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VENTILATION, HEATER & AIR CONDITIONER SECTION HAC HEATER & AIR CONDITIONING CONTROL SYSTEM A B C D E CONTENTS AUTOMATIC AIR CONDITIONING Sunload Sensor .19 Refrigerant Pressure Sensor 19 HOW TO USE THIS MANUAL APPLICATION NOTICE Information PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" Precautions for Removing Battery Terminal SYSTEM DESCRIPTION 10 COMPONENT PARTS .10 Component Parts Location 10 HEATER & COOLING UNIT ASSEMBLY 16 HEATER & COOLING UNIT ASSEMBLY : Aspirator 16 HEATER & COOLING UNIT ASSEMBLY : Intake Sensor 16 HEATER & COOLING UNIT ASSEMBLY : Air Mix Door Motor (Driver Side) 17 HEATER & COOLING UNIT ASSEMBLY : Air Mix Door Motor (Passenger Side) 17 HEATER & COOLING UNIT ASSEMBLY : Mode Door Motor 17 HEATER & COOLING UNIT ASSEMBLY : Fan Control Amp 17 BLOWER UNIT 17 BLOWER UNIT : Blower Motor 17 BLOWER UNIT : Intake Door Motor 18 Magnet Clutch 18 A/C Control 18 A/C Auto Amp 19 Ambient Sensor 19 In-vehicle Sensor 19 Revision: 2014 December SYSTEM 21 AUTOMATIC AIR CONDITIONING SYSTEM 21 AUTOMATIC AIR CONDITIONING SYSTEM : System Description 21 AUTOMATIC AIR CONDITIONING SYSTEM : Temperature Control .22 AUTOMATIC AIR CONDITIONING SYSTEM : Air Outlet Control 23 AUTOMATIC AIR CONDITIONING SYSTEM : Air Flow Control 23 AUTOMATIC AIR CONDITIONING SYSTEM : Air Inlet Control .24 AUTOMATIC AIR CONDITIONING SYSTEM : Compressor Control 24 AUTOMATIC AIR CONDITIONING SYSTEM : Door Control 25 AUTOMATIC AIR CONDITIONING SYSTEM : Circuit Diagram 29 AUTOMATIC AIR CONDITIONING SYSTEM : Fail-safe 29 F G H HAC J K L M OPERATION 31 Switch Name and Function 31 DIAGNOSIS SYSTEM (A/C AUTO AMP.) 34 N Description .34 CONSULT Function 34 O DIAGNOSIS SYSTEM (BCM) 36 COMMON ITEM 36 COMMON ITEM : CONSULT Function (BCM COMMON ITEM) (With Intelligent Key) 36 AIR CONDITIONER 37 AIR CONDITIONER : CONSULT Function (BCM AIR CONDITIONER) (Automatic A/C) .37 ECU DIAGNOSIS INFORMATION 39 HAC-1 D23 P A/C AUTO AMP 39 Reference Value 39 Fail-safe 41 DTC Index 42 BCM, ECM, IPDM E/R 43 List of ECU Reference 43 WIRING DIAGRAM 44 AUTOMATIC AIR CONDITIONING SYSTEM 44 DTC Description 79 Diagnosis Procedure 79 B2636, B2637, B2638, B2639, B2654, B2655 MODE DOOR MOTOR 82 DTC Description 82 Diagnosis Procedure 82 B263D, B263E, B263F INTAKE DOOR MOTOR 85 Wiring Diagram 44 DTC Description 85 Diagnosis Procedure 85 BASIC INSPECTION 55 B27B0 A/C AUTO AMP 88 DIAGNOSIS AND REPAIR WORK FLOW 55 DTC Description 88 Diagnosis Procedure 88 Work Flow 55 OPERATION INSPECTION 58 Work Procedure 58 SYSTEM SETTING 60 POWER SUPPLY AND GROUND CIRCUIT 89 A/C AUTO AMP 89 A/C AUTO AMP : Diagnosis Procedure 89 Temperature Setting Trimmer 60 Inlet Port Memory Function (REC) 60 Inlet Port Memory Function (FRE) 61 A/C CONTROL 90 A/C CONTROL : Diagnosis Procedure 90 DTC/CIRCUIT DIAGNOSIS 62 Diagnosis Procedure 91 U1000 CAN COMM CIRCUIT 62 DOOR MOTOR 93 DTC Description 62 Diagnosis Procedure 62 Diagnosis Procedure 93 U1010 CONTROL UNIT (CAN) 63 DTC Description 63 Diagnosis Procedure 63 B2578, B2579 IN-VEHICLE SENSOR 64 DTC Description 64 Diagnosis Procedure 64 Component Inspection 66 B257B, B257C AMBIENT SENSOR 67 DTC Description 67 Diagnosis Procedure 67 Component Inspection 69 B2581, B2582 INTAKE SENSOR 70 A/C CONTROL COMMUNICATION SIGNAL 91 A/C ON SIGNAL 96 Component Function Check 96 Diagnosis Procedure 96 BLOWER FAN ON SIGNAL 98 Component Function Check 98 Diagnosis Procedure 98 BLOWER MOTOR 100 Diagnosis Procedure 100 Component Inspection (Blower Motor) 103 Component Inspection (Blower Relay) 103 Component Inspection (Fan Control Amp.) 103 MAGNET CLUTCH 105 Component Function Check 105 Diagnosis Procedure 105 DTC Description 70 Diagnosis Procedure 70 Component Inspection 72 SYMPTOM DIAGNOSIS 106 B2630, B2631 SUNLOAD SENSOR 73 AUTOMATIC AIR CONDITIONER SYSTEM 106 DTC Description 73 Diagnosis Procedure 73 Symptom Table 106 INSUFFICIENT COOLING 108 B2632, B2633 AIR MIX DOOR MOTOR (DRIVER SIDE) 76 Description 108 Diagnosis Procedure 108 DTC Description 76 Diagnosis Procedure 76 INSUFFICIENT HEATING 109 B2634, B2635 AIR MIX DOOR MOTOR (PASSENGER SIDE) 79 Revision: 2014 December Description 109 Diagnosis Procedure 109 COMPRESSOR DOES NOT OPERATE 110 HAC-2 D23 Description 110 Diagnosis Procedure 110 REMOVAL AND INSTALLATION 111 A/C CONTROL 111 Exploded View 111 Removal and Installation 111 A/C AUTO AMP 112 Removal and Installation 112 AMBIENT SENSOR 113 Component Parts Location 125 HEATER & COOLING UNIT ASSEMBLY 132 HEATER & COOLING UNIT ASSEMBLY : Intake Sensor 132 HEATER & COOLING UNIT ASSEMBLY : Air Mix Door Motor 132 HEATER & COOLING UNIT ASSEMBLY : Mode Door Motor 132 HEATER & COOLING UNIT ASSEMBLY : Fan Control Amp 133 Removal and Installation 115 BLOWER UNIT 133 BLOWER UNIT : Blower Motor 133 BLOWER UNIT : Intake Door Motor 133 Magnet Clutch 133 A/C Control 134 A/C Amp 134 Refrigerant Pressure Sensor 134 INTAKE SENSOR 116 SYSTEM 136 Removal and Installation 113 IN-VEHICLE SENSOR 114 Removal and Installation 114 SUNLOAD SENSOR 115 Exploded View 116 Removal and Installation 116 REFRIGERANT PRESSURE SENSOR 117 Exploded View 117 Removal and Installation 117 FAN CONTROL AMPLIFIER 118 Removal and Installation 118 DOOR MOTOR 119 Exploded View 119 AIR MIX DOOR MOTOR 119 AIR MIX DOOR MOTOR : Removal and Installation 120 INTAKE DOOR MOTOR 120 INTAKE DOOR MOTOR : Removal and Installation 120 MODE DOOR MOTOR 121 MODE DOOR MOTOR : Removal and Installation 121 MANUAL A/C (FULL-ELC.) HOW TO USE THIS MANUAL 122 APPLICATION NOTICE 122 Information 122 PRECAUTION 123 PRECAUTIONS 123 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" 123 Precautions for Removing Battery Terminal 123 SYSTEM DESCRIPTION 125 COMPONENT PARTS 125 Revision: 2014 December System Description 136 Compressor Control 137 Door Control 138 Circuit Diagram 141 Fail-safe 142 A B C D E F G H OPERATION 143 Switch Name and Function 143 HAC DIAGNOSIS SYSTEM (A/C AMP.) 144 Description 144 CONSULT Function 144 DIAGNOSIS SYSTEM (BCM) (WITH INTELLIGENT KEY SYSTEM) 146 COMMON ITEM 146 COMMON ITEM : CONSULT Function (BCM COMMON ITEM) (With Intelligent Key) 146 AIR CONDITIONER 147 AIR CONDITIONER : CONSULT Function (BCM AIR CONDITIONER) [Manual A/C (Full-Electrical Type)] 147 J K L M DIAGNOSIS SYSTEM (BCM) (WITHOUT INTELLIGENT KEY SYSTEM) 149 N COMMON ITEM 149 COMMON ITEM : CONSULT Function (BCM COMMON ITEM) (Without Intelligent Key) 149 O AIR CONDITIONER 149 AIR CONDITIONER : CONSULT Function (BCM AIR CONDITIONER) [Manual A/C (Full-Electrical Type)] 149 ECU DIAGNOSIS INFORMATION 151 A/C AMP 151 Reference Value 151 HAC-3 D23 P Fail-safe 153 DTC Index .153 BCM, ECM, IPDM E/R 154 Diagnosis Procedure 187 BLOWER FAN ON SIGNAL 189 List of ECU Reference 154 Component Function Check 189 Diagnosis Procedure 189 WIRING DIAGRAM 155 BLOWER MOTOR 191 MANUAL AIR CONDITIONING SYSTEM 155 Wiring Diagram 155 BASIC INSPECTION 164 DIAGNOSIS AND REPAIR WORK FLOW 164 Diagnosis Procedure 191 Component Inspection (Blower Motor) 194 Component Inspection (Blower Relay) 194 Component Inspection (Fan Control Amp.) 194 MAGNET CLUTCH 196 Work Flow 164 Component Function Check 196 Diagnosis Procedure 196 OPERATION INSPECTION 167 SYMPTOM DIAGNOSIS 197 Work Procedure .167 DTC/CIRCUIT DIAGNOSIS 169 U1010 CONTROL UNIT (CAN) 169 DTC Description 169 Diagnosis Procedure .169 B2581, B2582 INTAKE SENSOR 170 DTC Description 170 Diagnosis Procedure .170 Component Inspection 172 B2632, B2633 AIR MIX DOOR MOTOR 173 DTC Description 173 Diagnosis Procedure .173 B2636, B2637, B2638, B2639, B2654, B2655 MODE DOOR MOTOR 175 MANUAL AIR CONDITIONING SYSTEM 197 Symptom Table 197 INSUFFICIENT COOLING 199 Description 199 Diagnosis Procedure 199 INSUFFICIENT HEATING 200 Description 200 Diagnosis Procedure 200 COMPRESSOR DOES NOT OPERATE 201 Description 201 Diagnosis Procedure 201 REMOVAL AND INSTALLATION 202 A/C CONTROL 202 DTC Description 175 Diagnosis Procedure .175 Exploded View 202 Removal and Installation 202 B263D, B263F INTAKE DOOR MOTOR 178 A/C AMP 203 DTC Description 178 Diagnosis Procedure .178 Removal and Installation 203 B27B0 A/C AMP 180 DTC Description 180 Diagnosis Procedure .180 POWER SUPPLY AND GROUND CIRCUIT 181 A/C AMP 181 A/C AMP : Diagnosis Procedure 181 A/C CONTROL 182 A/C CONTROL : Diagnosis Procedure 182 A/C CONTROL COMMUNICATION SIGNAL 183 Diagnosis Procedure .183 INTAKE SENSOR 204 Exploded View 204 Removal and Installation 204 REFRIGERANT PRESSURE SENSOR 205 Exploded View 205 Removal and Installation 205 FAN CONTROL AMPLIFIER 206 Exploded View 206 Removal and Installation 206 DOOR MOTOR 207 Exploded View 207 Diagnosis Procedure .185 AIR MIX DOOR MOTOR 207 AIR MIX DOOR MOTOR : Removal and Installation 208 A/C ON SIGNAL 187 INTAKE DOOR MOTOR 208 DOOR MOTOR 185 Component Function Check 187 Revision: 2014 December HAC-4 D23 INTAKE DOOR MOTOR : Removal and Installation 208 MODE DOOR MOTOR 209 MODE DOOR MOTOR : Removal and Installation 209 List of ECU Reference 235 WIRING DIAGRAM 236 MANUAL AIR CONDITIONING SYSTEM 236 Wiring Diagram 236 MANUAL A/C & COOL (SEMI-ELC.) HOW TO USE THIS MANUAL 210 APPLICATION NOTICE 210 Wiring Diagram 245 BASIC INSPECTION 252 PRECAUTION 211 DIAGNOSIS AND REPAIR WORK FLOW 252 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" 211 Precautions for Removing Battery Terminal 211 SYSTEM DESCRIPTION 213 COMPONENT PARTS 213 OPERATION INSPECTION 255 MANUAL AIR CONDITIONING SYSTEM 255 MANUAL AIR CONDITIONING SYSTEM : Work Procedure 255 HEATER & COOLING UNIT ASSEMBLY 219 HEATER & COOLING UNIT ASSEMBLY : Thermo Control Amp 219 HEATER & COOLING UNIT ASSEMBLY : Blower Fan Resistor 219 INTAKE DOOR MOTOR 258 System Description 222 Compressor Control 223 Door Control 224 Circuit Diagram 227 OPERATION 231 Diagnosis Procedure 258 Component Inspection 259 A/C ON SIGNAL 261 Component Function Check 261 Diagnosis Procedure 261 Component Inspection 263 BLOWER MOTOR 264 Diagnosis Procedure 264 Component Inspection (Blower Motor) 266 Component Inspection (Blower Relay) 267 Component Inspection (Blower Fan Resistor) 267 Component Inspection (Fan Switch) 267 MAGNET CLUTCH 269 DIAGNOSIS SYSTEM (BCM) 233 TEMPERATURE CONTROL SIGNAL 270 Description 233 Diagnosis Procedure 270 Component Inspection 270 ECU DIAGNOSIS INFORMATION 235 BCM, ECM, IPDM E/R 235 Revision: 2014 December F G H Diagnosis Procedure 260 Component Function Check 269 Diagnosis Procedure 269 AIR CONDITIONER 234 AIR CONDITIONER : CONSULT Function (BCM AIR CONDITIONER) [Manual A/C and Manual Cooling (Semi-Electrical Type)] 234 E POWER SUPPLY AND GROUND CIRCUIT 260 HAC Switch Name and Function 231 COMMON ITEM 233 COMMON ITEM : CONSULT Function (BCM COMMON ITEM) (Without Intelligent Key) 233 D MANUAL COOLING SYSTEM 256 MANUAL COOLING SYSTEM : Work Procedure 256 DTC/CIRCUIT DIAGNOSIS 258 SYSTEM 222 C Work Flow 252 Component Parts Location 213 BLOWER UNIT 219 BLOWER UNIT : Blower Motor 219 BLOWER UNIT : Intake Door Motor 220 A/C Control 220 Cooler Control 221 Refrigerant Pressure Sensor 221 Magnet Clutch 221 B MANUAL COOLING SYSTEM 245 Information 210 PRECAUTIONS 211 A J K L M N O SYMPTOM DIAGNOSIS 271 MANUAL AIR CONDITIONING SYSTEM 271 Symptom Table 271 MANUAL COOLING SYSTEM 273 Symptom Table 273 INSUFFICIENT COOLING 275 Description 275 HAC-5 D23 P Diagnosis Procedure .275 REFRIGERANT PRESSURE SENSOR 281 INSUFFICIENT HEATING 276 Exploded View 281 Removal and Installation 281 Description .276 Diagnosis Procedure .276 BLOWER FAN RESISTOR 282 COMPRESSOR DOES NOT OPERATE 277 Exploded View 282 Removal and Installation 282 Description .277 Diagnosis Procedure .277 REMOVAL AND INSTALLATION 278 A/C CONTROL 278 Exploded View .278 Removal and Installation .278 COOLER CONTROL 279 Exploded View .279 Removal and Installation .279 THERMO CONTROL AMPLIFIER 280 DOOR CABLE 283 Exploded View 283 AIR MIX DOOR CABLE 283 AIR MIX DOOR CABLE : Removal and Installation 284 INTAKE DOOR MOTOR 284 INTAKE DOOR MOTOR : Removal and Installation 284 MODE DOOR CABLE 284 MODE DOOR CABLE : Removal and Installation 284 Removal and Installation .280 Revision: 2014 December HAC-6 D23 APPLICATION NOTICE [AUTOMATIC AIR CONDITIONING] < HOW TO USE THIS MANUAL > HOW TO USE THIS MANUAL A APPLICATION NOTICE Information INFOID:0000000011117016 B Check the vehicle type to use the service information in this section Service information C Specification AUTOMATIC AIR CONDITIONING Automatic air conditioning system MANUAL A/C (FULL-ELC.) Manual air conditioning system (full-electrical type) (All doors is controlled by motor.) MANUAL A/C & COOL (SEMI-ELC.) Manual air conditioning system and manual cooling system (semi-electrical type) (Only intake door is controlled by motor.) D E F G H HAC J K L M N O P Revision: 2014 December HAC-7 D23 PRECAUTIONS [AUTOMATIC AIR CONDITIONING] < PRECAUTION > PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" INFOID:0000000011117017 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 AIR BAG” and “SEAT BELT” of this Service Manual WARNING: Always observe the following items for preventing accidental activation • To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision that 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 “SRS AIR BAG” • Never 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 harness connectors PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS WARNING: Always observe the following items for preventing accidental activation • When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with a hammer Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury • When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the battery, and wait at least minutes before performing any service Precautions for Removing Battery Terminal INFOID:0000000011874631 When disconnecting the battery terminal, pay attention to the following • Always use a 12V battery as power source • Never disconnect battery terminal while engine is running • When removing the 12V battery terminal, turn OFF the ignition switch and wait at least 30 seconds • For vehicles with the engine listed below, remove the battery terminal after a lapse of the specified time: D4D engine : 20 minutes ZD30DDTi : 60 seconds HRA2DDT : 12 minutes ZD30DDTT : 60 seconds K9K engine : minutes M9R engine : minutes R9M engine : minutes V9X engine : minutes YD25DDTi : minutes SEF289H NOTE: ECU may be active for several tens of seconds after the ignition switch is turned OFF If the battery terminal is removed before ECU stops, then a DTC detection error or ECU data corruption may occur • After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait for at least 15 minutes to remove the battery terminal NOTE: • Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF • Example of high-load driving - Driving for 30 minutes or more at 140 km/h (86 MPH) or more Revision: 2014 December HAC-8 D23 PRECAUTIONS [AUTOMATIC AIR CONDITIONING] < PRECAUTION > - Driving for 30 minutes or more on a steep slope • For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON the ignition switch NOTE: 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 A B C D E F G H HAC J K L M N O P Revision: 2014 December HAC-9 D23 COMPONENT PARTS [AUTOMATIC AIR CONDITIONING] < SYSTEM DESCRIPTION > SYSTEM DESCRIPTION COMPONENT PARTS Component Parts Location INFOID:0000000011117019 RHD MODELS YD Engine Models JMIIA3892ZZ No Component Function ECM ECM, when receiving A/C ON signal and blower fan ON signal from BCM, transmits A/C compressor request signal to IPDM E/R via CAN communication according to status of the engine and refrigerant pressure ECM transmits engine coolant temperature signal to A/C auto amp via CAN communication line Refer to EC-413, "Component Parts Location" for detailed installation location Refrigerant pressure sensor HAC-19, "Refrigerant Pressure Sensor" Ambient sensor HAC-19, "Ambient Sensor" Revision: 2014 December HAC-10 D23 DOOR FINISHER < REMOVAL AND INSTALLATION > a Apply protective tape (A) on inside handle escutcheon to protect it from damage [SINGLE CAB] A B C JMJIB0741ZZ D b Disengage inside handle escutcheon fixing pawls using a remover tool (A), and then remove inside handle escutcheon E : Pawl F G JMJIB0742ZZ Remove snap pin, and then remove regulator handle and regulator sealer NOTE: Insert hook and pick tool (A) between regulator handle and regulator sealer to remove snap pin H I INT JMJIA0491ZZ Disengage fixing pawls using a remover tool (A), and then remove pull handle cap CAUTION: • Use a remover tool wrapped protective tape (B) to protect pull handle cap from damage • Apply shop cloth (C) on door finisher to protect it from damage K L M : Pawl N JMJIB0743ZZ a Remove pull handle Remove door finisher fixing screw O P JMJIB0744ZZ Revision: 2014 December INT-89 D23 DOOR FINISHER [SINGLE CAB] < REMOVAL AND INSTALLATION > b Apply protective tape (A) on door finisher to protect it from damage JMJIB0745ZZ c Disengage pull handle fixing pawls using a remover tool (A), and then remove pull handle : Pawl JMJIB0746ZZ Apply protective tape (A) on door panel to protect it from damage JMJIB0747ZZ Disengage door finisher fixing clips and pawl using a remover tool (A), and then remove door finisher according to numerical order 1→2 indicated by arrows as shown in the figure CAUTION: Insert a remover tool between door panel and clip to disengage fixing clip : Clip : Pawl JMJIB0748ZZ Remove fixing screws, and then remove pull handle bracket INSTALLATION Note the following items, and then install in the reverse order of removal CAUTION: • Always replace door finisher fixing clips with new ones after every removal • Check in advance that clips are accurately aligned with the portions on door panel, and then install by pressing in • If power window main switch is replaced or is removed, it is necessary to perform the initialization procedure Refer to PWC-56, "Work Procedure" Revision: 2014 December INT-90 D23 DOOR FINISHER < REMOVAL AND INSTALLATION > • When installing regulator sealer , check orientation of regulator sealer, and then install it • When installing regulator handle , install snap pin to regulator handle, and then install regulator handle to front door regulator • Visually check snap pin for deformation and damage during installation Replace with a new one if necessary [SINGLE CAB] A B C D E F G JMJIB0757ZZ H I INT K L M N O P Revision: 2014 December INT-91 D23 BODY SIDE TRIM [SINGLE CAB] < REMOVAL AND INSTALLATION > BODY SIDE TRIM Exploded View INFOID:0000000011715006 JMJIB0738ZZ Body side welt Front pillar garnish (driver side) Dash side finisher Kicking plate Back pillar lower garnish Back pillar upper cap Back pillar upper garnish Assist grip cap Assist grip Front pillar garnish (passenger side) : Vehicle front Revision: 2014 December INT-92 D23 BODY SIDE TRIM [SINGLE CAB] < REMOVAL AND INSTALLATION > : Clip A : Pawl : Metal clip B : Always replace after every disassembly FRONT PILLAR GARNISH C FRONT PILLAR GARNISH : Removal and Installation INFOID:0000000011715007 CAUTION: Never damage the body panel D REMOVAL E Driver Side Release front pillar garnish portion of body side welt Disengage front pillar garnish fixing metal clip and anchor clip according to numerical order 1→2 indicated by arrows as shown in the figure F G : Anchor clip : Metal clip H JSJIA0366ZZ Cut anchor clip I INT K L JMJIB0355ZZ M Disengage fixing pawls, and then remove front pillar garnish : Pawl N O JSJIA0297ZZ Remove anchor clips from the body panel Passenger Side Release front pillar garnish portion of body side welt Remove assist grip Revision: 2014 December INT-93 D23 P BODY SIDE TRIM < REMOVAL AND INSTALLATION > a Disengage fixing pawls, and then remove assist grip cap [SINGLE CAB] : Pawl JMJIB0489ZZ b Remove mounting bolts , and then remove assist grip JSJIA0438ZZ Disengage front pillar garnish fixing metal clip : Metal clip JMJIB0759ZZ Disengage fixing pawls, and then remove front pillar garnish : Pawl JMJIB0490ZZ INSTALLATION Note the following items, and then install in the reverse order of removal CAUTION: • Always replace anchor clip with a new one after every removal • Be sure to install anchor clip to front pillar garnish before installing front pillar garnish • Visually check metal clip for deformation and damage during installation Replace with a new one if necessary • Check in advance that anchor clip and metal clip are accurately aligned with the portions on body panel, and then install by pressing in KICKING PLATE Revision: 2014 December INT-94 D23 BODY SIDE TRIM [SINGLE CAB] < REMOVAL AND INSTALLATION > KICKING PLATE : Removal and Installation INFOID:0000000011715008 A CAUTION: Never damage the body panel B REMOVAL Apply protective tape (A) to back pillar lower garnish to protect it from damage C D E JSJIA0367ZZ F Disengage kicking plate fixing pawls, clip and metal clip using a remover tool (A) : Clip G : Pawl : Metal clip H JSJIA0278ZZ Remove kicking plate according to numerical order 1→4 indicated by arrows as shown in the figure, I INT K L JMJIB0494ZZ M INSTALLATION Note the following items, and then install in the following order of removal CAUTION: • Always replace clips with new ones after every removal • Check in advance that clips, pawls and metal clip are accurately aligned with the portions on dash side finisher and the body panel, and then install by pressing in DASH SIDE FINISHER DASH SIDE FINISHER : Removal and Installation INFOID:0000000011715009 CAUTION: Never damage the body panel REMOVAL Remove kicking plate.Refer to INT-95, "KICKING PLATE : Removal and Installation" Revision: 2014 December INT-95 D23 N O P BODY SIDE TRIM < REMOVAL AND INSTALLATION > Disengage fixing metal clips using a remover tool (A) according to numerical order 1→3 indicated by arrows as shown in the figure, and then remove dash side finisher CAUTION: Use a remover tool wrapped in protective tape (B) to protect dash side finisher and the body panel from damage [SINGLE CAB] : Metal clip JSJIA0282ZZ INSTALLATION Note the following items, and then install in the reverse order of removal CAUTION: • Visually check metal clips for deformation and damage during installation Replace with new ones if necessary • Check in advance that metal clips are accurately aligned with the portions on body panel, and then install by pressing in BODY SIDE WELT BODY SIDE WELT : Removal and Installation INFOID:0000000011715010 CAUTION: Never excessively pull body side welt REMOVAL Remove kicking plate Refer to INT-95, "KICKING PLATE : Removal and Installation" Remove body side welt INSTALLATION Install in the reverse order of removal BACK PILLAR LOWER GARNISH BACK PILLAR LOWER GARNISH : Removal and Installation INFOID:0000000011715011 CAUTION: Never damage the body panel REMOVAL Remove seat assembly Refer to SE-45, "Removal and Installation" Remove kicking plate Refer to INT-95, "KICKING PLATE : Removal and Installation" Remove seat belt outer anchor mounting anchor bolt Refer to SB-8, "SEAT BELT RETRACTOR : Removal and Installation" Revision: 2014 December INT-96 D23 BODY SIDE TRIM [SINGLE CAB] < REMOVAL AND INSTALLATION > Disengage fixing pawls and clips according to numerical order 1→3 indicated by arrows as shown in the figure, and then remove back pillar lower garnish A B C D E JMJIB0749ZZ F : Clip : Pawl G : Vehicle front INSTALLATION Note the following items, and then install in the reverse order of removal CAUTION: • Always replace clips with new ones after every removal • Check in advance that clips and pawls are accurately aligned with the portions on the body panel, and then install by pressing in BACK PILLAR UPPER GARNISH INFOID:0000000011715012 K CAUTION: Never damage the body panel REMOVAL I INT BACK PILLAR UPPER GARNISH : Removal and Installation H L Remove back pillar lower garnish Refer to INT-96, "BACK PILLAR LOWER GARNISH : Removal and Installation" Remove seat belt shoulder anchor Refer to SB-8, "SEAT BELT RETRACTOR : Removal and Installation" Disengage fixing pawls, and then remove back pillar upper cap : Pawl M N O P JMJIB0750ZZ Revision: 2014 December INT-97 D23 BODY SIDE TRIM < REMOVAL AND INSTALLATION > Remove back pillar upper garnish mounting bolt [SINGLE CAB] JMJIB0751ZZ Disengage fixing clips and metal clips, and then remove back pillar upper garnish : Clip : Metal clip JMJIB0752ZZ INSTALLATION Note the following items, and then install in the reverse order of removal CAUTION: • Always replace clip with a new one after every removal • Check in advance that clip and metal clips are accurately aligned with the portions on the body panel, and then install by pressing in Revision: 2014 December INT-98 D23 FLOOR TRIM [SINGLE CAB] < REMOVAL AND INSTALLATION > FLOOR TRIM A Exploded View INFOID:0000000011715016 B C D E F G H I JMJIB0740ZZ Carpet hook Foot rest INT Floor carpet Instrument stay cover : Vehicle front K : Clip : Metal clip L Removal and Installation INFOID:0000000011715017 CAUTION: • When removing, always use a remover tool that is made of plastic to prevent damage to the parts • Never damage the body panel REMOVAL Remove seat assembly (LH and RH) Refer to SE-45, "Removal and Installation" Remove seat belt buckle and seat belt tongue Refer to SB-10, "SEAT BELT BUCKLE AND TONGUE : Removal and Installation" Remove kicking plate (LH and RH) Refer to INT-95, "KICKING PLATE : Removal and Installation" Remove dash side finisher (LH and RH) Refer to INT-95, "DASH SIDE FINISHER : Removal and Installation" Remove back pillar lower garnish Refer to INT-96, "BACK PILLAR LOWER GARNISH : Removal and Installation" Remove instrument stay cover Refer to IP-40, "Removal and Installation" Remove heater nozzle (LH and RH) Refer to VTL-13, "FOOT DUCT : Removal and Installation" Revision: 2014 December INT-99 D23 M N O P FLOOR TRIM < REMOVAL AND INSTALLATION > Remove fixing clips , and then remove foot rest [SINGLE CAB] JMJIB0483ZZ Remove floor carpet fixing clip JMJIB0468ZZ 10 Disengage fixing clip using a remover tool (A) according to numerical order 1→2 indicated by arrows as shown in the figure, and then remove carpet hook : Clip JMJIA6083ZZ 11 Remove floor carpet INSTALLATION Install in the reverse order of removal Revision: 2014 December INT-100 D23 HEADLINING [SINGLE CAB] < REMOVAL AND INSTALLATION > HEADLINING A Exploded View INFOID:0000000011715019 B C D E F G H I INT K L M N O JMJIB0739GB Map lamp bracket Headlining assembly Sun visor cover RH Sun visor holder RH Map lamp assembly Sun visor assembly LH Sun visor holder LH Sun visor cover LH P Sun visor assembly RH Assist grip : Clip Revision: 2014 December INT-101 D23 HEADLINING [SINGLE CAB] < REMOVAL AND INSTALLATION > : Pawl : Always replace after every disassembly Removal and Installation INFOID:0000000011715020 CAUTION: • When removing, always use a remover tool that is made of plastic to prevent damage to the parts • Never damage the roof panel REMOVAL a Remove front pillar garnish (LH and RH) Refer to INT-93, "FRONT PILLAR GARNISH : Removal and Installation" Disconnect headlining harness connector and disengage headlining harness fixing clips of front pillar (Driver side) Remove back pillar upper garnish (LH and RH) Refer to INT-97, "BACK PILLAR UPPER GARNISH : Removal and Installation" Remove sun visor assembly (LH and RH) Disengage sun visor cover fixing pawls using a remover tool (A), and then remove sun visor cover : Pawl JMJIA4399ZZ b c Remove sun visor assembly fixing screws, and then slide toward vehicle rear to remove sun visor assembly Disconnect vanity mirror lamp harness connector (if equipped) According to numerical order 1→3 indicated by arrows in the figure, insert a remover tool (A) into the hole of sun visor holder and rotate sun visor holder while pressing the portion of sun visor holder, and then remove sun visor holder JMJIB0482ZZ a Remove map lamp assembly Refer to INL-156, "MAP LAMP : Removal and Installation" Remove assist grip Disengage fixing pawls, and then pull assist grip cap : Pawl JMJIB0469ZZ Revision: 2014 December INT-102 D23 HEADLINING [SINGLE CAB] < REMOVAL AND INSTALLATION > b Remove assist grip mounting bolt grip , and then remove assist A B C JSJIA0295ZZ Remove fixing clips located at the rear side using a remover tool, and then remove headlining assembly from vehicle CAUTION: • Two workers are required for removal in order to prevent damage • Apply protective tape to the portion where contact may occur during work • Never bend headlining when removing D E F G JMJIB0470ZZ INSTALLATION H I Accurately aligned headlining with the roof panel Install sun visor holder Install sun visor assembly in the reverse order of removal Note the following items, and then install in the reverse order of removal CAUTION: • Always replace headlining fixing clips with new ones after every removal • Never bend headlining when installing • Be careful that the surface is not wrinkled when installing INT K L M N O P Revision: 2014 December INT-103 D23