwdriver with its tip wrapped in protective tape, disengage the claws and clip, then remove the power window regulator master switch assembly (b) Disconnect the connector REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Using a screwdriver with its tip wrapped in protective tape, disengage the claws and clip, then remove the power window regulator switch assembly (b) Disconnect the connector B088092E01 B088093E01 B088094E01 B088095E01 ED ED–14 ENGINE HOOD / DOOR – FRONT DOOR (w/ Power Window) REMOVE FRONT DOOR TRIM PANEL ASSEMBLY LH (a) Using a screwdriver with its tip wrapped in protective tape, open the cover B088405E01 (b) Remove the screws ED B088096 (c) Disengage the 10 clips and remove the front door trim panel assembly LH REMOVE FRONT NO SPEAKER ASSEMBLY HINT: • Regular cab (See page AV-76) • Except regular cab (See page AV-78) REMOVE FRONT NO SPEAKER ASSEMBLY (See page AV-83) REMOVE FRONT NO SPEAKER BRACKET (a) Disconnect the wire harness clamp and connector (b) Remove the screws and front No speaker bracket B088097E01 B088098E01 10 REMOVE NO DOOR TRIM BRACKET RH (a) Remove the screws and No door trim bracket B088099 ENGINE HOOD / DOOR – FRONT DOOR (w/ Power Window) Claw A B088074E01 ED–15 11 REMOVE FRONT DOOR INSIDE HANDLE SUBASSEMBLY LH (a) Using a screwdriver with its tip wrapped in protective tape, disengage claw A as shown in the illustration (b) Move the front door inside handle sub-assembly LH in the direction indicated by the arrow mark in the illustration This will release the claw and allow the removal of the front door inside handle subassembly LH (c) Disconnect the cables from the front door inside handle sub-assembly LH ED B088075 12 REMOVE FRONT DOOR SERVICE HOLE COVER LH (a) Remove the front door service hole cover LH NOTICE: Remove the remaining tape on the door side 13 REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH (See page MI-8) 14 REMOVE FRONT DOOR BELT MOULDING LH (See page ET-32) B088100 15 REMOVE FRONT DOOR INSIDE PANEL PLATE LH (a) Remove the screws and front door inside panel plate LH B088101 (d) (d) B088102E01 16 REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched (a) Driver side: Connect the power window regulator master switch (b) Passenger side: Connect the power window regulator switch (c) Move the front door glass sub-assembly LH until the bolts appear in the service holes ED–16 ENGINE HOOD / DOOR – FRONT DOOR (w/ Power Window) (d) Remove the bolts NOTICE: Be careful when removing the bolts as the glass may fall and be damaged (e) Remove the front door glass sub-assembly LH in the direction indicated by the arrow marks in the illustration NOTICE: Be careful not to damage the glass (f) Driver side: Disconnect the power window regulator master switch (g) Passenger side: Disconnect the power window regulator switch B088103 17 REMOVE FRONT DOOR GLASS RUN LH (a) Remove the front door glass run LH ED B088104 (c) A (c) (a) (c) (c) (c) B088105E01 18 REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH (a) Disconnect the front door power window regulator connector (b) Loosen bolt A (c) Remove the bolts, then remove the front door window regulator sub-assembly LH NOTICE: Be careful when removing the bolts as the window regulator may fall and be damaged HINT: Remove the window regulator through the service hole 19 REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (a) Place matchmarks on the power window regulator motor gear and regulator gear (b) Using a torx driver T25, remove the screws and power window regulator motor assembly LH B088084 ENGINE HOOD / DOOR – FRONT DOOR (w/ Power Window) ED–17 20 REMOVE FRONT DOOR REAR LOWER FRAME SUBASSEMBLY LH (a) Remove the bolts, then remove the front door rear lower frame sub-assembly LH B088106 21 REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH (a) Remove the nuts, then remove the front door front lower frame sub-assembly LH ED B088107 22 REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH (a) Remove the hole plug (b) Using a torx socket wrench T30, loosen the screw and remove the front door outside handle cover LH Hole Plug B061438E09 (a) (b) (b) (b) B088108E01 23 REMOVE FRONT DOOR LOCK ASSEMBLY LH (a) Disconnect the front door lock connector (b) Using a torx socket wrench T30, remove the screws, then remove the front door lock assembly LH NOTICE: Be careful when removing the screws as the door lock may fall and be damaged HINT: Remove the door lock through the service hole 24 REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH (a) Remove the front door outside handle assembly LH by sliding and pulling it in the direction indicated by the arrow mark in the illustration B056613E07 ED–18 ENGINE HOOD / DOOR – FRONT DOOR (w/ Power Window) (b) Disengage the claws and remove the front door outside handle front pad B088087E01 (c) Disengage the claws and remove the front door outside handle rear pad ED B088088E01 Outside Slide Frame Door Panel Nut 25 REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (a) Using a torx socket wrench T30, loosen the screw (b) Slide the outside handle frame sub-assembly to remove it HINT: Remove the outside handle frame sub-assembly through the service hole Screw Inside Slide Screw B066256E02 26 REMOVE FRONT DOOR CHECK ASSEMBLY LH (a) Remove the nuts and bolt, then remove the front door check assembly LH B088109 ENGINE HOOD / DOOR – FRONT DOOR (w/ Power Window) ED–19 27 REMOVE FRONT DOOR WEATHERSTRIP LH (for Double Cab) (a) Disengage the 34 clips and remove the front door weatherstrip LH NOTICE: Remove the remaining tape on the door side B088110E01 28 REMOVE FRONT DOOR WEATHERSTRIP LH (for Access Cab) (a) Disengage the 36 clips and remove the front door weatherstrip LH NOTICE: Remove the remaining tape on the door side ED B088111E01 ED–51 ENGINE HOOD / DOOR – ACCESS DOOR ACCESS PANEL UPPER LOCK ASSEMBLY LH 12 (122, 9) x3 NO DOOR TRIM BRACKET RH ED SCREW x2 REAR SPEAKER ASSEMBLY SCREW ACCESS PANEL LOCK REMOTE CONTROL ASSEMBLY LH x3 12 (122, 9) SCREW SCREW ACCESS PANEL LOWER LOCK ASSEMBLY LH x3 ACCESS PANEL INSIDE HANDLE SUB-ASSEMBLY LH 12 (122, 9) x3 N*m (kgf*cm, ft.*lbf) ; Specified torque B088151E01 ED–52 ENGINE HOOD / DOOR – ACCESS DOOR 26 (265, 19) REAR DOOR UPPER HINGE ASSEMBLY LH x2 9.0 (92, 80 in.*lbf) 26 (265, 19) REAR DOOR CHECK ASSEMBLY LH ED x2 FRONT DOOR COURTESY LAMP SWITCH ASSEMBLY 5.5 (50, 49 in.*lbf) x2 30 (306, 22) 26 (265, 19) x2 23 (235, 17) x2 x2 26 (265, 19) FRONT DOOR LOCK STRIKER PLATE ASSEMBLY REAR DOOR LOWER HINGE ASSEMBLY LH REAR DOOR WEATHERSTRIP LH x2 REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH 5.0 (51, 44 in.*lbf) REAR DOOR SERVICE HOLE COVER LH N*m (kgf*cm, ft.*lbf) ; Specified torque Non-reusable part B128228E01 ENGINE HOOD / DOOR – REAR DOOR ED–65 REAR DOOR ENGINE HOOD / DOOR BODY COMPONENTS REAR DOOR FRAME GARNISH LH ED REAR DOOR TRIM PANEL ASSEMBLY LH CLIP SCREW DOOR ASSIST GRIP ASSEMBLY LH REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY B088147E01 ED–66 ENGINE HOOD / DOOR – REAR DOOR REAR DOOR OUTSIDE HANDLE COVER LH REAR DOOR OUTSIDE HANDLE ASSEMBLY NUT REAR DOOR BELT MOULDING LH OUTSIDE HANDLE REAR PAD 7.0 (71, 62 in.*lbf) OUTSIDE HANDLE FRONT PAD REAR DOOR LOCK ASSEMBLY LH x3 ED REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 7.0 (71, 62 in.*lbf) 12 (122, 9) DOOR LOCK WIRE HARNESS PACKING SCREW REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH NO REAR DOOR TRIM BRACKET BUTYL TAPE SCREW x3 x3 REAR SPEAKER ASSEMBLY SCREW REAR DOOR SERVICE HOLE COVER LH N*m (kgf*cm, ft.*lbf) ; Specified torque Non-reusable part B088148E01 ED–67 ENGINE HOOD / DOOR – REAR DOOR REAR DOOR REAR LOWER WINDOW FRAME SUB-ASSEMBLY LH REAR DOOR FRONT WINDOW GUIDE SUB-ASSEMBLY LH 8.0 (82, 70 in.*lbf) REAR DOOR REAR LOWER GLASS RUN REAR DOOR FRONT LOWER GLASS RUN REAR DOOR GLASS RUN LH x2 HOLE PLUG 8.0 (82, 70 in.*lbf) REAR DOOR WEATHERSTRIP LH REAR DOOR UPPER HINGE ASSEMBLY LH ED x2 26 (265, 19) 26 (265, 19) x2 5.5 (56, 49 in.*lbf) 26 (265, 19) x2 x2 x2 REAR DOOR LOWER HINGE ASSEMBLY LH 26 (265, 19) 30 (306, 22) REAR DOOR CHECK ASSEMBLY LH REAR DOOR GLASS SUB-ASSEMBLY LH 8.0 (82, 71 in.*lbf) x2 x3 5.4 (55, 48 in.*lbf) x2 11 (112, 8) REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH x4 11 (112, 8) POWER WINDOW REGULATOR MOTOR ASSEMBLY LH N*m (kgf*cm, ft.*lbf) ; Specified torque B128227E02 ED–82 ENGINE HOOD / DOOR – TAIL GATE TAIL GATE ENGINE HOOD / DOOR BODY COMPONENTS TAIL GATE LOCK STRIKER x2 29 (296, 21) TAIL GATE STAY STOPPER 14 (143, 10) 13 (127, 9) TAIL GATE HANDLE ASSEMBLY TAIL GATE LINK x2 ED TAIL GATE LOCK ASSEMBLY LH x2 SCREW 29 (296, 21) x7 TAIL GATE PROTECTOR RH TAIL GATE STAY ASSEMBLY WASHER 14 (143, 10) TAIL GATE HINGE ASSEMBLY LH 18 (178, 13) x2 18 (178, 13) x8 SCREW TAIL GATE SERVICE HOLE COVER N*m (kgf*cm, ft.*lbf) : Specified torque B088153E01 ENGINE HOOD / DOOR – TAIL GATE ED–83 DISASSEMBLY REMOVE TAIL GATE PROTECTOR RH (a) Using a torx socket wrench T30 , remove the screws B088128 (b) Disengage the 10 claws and remove the tail gate protector RH ED B088129E01 REMOVE TAIL GATE SERVICE HOLE COVER (a) Using a torx socket wrench T30, remove the screws and tail gate service hole cover REMOVE TAIL GATE LOCK ASSEMBLY LH (a) Disconnect the tail gate link as shown in the illustration B088130 B088131 (b) Disengage the clip and remove the bolts, then remove the tail gate lock assembly LH from the tail gate B088132E01 REMOVE TAIL GATE LOCK ASSEMBLY RH HINT: Use the same procedure as described for the LH side ED–84 ENGINE HOOD / DOOR – TAIL GATE REMOVE TAIL GATE HANDLE ASSEMBLY (a) Remove the bolts (b) Disengage the claws and remove the tail gate handle assembly REMOVE TAIL GATE LOCK STRIKER (a) Remove the bolts and tail gate lock striker HINT: Use the same procedures for both the LH and RH sides REMOVE TAIL GATE (a) Disconnect the tail gate stay HINT: Use the same procedures for both the LH and RH sides (a) (a) B088133E01 ED B088134 B088135 (b) Remove the tail gate from the vehicle as shown in the illustration NOTICE: Be careful not to drop the tail gate HINT: Remove the tail gate from the vehicle by lifting up the right side and sliding it slightly to the right B088137E01 B088136 REMOVE TAIL GATE STAY STOPPER (a) Using a torx socket wrench T40, remove the screw and tail gate stopper HINT: Use the same procedure for both the LH and RH sides ENGINE HOOD / DOOR – TAIL GATE ED–85 REMOVE TAIL GATE STAY ASSEMBLY (a) Using a torx socket wrench T40 , remove the screw, washer and tail gate stay assembly HINT: Use the same procedure for both the LH and RH sides B088138 10 REMOVE TAIL GATE HINGE ASSEMBLY LH (a) Using a torx socket wrench T40 , remove the bolt, screws and tail gate hinge assembly LH HINT: Perform the same procedure as above on the opposite side 11 REMOVE TAIL GATE HINGE ASSEMBLY RH HINT: Use the same procedures as described for the LH side B088139 REASSEMBLY INSTALL TAIL GATE HINGE ASSEMBLY LH (a) Using a torx socket wrench T40 , install the tail gate hinge assembly LH with the bolt and screws Torque: 18 N*m (178 kgf*cm, 13 ft.*lbf) INSTALL TAIL GATE HINGE ASSEMBLY RH HINT: Use the same procedures as described for the LH side INSTALL TAIL GATE STAY ASSEMBLY (a) Using a torx socket wrench T40 , install the tail gate stay assembly with the screw and washer Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) HINT: Use the same procedure for both the LH and RH sides INSTALL TAIL GATE STAY STOPPER (a) Using a torx socket wrench T40 , install the tail gate stopper with the screw Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) HINT: Use the same procedure for both the LH and RH sides B088139 B088138 B088136 ED ED–86 ENGINE HOOD / DOOR – TAIL GATE INSTALL TAIL GATE (a) Install the tail gate onto the vehicle NOTICE: Be careful not to drop the tail gate HINT: Install the tail gate onto the vehicle by engaging the hinge on the left side first and then the hinge on the right side B088140E01 (b) Connect the tail gate stay HINT: Use the same procedure for both the LH and RH sides ED B088135 INSTALL TAIL GATE LOCK STRIKER (a) Install the tail gate lock striker with the bolts Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) HINT: Use the same procedure for both the LH and RH sides INSTALL TAIL GATE HANDLE ASSEMBLY (a) Engage the claws and install the tail gate handle assembly with the bolts Torque: 13 N*m (127 kgf*cm, ft.*lbf) INSTALL TAIL GATE LOCK ASSEMBLY LH (a) Engage the clip and install the tail gate lock assembly LH with the bolts and clip Torque: 29 N*m (269 kgf*cm, 21 ft.*lbf) B088134 (a) (a) B088133E01 B088132E01 ENGINE HOOD / DOOR – TAIL GATE ED–87 (b) Connect the tail gate link as shown in the illustration INSTALL TAIL GATE LOCK ASSEMBLY RH HINT: Use the same procedure as described for the LH side B088409 10 INSTALL TAIL GATE SERVICE HOLE COVER (a) Using a torx socket wrench T30 , install the tail gate service hole cover with the screws ED B088130 11 INSTALL TAIL GATE PROTECTOR RH (a) Engage the 10 claws and install the tail gate protector B088129E01 (b) Using a torx socket wrench T30 , tighten the screws to the tail gate protector B088128 ED–4 ENGINE HOOD / DOOR – HOOD (b) Remove the hood lock control cable assembly referring to the illustration ED B088396 NOTICE: Leave the string inside the wire harness grommet for the installation of the hood lock control cable assembly ADJUSTMENT Centering Bolt Standard Bolt B057104E08 HINT: • Centering bolts are used to mount the hood hinge and hood lock The hood and hood lock cannot be adjusted with the centering bolts on Substitute the standard bolts (with washers) for the centering bolts when making adjustments • For bolts without torque specifications, check the standard bolt chart (See page SS-2) ED–5 ENGINE HOOD / DOOR – HOOD INSPECT HOOD SUB-ASSEMBLY B A B088380E01 (a) Check that the clearance measurements of areas A and B are within the standard ranges Standard: Area Measurement A 4.4 +- 1.5 mm (0.173 +- 0.059 in.) B 0.3 +- 1.5 mm (0.012 +- 0.059 in.) ADJUST HOOD SUB-ASSEMBLY (a) Adjust the hood position (1) Loosen the hinge bolts on the hood side B088159 (2) Move the hood and adjust the clearance between the hood and front fender Make sure that the clearance is within the standard range Standard(A): 4.4 +- 1.5 mm(0.173 +- 0.059 in.) (3) Tighten the hood side hinge bolts after the adjustment Torque: 30N*m(306kgf*cm,22ft.*lbf) A Aligned B088385E02 ED ED–6 ENGINE HOOD / DOOR – HOOD (b) Adjust the cushion rubber so that the heights of the hood and the fender are aligned (1) Raise or lower the hood front end by turning the cushion rubber Make sure that the clearance is within the standard range HINT: Raise or lower the cushion rubber by turning it B088160 (c) Adjust the hood lock (1) Remove the bolts and No hood lock release lever protector ED B088161 (2) Loosen the bolts B088162 (3) Adjust the hood lock position so that the striker can enter it smoothly B088163 (4) Tighten the bolts after the adjustment Torque: 12 N*m (122 kgf*cm, ft.*lbf) B088162 ENGINE HOOD / DOOR – HOOD ED–7 (5) Install the No hood lock release lever protector Torque: 12 N*m (122 kgf*cm, ft.*lbf) B088161 ED