Tài liệu hướng dẫn sửa chữa xe Nissan navara np300 (d23) esm tai lieu sua chua phan 2 . Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán, sửa chữa nhanh chóng, chính xác, hiệu quả
BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY SECTION BRM BODY REPAIR A B C D E CONTENTS KING CAB VEHICLE INFORMATION BODY EXTERIOR PAINT COLOR FOR AUSTRALIA 40 FOR AUSTRALIA : Undercoating 41 FOR AUSTRALIA : Stone Guard Coat 41 FOR AUSTRALIA : Body Sealing 43 Body Exterior Paint Color BODY CONSTRUCTION 49 PRECAUTION FOR THAILAND 49 FOR THAILAND : Body Construction 49 PRECAUTIONS Precautions for Removing Battery Terminal REPAIRING HIGH STRENGTH STEEL High Strength Steel (HSS) PREPARATION 13 REPAIRING MATERIAL 13 Foam Repair 13 BODY COMPONENT PARTS 15 FOR THAILAND 15 FOR THAILAND : Underbody Component Parts 15 FOR THAILAND : Body Component Parts 16 FOR THAILAND : Rear Body Component Parts 18 FOR THAILAND : Frame Component Parts 20 FOR AUSTRALIA 23 FOR AUSTRALIA : Underbody Component Parts 23 FOR AUSTRALIA : Body Component Parts 24 FOR AUSTRALIA : Rear Body Component Parts 26 FOR AUSTRALIA : Frame Component Parts 28 REMOVAL AND INSTALLATION 32 CORROSION PROTECTION .32 Description 32 FOR THAILAND 32 FOR THAILAND : Undercoating 32 FOR THAILAND : Stone Guard Coat 33 FOR THAILAND : Body Sealing 35 Revision: 2014 December FOR AUSTRALIA 50 FOR AUSTRALIA : Body Construction 51 F G H I REPLACEMENT OPERATIONS 53 Description .53 FOR THAILAND 54 FOR THAILAND : Radiator Core Support .55 FOR THAILAND : Hoodledge 55 FOR THAILAND : Hoodledge (Partial Replacement) .56 FOR THAILAND : Front Pillar 57 FOR THAILAND : Outer Sill (Partial Replacement) 61 FOR THAILAND : Outer Sill 62 FOR THAILAND : Rear Cab Pillar 62 FOR THAILAND : Back Panel 65 FOR THAILAND : Rear Body Fender 66 FOR THAILAND : Rear Crossmember 67 FOR THAILAND : Crush Horn 68 FOR THAILAND : Roof 70 FOR AUSTRALIA 70 FOR AUSTRALIA : Radiator Core Support .71 FOR AUSTRALIA : Hoodledge 71 FOR AUSTRALIA : Hoodledge (Partial Replacement) .72 FOR AUSTRALIA : Front Pillar 73 FOR AUSTRALIA : Outer Sill (Partial Replacement) .77 FOR AUSTRALIA : Outer Sill 78 FOR AUSTRALIA : Rear Cab Pillar 78 BRM-1 D23 J BRM L M N O P FOR AUSTRALIA : Back Panel 81 FOR AUSTRALIA : Rear Body Fender 82 FOR AUSTRALIA : Rear Crossmember 83 FOR AUSTRALIA : Crush Horn 84 FOR AUSTRALIA : Roof 86 SERVICE DATA AND SPECIFICATIONS (SDS) 87 BODY ALIGNMENT 87 FOR THAILAND 87 FOR THAILAND : Body Center Marks 87 FOR THAILAND : Description 88 FOR THAILAND : Engine Compartment 88 FOR THAILAND : Underbody 90 FOR THAILAND : Passenger Compartment (Windshield and Door Opening) 93 FOR THAILAND : Passenger Compartment (Rear Window Opening) 94 FOR THAILAND : Rear Body 96 FOR AUSTRALIA 98 FOR AUSTRALIA : Body Center Marks 98 FOR AUSTRALIA : Description 99 FOR AUSTRALIA : Engine Compartment .100 FOR AUSTRALIA : Underbody .101 FOR AUSTRALIA : Passenger Compartment (Windshield and Door Opening) 104 FOR AUSTRALIA : Passenger Compartment (Rear Window Opening) 105 FOR AUSTRALIA : Rear Body 107 LHD : Frame Component Parts 127 FOR THAILAND 132 FOR THAILAND : Underbody Component Parts 132 FOR THAILAND : Body Component Parts 134 FOR THAILAND : Rear Body Component Parts 136 FOR THAILAND : Frame Component Parts 138 EXCEPT FOR THAILAND (RHD) 141 EXCEPT FOR THAILAND (RHD) : Underbody Component Parts 141 EXCEPT FOR THAILAND (RHD) : Body Component Parts 142 EXCEPT FOR THAILAND (RHD) : Rear Body Component Parts 144 EXCEPT FOR THAILAND (RHD) : Frame Component Parts 146 REMOVAL AND INSTALLATION 152 CORROSION PROTECTION 152 Description 152 LHD 152 LHD : Undercoating 152 LHD : Stone Guard Coat 153 LHD : Body Sealing 155 FOR THAILAND 160 FOR THAILAND : Undercoating 161 FOR THAILAND : Stone Guard Coat 161 FOR THAILAND : Body Sealing 163 DOUBLE CAB EXCEPT FOR THAILAND (RHD) 168 EXCEPT FOR THAILAND (RHD) : Undercoating 169 EXCEPT FOR THAILAND (RHD) : Stone Guard Coat 169 EXCEPT FOR THAILAND (RHD) : Body Sealing 171 VEHICLE INFORMATION 113 BODY CONSTRUCTION 177 BODY EXTERIOR PAINT COLOR 113 LHD 177 LHD : Body Construction 177 LOCATION OF PLASTIC PARTS 110 Precautions for Plastics 110 Location of Plastic Parts 111 Body Exterior Paint Color 113 PRECAUTION 115 PRECAUTIONS 115 Precautions for Removing Battery Terminal 115 REPAIRING HIGH STRENGTH STEEL 116 High Strength Steel (HSS) .116 PREPARATION 120 REPAIRING MATERIAL 120 Foam Repair 120 BODY COMPONENT PARTS 122 LHD 122 LHD : Underbody Component Parts 122 LHD : Body Component Parts .123 LHD : Rear Body Component Parts 125 Revision: 2014 December FOR THAILAND 178 FOR THAILAND : Body Construction 179 FOR AUSTRALIA 180 FOR AUSTRALIA : Body Construction 181 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) 182 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Body Construction 183 REPLACEMENT OPERATIONS 185 Description 185 LHD 186 LHD : Radiator Core Support 187 LHD : Hoodledge 187 LHD : Hoodledge (Partial Replacement) 188 LHD : Front Pillar 189 BRM-2 D23 LHD : Center Pillar 193 LHD : Outer Sill (Partial Replacement) 195 LHD : Outer Sill 196 LHD : Rear Cab Pillar 197 LHD : Back Panel 200 LHD : Rear Body Fender 201 LHD : Rear Crossmember 202 LHD : Crush Horn 203 LHD : Roof (Normal Roof Models) 205 FOR THAILAND 206 FOR THAILAND : Radiator Core Support 206 FOR THAILAND : Hoodledge 207 FOR THAILAND : Hoodledge (Partial Replacement) 208 FOR THAILAND : Front Pillar 208 FOR THAILAND : Center Pillar 212 FOR THAILAND : Outer Sill (Partial Replacement) 214 FOR THAILAND : Outer Sill 215 FOR THAILAND : Rear Cab Pillar 216 FOR THAILAND : Back Panel 219 FOR THAILAND : Rear Body Fender 220 FOR THAILAND : Rear Crossmember 221 FOR THAILAND : Crush Horn 222 FOR THAILAND : Roof (Normal Roof Models) 224 FOR AUSTRALIA 225 FOR AUSTRALIA : Radiator Core Support 225 FOR AUSTRALIA : Hoodledge 226 FOR AUSTRALIA : Hoodledge (Partial Replacement) 227 FOR AUSTRALIA : Front Pillar 227 FOR AUSTRALIA : Center Pillar 231 FOR AUSTRALIA : Outer Sill (Partial Replacement) 233 FOR AUSTRALIA : Outer Sill 234 FOR AUSTRALIA : Rear Cab Pillar 235 FOR AUSTRALIA : Back Panel 238 FOR AUSTRALIA : Rear Body Fender 239 FOR AUSTRALIA : Rear Crossmember 240 FOR AUSTRALIA : Crush Horn 241 FOR AUSTRALIA : Roof (Normal Roof Models) 243 FOR AUSTRALIA : Roof (Sunroof Models) 244 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) 244 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Radiator Core Support 245 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Hoodledge 245 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Hoodledge (Partial Replacement) 246 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Front Pillar 247 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Center Pillar 251 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Outer Sill (Partial Replacement) 253 Revision: 2014 December EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Outer Sill 254 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Cab Pillar 255 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Back Panel 258 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Body Fender 259 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Crossmember 260 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Crush Horn 261 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Roof (Normal Roof Models) 263 A B C D SERVICE DATA AND SPECIFICATIONS (SDS) 264 E BODY ALIGNMENT 264 F LHD 264 LHD : Body Center Marks 264 LHD : Description 265 LHD : Engine Compartment 265 LHD : Underbody 267 LHD : Passenger Compartment (Windshield and Door Opening) 269 LHD : Passenger Compartment (Rear Window Opening) 273 LHD : Rear Body 274 RHD 276 RHD : Body Center Marks 276 RHD : Description 277 RHD : Engine Compartment 278 RHD : Underbody 279 RHD : Passenger Compartment (Windshield and Door Opening) 281 RHD : Passenger Compartment (Rear Window Opening) 285 RHD : Rear Body 286 LOCATION OF PLASTIC PARTS 289 G H I J BRM L M Precautions for Plastics 289 LHD 289 LHD : Location of Plastic Parts 290 RHD 291 RHD : Location of Plastic Parts 292 SINGLE CAB VEHICLE INFORMATION 294 BODY EXTERIOR PAINT COLOR 294 Body Exterior Paint Color 294 PRECAUTION 296 PRECAUTIONS 296 Precautions for Removing Battery Terminal 296 BRM-3 D23 N O P REPAIRING HIGH STRENGTH STEEL 297 High Strength Steel (HSS) .297 PREPARATION 301 REPAIRING MATERIAL 301 Foam Repair 301 BODY COMPONENT PARTS 303 FOR THAILAND .303 FOR THAILAND : Underbody Component Parts 303 FOR THAILAND : Body Component Parts 304 FOR THAILAND : Rear Body Component Parts 306 FOR THAILAND : Frame Component Parts 308 EXCEPT FOR THAILAND .311 EXCEPT FOR THAILAND : Underbody Component Parts 311 EXCEPT FOR THAILAND : Body Component Parts 312 EXCEPT FOR THAILAND : Rear Body Component Parts 314 EXCEPT FOR THAILAND : Frame Component Parts 316 REMOVAL AND INSTALLATION 320 CORROSION PROTECTION 320 Description .320 FOR THAILAND .320 FOR THAILAND : Undercoating 320 FOR THAILAND : Stone Guard Coat 321 FOR THAILAND : Body Sealing 323 EXCEPT FOR THAILAND .328 EXCEPT FOR THAILAND : Undercoating .329 EXCEPT FOR THAILAND : Stone Guard Coat .329 EXCEPT FOR THAILAND : Body Sealing .331 BODY CONSTRUCTION 337 FOR THAILAND .337 FOR THAILAND : Body Construction 337 EXCEPT FOR THAILAND .338 EXCEPT FOR THAILAND : Body Construction .339 REPLACEMENT OPERATIONS 341 Description .341 FOR THAILAND .342 FOR THAILAND : Radiator Core Support .343 FOR THAILAND : Hoodledge 343 FOR THAILAND : Hoodledge (Partial Replacement) .344 FOR THAILAND : Front Pillar 345 FOR THAILAND : Outer Sill (Partial Replacement) 349 FOR THAILAND : Outer Sill 350 FOR THAILAND : Rear Cab Pillar 351 FOR THAILAND : Back Panel .354 Revision: 2014 December FOR THAILAND : Rear Body Fender 355 FOR THAILAND : Rear Crossmember 357 FOR THAILAND : Crush Horn 358 FOR THAILAND : Roof 359 FOR AUSTRALIA 360 FOR AUSTRALIA : Radiator Core Support 360 FOR AUSTRALIA : Hoodledge 361 FOR AUSTRALIA : Hoodledge (Partial Replacement) 362 FOR AUSTRALIA : Front Pillar 362 FOR AUSTRALIA : Outer Sill (Partial Replacement) 366 FOR AUSTRALIA : Outer Sill 367 FOR AUSTRALIA : Rear Cab Pillar 368 FOR AUSTRALIA : Back Panel 371 FOR AUSTRALIA : Rear Body Fender 372 FOR AUSTRALIA : Rear Crossmember 374 FOR AUSTRALIA : Crush Horn 375 FOR AUSTRALIA : Roof 376 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) 377 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Radiator Core Support 377 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Hoodledge 378 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Hoodledge (Partial Replacement) 379 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Front Pillar 380 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Outer Sill (Partial Replacement) 383 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Outer Sill 384 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Cab Pillar 385 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Back Panel 388 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Body Fender 389 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Crossmember 391 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Crush Horn 392 EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Roof 393 SERVICE DATA AND SPECIFICATIONS (SDS) 395 BODY ALIGNMENT 395 Body Center Marks 395 Description 396 Engine Compartment 396 Underbody 398 Passenger Compartment (Windshield and Door Opening) 400 Passenger Compartment (Rear Window Opening) 402 BRM-4 D23 Rear Body 404 LOCATION OF PLASTIC PARTS 407 Precautions for Plastics 407 Location of Plastic Parts 408 A B C D E F G H I J BRM L M N O P Revision: 2014 December BRM-5 D23 BODY EXTERIOR PAINT COLOR [KING CAB] < VEHICLE INFORMATION > VEHICLE INFORMATION BODY EXTERIOR PAINT COLOR Body Exterior Paint Color INFOID:0000000011680921 FOR THAILAND JSKIA5724ZZ Component Door mirror Front grille Color code BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1 Description Dark Brown Orange Black Gray Silver White Dark Blue White 2PM 2PM 2S 2FPM 2M 3P 2P S Standard clear coat × × × × × × × – Chromium plate Cr Cr Cr Cr Cr Cr Cr Cr Material color – – – – – – – – Chromium plate Cr Cr Cr Cr Cr Cr Cr Cr K23 K23 K23 K23 K23 K23 K23 K23 BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1 Paint type note Silver Front bumper fascia Body color Tail gate handle Material color – – – – – – – – Door outside handle Chromium plate Cr Cr Cr Cr Cr Cr Cr Cr Material color – – – – – – – – Upper and Lower finisher Material color – – – – – – – – Rear bumper reinforcement Chromium plate Cr Cr Cr Cr Cr Cr Cr Cr Rear bumper NOTE: • S: 1-Coat solid • 2M: 2-Coat Metallic • 2P: 2-Coat pearl • 2S: 2-Coat solid • 3P: 3-Coat pearl Revision: 2014 December BRM-6 D23 BODY EXTERIOR PAINT COLOR [KING CAB] < VEHICLE INFORMATION > • 2PM: 2-Coat Pearl metallic A • 2FPM: 2-Coat Iron pearl metallic FOR AUSTRALIA B C D E F JSKIA5724ZZ Component Door mirror Front grille Color code BAX6 BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1 Description Red Dark Brown Orange Black Gray Silver White Dark Blue White 2S 2PM 2PM 2S 2FPM 2M 3P 2P S Standard clear coat × × × × × × × × – Chromium plate Cr Cr Cr Cr Cr Cr Cr Cr Cr Material color – – – – – – – – – Chromium plate Cr Cr Cr Cr Cr Cr Cr Cr Cr K23 K23 K23 K23 K23 K23 K23 K23 K23 BAX6 BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1 Paint type note Silver H I Front bumper fascia Body color Tail gate handle Material color – – – – – – – – – Door outside handle Chromium plate Cr Cr Cr Cr Cr Cr Cr Cr Cr Rear bumper G J BRM L Material color – – – – – – – – – Upper and Lower finisher Material color – – – – – – – – – Rear bumper reinforcement Chromium plate M N Cr Cr Cr Cr Cr Cr Cr Cr Cr O NOTE: • S: 1-Coat solid • 2M: 2-Coat Metallic P • 2P: 2-Coat pearl • 2S: 2-Coat solid • 3P: 3-Coat pearl • 2PM: 2-Coat Pearl metallic • 2FPM: 2-Coat Iron pearl metallic Revision: 2014 December BRM-7 D23 PRECAUTIONS [KING CAB] < PRECAUTION > PRECAUTION PRECAUTIONS Precautions for Removing Battery Terminal INFOID:0000000011667139 • With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key or remote keyless entry or by opening/closing the driver side door In addition, ACC power is supplied even after the ignition switch is turned to the OFF position, i.e ACC power is supplied for a certain fixed time • When disconnecting the 12V battery terminal, turn off the ACC power before disconnecting the 12V battery terminal, observing “How to disconnect 12V battery terminal” described below NOTE: Some ECUs operate for a certain fixed time even after ignition switch is turned OFF and ignition power supply is stopped If the battery terminal is disconnected before ECU stops, accidental DTC detection or ECU data damage may occur • For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON the ignition switch NOTE: SEF289H If the ignition switch is turned ON with any one of the terminals of main battery and sub battery disconnected, then DTC may be detected • After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC NOTE: The removal of 12V battery may cause a DTC detection error HOW TO DISCONNECT 12V BATTERY TERMINAL Disconnect 12V battery terminal according to instruction described below Open the hood Turn ignition switch to the ON position Turn ignition switch to the OFF position with the driver side door opened Get out of the vehicle and close the driver side door Wait at least minutes For vehicle with the engine listed below, remove the battery terminal after a lapse of the specified time D4D engine : 20 minutes HRA2DDT : 12 minutes K9K engine : minutes M9R engine : minutes R9M engine : minutes V9X engine : minutes CAUTION: While waiting, never operate the vehicle such as locking, opening, and closing doors Violation of this caution results in the activation of ACC power supply according to the Auto ACC function Remove 12V battery terminal CAUTION: After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC Revision: 2014 December BRM-8 D23 REPAIRING HIGH STRENGTH STEEL [KING CAB] < PRECAUTION > REPAIRING HIGH STRENGTH STEEL A High Strength Steel (HSS) INFOID:0000000011667140 High strength steel is used for body panels in order to reduce vehicle weight Accordingly, precautions in repairing automotive bodies made of high strength steel are described below: Tensile strength 440 - 780 MPa Revision: 2014 December B Major applicable parts C • 4th cab mounting crossmember (Rear floor assembly component part) • Rear floor side reinforcement (Rear floor assembly component part) • Inner sill wheelhouse (Inner sill extension assembly component part) • Front seat mounting rear crossmember (Front floor assembly component part) • Center pillar crossmember (Front floor assembly component part) • Side member outrigger (Front floor assembly component part) • 2nd body mounting member (Front floor assembly component part) • Inner sill (Inner front sill assembly component part) • Lower dash reinforcement (Lower dash complete component part) • Upper hoodledge (Hoodledge assembly component part) • Lower hoodledge (Lower hoodledge component part) • Hoodledge reinforcement extension (Lower hoodledge component part) • Lower battery support bracket (Lower hoodledge component part) • Lower battery bracket (Lower hoodledge component part) • Side radiator core stay (Side radiator core support component part) • Front roof rail (Front roof rail component part) • Upper inner front pillar • Inner lock pillar assembly • Upper front pillar hinge brace (Outer front pillar reinforcement component part) • Outer sill reinforcement • Outer side roof rail reinforcement • Outer lock pillar reinforcement • Lower rear panel reinforcement (Back panel assembly component part) • Upper front door hinge reinforcement (Front door assembly component part) • Lower front door hinge reinforcement (Front door assembly component part) • Outer rear door seat belt reinforcement (Rear door assembly component part) • 4th floor bolster (4th floor bolster assembly component part) • 3rd floor bolster (3rd floor bolster assembly component part) BRM-9 D E F G H I J BRM L M N O P D23 REPAIRING HIGH STRENGTH STEEL [KING CAB] < PRECAUTION > Tensile strength Major applicable parts 440 - 780 MPa • Inner front side member (Frame assembly component part) • Outer front side member (Frame assembly component part) • Outer rear side member (Frame assembly component part) • Inner center side member (Frame assembly component part) • Front bumper crossmember assembly • Front suspension rear crossmember assembly • 4th crossmember • Diagonal member complete • Upper rear engine mounting crossmember (Rear engine mounting crossmember complete component part) • Rear fuel tank crossmember (7th crossmember component part) • Spare wheel cross reinforcement (Spare wheel crossmember assembly component part) • Outer front side member extension (Front side member extension assembly component part) • Inner front side member extension (Front side member extension assembly component part) Read the following precautions when repairing HSS: Additional points to consider • The repair of reinforcements (such as side members) by heating is not recommended, because it may weaken the component When heating is unavoidable, never heat HSS parts above 550°C (1,022°F) Verify heating temperature with a thermometer (Crayon-type and other similar type thermometer are appropriate.) PIIA0115E • When straightening body panels, use caution in pulling any HSS panel Because HSS is very strong, pulling may cause deformation in adjacent sections of the body In this case, increase the number of measuring points, and carefully pull the HSS panel • When cutting HSS panels, avoid gas (torch) cutting if possible Instead, use a saw to avoid weakening surrounding areas due to heat If gas (torch) cutting is unavoidable, allow a minimum margin of 50 mm (1.97 in) PIIA0117E Revision: 2014 December BRM-10 D23 REAR WINDOW DEFOGGER SWITCH < DTC/CIRCUIT DIAGNOSIS > Check continuity between BCM harness connector and ground A BCM Connector Terminal M8 15 Ground Continuity B Not existed Is the inspection result normal? YES >> Replace BCM Refer to BCS-95, "Removal and Installation" NO >> Repair or replace harness C 4.REPLACE A/C CONTROL D Turn ignition switch OFF Connect A/C auto amp connector Replace A/C control (rear window defogger switch) Turn ignition switch ON Operate rear window defogger switch and check the operating condition Is the inspection result normal? YES >> INSPECTION END NO >> GO TO E F 5.REPLACE A/C AUTO AMP G Turn ignition switch OFF Replace A/C auto amp Turn ignition switch ON Operate rear window defogger switch and check the operating condition Is the inspection result normal? YES >> INSPECTION END NO >> GO TO H I 6.CHECK INTERMITTENT INCIDENT Refer to GI-42, "Intermittent Incident" J >> INSPECTION END WITH MANUAL A/C K WITH MANUAL A/C : Component Function Check INFOID:0000000011378167 1.CHECK REAR WINDOW DEFOGGER SWITCH FUNCTION DEF Perform (“REAR DEF SW”) in BCM - REAR DEFOGGER “DATA MONITOR” mode by using CONSULT Operate rear window defogger switch and check Monitor Status on CONSULT screen Monitor Item REAR DEF SW Condition Rear window defogger switch Monitor Status Pressed ON Released OFF N Is the inspection result normal? YES >> Rear window defogger switch function is OK NO >> Refer to DEF-37, "WITH MANUAL A/C : Diagnosis Procedure" WITH MANUAL A/C : Diagnosis Procedure O INFOID:0000000011378168 P 1.CHECK MANUAL A/C Check the operating condition of manual A/C Does manual A/C operate normally? YES >> GO TO NO >> Perform manual A/C diagnosis Refer to HAC-164, "Work Flow" Revision: 2014 December DEF-37 M D23 REAR WINDOW DEFOGGER SWITCH < DTC/CIRCUIT DIAGNOSIS > 2.CHECK MANUAL A/C TYPE Check manual A/C type Manual A/C (Full electrical type)>>GO TO Manual A/C (Semi electrical type)>>GO TO 3.CHECK BCM OUTPUT SIGNAL Turn ignition switch OFF Disconnect A/C amp connector Turn ignition switch ON Check voltage between A/C amp harness connector and ground by oscilloscope With Intelligent Key system (+) A/C amp (–) Connector Terminal M40 15 Voltage Ground JPMIA0012GB 1.0 – 1.5 V Without Intelligent Key system (+) A/C amp Connector Terminal M40 15 (–) Voltage Ground – 16 V Is the inspection result normal? YES >> GO TO NO >> GO TO 4.CHECK REAR WINDOW DEFOGGER SWITCH CIRCUIT Turn ignition switch OFF Disconnect BCM connector Check continuity between BCM harness connector and A/C amp harness connector With Intelligent Key system BCM A/C amp Connector Terminal Connector Terminal M8 15 M40 15 Continuity Existed Monochrome information display models without Intelligent Key system Combination meter A/C amp Connector Terminal Connector Terminal M54 84 M40 15 Continuity Existed Color information display models without Intelligent Key system Combination meter A/C amp Connector Terminal Connector Terminal M105 102 M40 15 Continuity Existed Check continuity between BCM harness connector and ground Revision: 2014 December DEF-38 D23 REAR WINDOW DEFOGGER SWITCH < DTC/CIRCUIT DIAGNOSIS > With Intelligent Key system BCM Connector Terminal M8 15 Ground A Continuity Not existed B Monochrome information display models without Intelligent Key system Combination meter Connector Terminal M54 84 Ground Continuity C Not existed Color information display models without Intelligent Key system Combination meter Connector Terminal M105 102 Ground D Continuity Not existed Is the inspection result normal? YES-1 >> With Intelligent Key system: Replace BCM Refer to BCS-95, "Removal and Installation" YES-2 >> Without Intelligent Key system: Replace combination meter Refer to MWI-264, "Removal and Installation" NO >> Repair or replace harness 5.REPLACE A/C CONTROL E F G Turn ignition switch OFF Connect A/C amp connector Replace A/C control (rear window defogger switch) Turn ignition switch ON Operate rear window defogger switch and check the operating condition Is the inspection result normal? YES >> INSPECTION END NO >> GO TO H I 6.REPLACE A/C AMP J Turn ignition switch OFF Replace A/C amp Turn ignition switch ON Operate rear window defogger switch and check the operating condition Is the inspection result normal? YES >> INSPECTION END NO >> GO TO 10 K DEF 7.CHECK COMBINATION METER OUTPUT SIGNAL M Turn ignition switch OFF Disconnect A/C control connector Turn ignition switch ON Check voltage between A/C control harness connector and ground N (+) A/C control Connector Terminal M39 28 (–) Voltage Ground – 16 V O P Is the inspection result normal? YES >> GO TO NO >> GO TO 8.CHECK REAR WINDOW DEFOGGER SWITCH CIRCUIT Turn ignition switch OFF Disconnect combination meter connector Check continuity between communication meter harness connector and A/C control harness connector Revision: 2014 December DEF-39 D23 REAR WINDOW DEFOGGER SWITCH < DTC/CIRCUIT DIAGNOSIS > Combination meter A/C control Connector Terminal Connector Terminal M54 84 M39 28 Continuity Existed Check continuity between combination meter harness connector and ground Combination meter Connector Terminal M54 84 Ground Continuity Not existed Is the inspection result normal? YES >> Replace combination meter Refer to MWI-264, "Removal and Installation" NO >> Repair or replace harness 9.REPLACE A/C CONTROL Turn ignition switch OFF Replace A/C control (rear window defogger switch) Turn ignition switch ON Operate rear window defogger switch and check the operating condition Is the inspection result normal? YES >> INSPECTION END NO >> GO TO 10 10.CHECK INTERMITTENT INCIDENT Refer to GI-42, "Intermittent Incident" >> INSPECTION END Revision: 2014 December DEF-40 D23 REAR WINDOW DEFOGGER RELAY < DTC/CIRCUIT DIAGNOSIS > REAR WINDOW DEFOGGER RELAY A Component Function Check INFOID:0000000011365877 1.CHECK FUNCTION B Perform IPDM E/R Active Test (“REAR DEFOGGER”) using CONSULT Touch “ON” Check that the rear window heating wire is getting warmer Is the inspection result normal? YES >> Rear window defogger relay function is OK NO >> Refer to DEF-41, "Diagnosis Procedure" C D Diagnosis Procedure INFOID:0000000011365878 1.CHECK FUSE E Turn ignition switch OFF Check the 20A fuse (No 61 located in IPDM E/R) Is the inspection result normal? YES >> GO TO NO >> Replace the blown fuse after repairing the affected circuit if a fuse is blown F G 2.CHECK IPDM E/R OUTPUT SIGNAL Perform IPDM E/R Active Test (“REAR DEFOGGER”) using CONSULT Touch “ON” Check voltage between IPDM E/R harness connector and ground H (+) I IPDM E/R (−) Connector Terminal E65 57 Ground CONSULT Active Test condition REAR DEFOGGER Voltage ON – 16 V OFF 0–1V J Is the inspection result normal? YES >> INSPECTION END NO >> Replace IPDM E/R Refer to PCS-38, "Removal and Installation" (With Intelligent Key system) or PCS-71, "Removal and Installation" (Without Intelligent Key system) K DEF M N O P Revision: 2014 December DEF-41 D23 REAR WINDOW DEFOGGER < DTC/CIRCUIT DIAGNOSIS > REAR WINDOW DEFOGGER Component Function Check INFOID:0000000011365880 1.CHECK FUNCTION Perform IPDM E/R Active Test (“REAR DEFOGGER”) using CONSULT Touch “ON” Check that the rear window heating wire is getting warmer Is the inspection result normal? YES >> Rear window defogger is OK NO >> Refer to DEF-42, "Diagnosis Procedure" Diagnosis Procedure INFOID:0000000011365881 1.CHECK REAR WINDOW DEFOGGER POWER SUPPLY CIRCUIT Turn ignition switch OFF Disconnect rear window defogger connector Turn ignition switch ON Check voltage between rear window defogger harness connector and ground King cab models (+) Rear window defogger Connector Terminal B11 (−) Condition Ground Rear window defogger switch Voltage ON – 16 V OFF 0–1V Double cab models (+) Rear window defogger Connector Terminal B560 (−) Condition Ground Rear window defogger switch Voltage ON – 16 V OFF 0–1V With slid glass (+) Rear window defogger Connector Terminal B564 (−) Condition Ground Rear window defogger switch Voltage ON – 16 V OFF 0–1V Is the inspection result normal? YES >> GO TO NO-1 >> Except for double cab models: GO TO NO-2 >> For double cab models: GO TO 2.CHECK REAR WINDOW DEFOGGER GROUND CIRCUIT Turn ignition switch OFF Check continuity between rear window defogger harness connector and ground King cab models Rear window defogger Connector Terminal B53 Revision: 2014 December Ground Continuity Existed DEF-42 D23 REAR WINDOW DEFOGGER < DTC/CIRCUIT DIAGNOSIS > Double cab models Rear window defogger Connector Terminal B52 A Continuity Ground Existed B With slid glass Rear window defogger Connector Terminal B565 Continuity Ground C Existed Is the inspection result normal? YES >> GO TO NO >> Repair or replace harness D 3.CHECK FILAMENT E Refer to DEF-49, "Inspection and Repair" Is the inspection result normal? YES >> GO TO NO >> Repair filament F 4.CHECK REAR WINDOW DEFOGGER POWER SUPPLY CIRCUIT Turn ignition switch OFF Disconnect IPDM E/R connectors Check continuity between IPDM E/R harness connector and rear window defogger harness connector G H King cab models IPDM E/R Rear window defogger Connector Terminal Connector Terminal E65 57 B11 Continuity I Existed With slid glass IPDM E/R Rear window defogger Connector Terminal Connector Terminal E65 57 B564 J Continuity Existed K Check continuity between condenser connector and ground IPDM E/R Connector Terminal E65 57 Continuity Ground DEF Not existed Is the inspection result normal? YES >> GO TO NO >> Repair or replace harness M 5.CHECK REAR WINDOW DEFOGGER POWER SUPPLY CIRCUIT N O Turn ignition switch OFF Disconnect condenser connector Check continuity between condenser harness connector and rear window defogger harness connector RHD models Condenser Rear window defogger Connector Terminal Connector Terminal B559 B52 Continuity P Existed LHD models Condenser Rear window defogger Connector Terminal Connector Terminal B561 B52 Revision: 2014 December DEF-43 Continuity Existed D23 REAR WINDOW DEFOGGER < DTC/CIRCUIT DIAGNOSIS > With slid glass Condenser Connector Rear window defogger Terminal Connector Terminal B52 B562 B563 Continuity Existed Check continuity between condenser connector and ground RHD models Condenser Connector Terminal B559 Continuity Ground Not existed LHD models Condenser Connector Terminal B561 Continuity Ground Not existed With slid glass Condenser Connector Continuity Terminal B562 Ground B563 Not existed Is the inspection result normal? YES >> GO TO NO >> Repair or replace harness 6.CHECK REAR WINDOW DEFOGGER POWER SUPPLY CIRCUIT 2 Disconnect IPDM E/R connectors Check continuity between IPDM E/R harness connector and condenser harness connector RHD models IPDM E/R Condenser Connector Terminal Connector Terminal E65 57 B2 Continuity Existed LHD models IPDM E/R Condenser Connector Terminal Connector Terminal E65 57 B44 Continuity Existed With slid glass IPDM E/R Condenser Connector Terminal E65 57 Connector Terminal B20 B48 Continuity Existed Check continuity between IPDM E/R connector and ground IPDM E/R Connector Terminal E65 57 Ground Continuity Not existed Is the inspection result normal? YES >> GO TO NO >> Repair or replace harness 7.CHECK CONDENSER Revision: 2014 December DEF-44 D23 REAR WINDOW DEFOGGER < DTC/CIRCUIT DIAGNOSIS > Refer to DEF-45, "Component Inspection" Is the inspection result normal? YES >> GO TO NO >> Replace condenser Refer to DEF-51, "Removal and Installation" A 8.CHECK INTERMITTENT INCIDENT B Refer to GI-42, "Intermittent Incident" C >> INSPECTION END Component Inspection INFOID:0000000011365882 D 1.CHECK CONDENSER Turn ignition switch OFF Disconnect condenser connector Check continuity between condenser connector and ground part of condenser F Condenser Continuity Terminal Ground part of condenser E G Not existed Check continuity between condenser terminals H Condenser Continuity Terminal I Not existed Is the inspection result normal? YES >> INSPECTION END NO >> Replace condenser Refer to DEF-51, "Removal and Installation" J K DEF M N O P Revision: 2014 December DEF-45 D23 REAR WINDOW DEFOGGER FEEDBACK SIGNAL < DTC/CIRCUIT DIAGNOSIS > REAR WINDOW DEFOGGER FEEDBACK SIGNAL Component Function Check INFOID:0000000011365901 1.CHECK REAR WINDOW DEFOGGER FEEDBACK SIGNAL Check that the indicator lamp of rear window defogger switch is illuminated when turning the rear window defogger switch ON Is the inspection result normal? OK >> Rear window defogger feedback signal is OK NG >> Refer to DEF-46, "Diagnosis Procedure" Diagnosis Procedure INFOID:0000000011365902 1.CHECK REAR WINDOW DEFOGGER FEEDBACK SIGNAL Turn ignition switch ON Check voltage between A/C auto amp (With auto A/C), A/C amp [With manual A/C (Full electrical type)] or A/C control [With manual A/C (Semi electrical type)] harness connector and ground Manual A/C (Full electrical type) A/C amp Connector Terminal M40 35 Condition Ground Rear window defogger switch Voltage ON – 16 V OFF 0–1V Manual A/C (Semi electrical type) A/C control Connector Terminal M39 29 Condition Ground Rear window defogger switch Voltage ON – 16 V OFF 0–1V Auto A/C A/C auto amp Connector Terminal M76 35 Condition Ground Rear window defogger switch Voltage ON – 16 V OFF 0–1V Is the inspection result normal? YES >> Replace A/C amp A/C control or A/C auto amp NO >> Repair or replace harness Revision: 2014 December DEF-46 D23 ALL DEFOGGER SYSTEMS DO NOT OPERATE < SYMPTOM DIAGNOSIS > SYMPTOM DIAGNOSIS A ALL DEFOGGER SYSTEMS DO NOT OPERATE Description INFOID:0000000011365903 B INFOID:0000000011365904 C Check rear window defogger switch Refer to DEF-36, "WITH AUTO A/C : Component Function Check" (With Auto A/C) or DEF-37, "WITH MANUAL A/C : Component Function Check" (With manual A/C) Is the inspection result normal? YES >> GO TO NO >> Repair or replace the malfunctioning parts D 2.CHECK REAR WINDOW DEFOGGER RELAY F Rear window defogger not operate when rear window defogger switch operated Diagnosis Procedure 1.CHECK REAR WINDOW DEFOGGER SWITCH Check rear window defogger relay Refer to DEF-41, "Component Function Check" Is the inspection result normal? YES >> GO TO NO >> Repair or replace the malfunctioning parts E G H 3.CHECK REAR WINDOW DEFOGGER Check rear window defogger Refer to DEF-42, "Component Function Check" Is the inspection result normal? YES >> GO TO NO >> Repair or replace the malfunctioning parts I J 4.CONFIRM THE OPERATION Confirm the operation again Is the inspection result normal? YES >> Check intermittent incident Refer to GI-42, "Intermittent Incident" NO >> GO TO K DEF M N O P Revision: 2014 December DEF-47 D23 REAR WINDOW DEFOGGER INDICATOR DOES NOT ILLUMINATE < SYMPTOM DIAGNOSIS > REAR WINDOW DEFOGGER INDICATOR DOES NOT ILLUMINATE Diagnosis Procedure INFOID:0000000011365906 1.CHECK REAR WINDOW DEFOGGER FEEDBACK SIGNAL Check rear window defogger feedback signal Refer to DEF-46, "Diagnosis Procedure" Is the inspection result normal? YES >> GO TO NO >> Repair or replace the malfunctioning parts 2.CONFIRM THE OPERATION Confirm the operation again Is the inspection result normal? YES >> Check intermittent incident Refer to GI-42, "Intermittent Incident" NO >> GO TO Revision: 2014 December DEF-48 D23 FILAMENT < REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION A FILAMENT Inspection and Repair INFOID:0000000010568003 B INSPECTION When measuring voltage, wrap tin foil around the top of the negative probe Then press the foil against the wire with your finger C D E F SEL122R Attach probe circuit tester (in Volt range) to middle portion of each filament G H I SEL263 J If a filament is burned out, circuit tester registers or battery voltage To locate burned out point, move probe to left and right along filament Test needle swings abruptly when probe passes the point K DEF M N O P SEL265 REPAIR REPAIR EQUIPMENT • Conductive silver composition (Dupont No 4817 or an equivalent) Revision: 2014 December DEF-49 D23 FILAMENT < REMOVAL AND INSTALLATION > • Ruler 30 cm (11.8 in) long • Drawing pen • Heat gun • Alcohol • Cloth REPAIRING PROCEDURE Wipe broken heat wire and its surrounding area clean with a cloth dampened in alcohol Apply a small amount of conductive silver composition to tip of drawing pen Shake silver composition container before use Place ruler on glass along broken line Deposit conductive silver composition on break with drawing pen Slightly overlap existing heat wire on both sides [preferably mm (0.20 in)] of the break PIIA0215E After repair has been completed, check repaired wire for continuity This check should be conducted 10 minutes after silver composition is deposited Do not touch repaired area while test is being conducted SEL012D Apply a constant stream of hot air directly to the repaired area for approximately 20 minutes with a heat gun A minimum distance of cm (1.2 in) should be kept between repaired area and hot air outlet If a heat gun is not available, let the repaired area dry for 24 hours SEL013D Revision: 2014 December DEF-50 D23 CONDENSER < REMOVAL AND INSTALLATION > CONDENSER A Removal and Installation INFOID:0000000010568005 REMOVAL B Remove the rear pillar finisher Refer to INT-39, "REAR PILLAR FINISHER : Removal and Installation" Remove the condenser mounting bolt , and then remove the condenser C D E JSLIA0424ZZ F INSTALLATION Install in the reverse order of removal G H I J K DEF M N O P Revision: 2014 December DEF-51 D23