Workshop Manual: TF Series

WORKSHOP MANUAL
TF SERIES
CAB
SECTION 10
CAB 10-1
SECTION 10
CAB
TABLE OF CONTENTS
PAGE Windshield..........................................................................................................................10- 2 Rear Window Assembly ....................................................................................................10- 7 Front Door Assembly ........................................................................................................10- 10 Rear Door Assembly (Crew Cab)......................................................................................10- 20 Instrument Panel................................................................................................................10- 28 Floor Console.....................................................................................................................10- 34 Console Box (Without Floor Console) .............................................................................10- 38 Headlining ..........................................................................................................................10- 39 Interior Trim Panels ........................................................................................................... 10- 44 Fuel Filler Lid Opener Lever/Cable...................................................................................10- 55 Quarter Glass (Extend Cab) ..............................................................................................10- 70 Font Seat ............................................................................................................................10- 71 Rear Seat (Crew Cab) ........................................................................................................10- 74 Jump Seat (Extend Cab) ...................................................................................................10- 75 Front Seat Belt ...................................................................................................................10- 76 Rear Seat Belt (Crew Cab) ................................................................................................10- 80 Rear Seat Belt (Extend Cab) .............................................................................................10- 84 Front Wheel Extension......................................................................................................10- 87 Rear Wheel Extension .......................................................................................................10- 88 Tail Gate Assembly............................................................................................................10- 89
10-2 CAB
WINDSHIELD
REMOVAL
RTW4A0LF000901
Removal Steps
1. Interior trim panels (Front side) /Headlining/Instrument panel assembly 2. Wiper arm assembly L 3. Room mirror 4. Side moulding 5. Vent cowl cover 6. Windshield stopper 7. Upper moulding L 8. Windshield glass 9. Engine hood rear seal
CAB 10-3
Important Operations - Removal

3. Room Mirror Remove the screw and pull the room mirror to upper side.
8. Windshield Glass Remove the windshield glass, carefully following the steps listed below: 1) Use a knife to cut through part of the adhesive caulking material. 2) Secure one end of a piece of steel piano wire (0.02 inches in diameter) to a piece of wood that can serve as a handle. 3) Use a pair of needle nose pliers to insert the other end of the piano wire through the adhesive caulking material at the edge of the windshield glass. 4) Secure the other end of the piano wire to another piece of wood. 5) With the aid of an assistant, carefully move the piano wire with a sawing motion to cut through the adhesive caulking material around the entire circumference of the windshield glass. 6) Lift the windshield from the body. 7) Clean any remaining adhesive caulking material from the area of the body which holds the windshield. 8) Use a soft rag and unleaded gasoline to wipe off any adhesive remaining on the windshield glass.
10-4 CAB
INSTALLATION
RTW4A0LF001201
Installation Steps
L 1. Engine hood rear seal 2. Upper moulding L 3. Windshield glass 4. Windshield stopper 5. Vent cowl cover 6. Side moulding 7. Room mirror L 8. Wiper arm assembly 9. Interior trim panels (Front side) /Headlining/Instrument panel assembly
CAB 10-5
Important Operations - Installation

1. Engine Hood Rear Seal Install the engine hood rear seal as shown in the illustration. 1 : Seal 2 : Clip 3 : Rear (windshield glass side) 4 : Front
3. Windshield Glass 1) Clean the windshield glass bonding surface. 2) Use a soft rag and unleaded gasoline to wipe off any adhesive remaining on the body. 3) Mount the body window glass as shown in the illustration. Attach spacers at five locations. Always use new spacer. 4) Install the windshield upper molding. Peel off the tear-away paper from the windshield upper molding, and start applying it with one end of the glass and cut away the surplus at the other end of the glass for length adjustment. Always use new upper molding. 5) Temporary install the windshield support. 6) Apply primer 1 Sunstar #435-98 or equivalent to the body side bonding surface. The primer should extend at least 25 mm (1 in). Apply primer Sunstar #435-40 or equivalent to the windshield glass side bonding surface. The primer should extend 16.5 mm (0.6 in) and 25 mm (1.0 in) from end of the glass.
RTW3A0SH000201
10-6 CAB 7) Apply the window glass sealing adhesive 2 . If you are using an air gun, air pressure should be maintained at 147 - 294 kpa. After drying primer completely, apply a sealing adhesive (Sunstar #557 or equivalent) along the edge of the glass so that the sealing adhesive has a 20 mm (0.79 in) junction at middle of the vase of the glass. Note : Open time (1 min. or more) should be set after application of the primer. Bonding shall be done within 5 minutes after the sealing adhesive has been applied.
8) Adjust the setting of the windshield glass with suction discs. Set the windshield with sealing adhesive applied to entire circumference in the body panel. Specifically, adjust windshield support with the upper molding making contact with the body panel, press the glass, and tighten the windshield support.
9) Use unleaded gasoline and a soft cloth to wipe away any excess adhesive. Cure the bonding at a temperature of 68 - 86 F (20 30 C) for twenty-four hours. Check that the windshield does not leak water. 8. Wiper Arm Assembly Set the wiper arm/blade so that the tips of both blades are positioned the specified value of A and B from the upper edge of the cowl cover as shown in the figure.
A B
40 mm (1.57 in) 52 mm (2.05 in)
Tighten the wiper arm assembly fixing nuts to the specified torque. Torque 31 (3.1/23) N m (kgf m/lb ft)
CAB 10-7
REAR WINDOW ASSEMBLY

REMOVE AND INSTALLATION
Removal Steps
1. Interior trim panels/Headlining 2. Rear defogger connector (W/Rear defogger) L 3. Rear window
Installation Steps
L 3. Rear window 2. Rear defogger connector (W/Rear defogger) 1. Interior trim panels/Headlining
10-8 CAB
Important Operation - Removal

3. Rear Window Glass Remove the glass, carefully following the steps listed below : 1) Use a knife to cut through part of the adhesive caulking material. 2) Secure one end of a piece of steel piano wire (0.02 inches in diameter) to a piece of wood that can serve as a handle. 3) Use a pair of needle nose pliers to insert the other end of the piano wire through the adhesive caulking material at the edge of the rear window glass. 4) Secure the other end of the piano wire to another piece of wood. 5) With the aid of an assistant, carefully move the piano wire with a sawing motion to cut through the adhesive caulking material around the entire circumference of the rear window glass. 6) Lift the rear window glass from the body. 7) Clean any remaining adhesive caulking material from the area of the body which holds the rear window glass. 8) Use a soft rag and unleaded gasoline to wipe off any adhesive remaining on the rear window glass.
Important Operation - Installation

3. Rear Window Glass 1) Clean the rear window glass bonding surface. 2) Use a soft rag and unleaded gasoline to wipe off any adhesive remaining on the body. 3) Install the fastener tape to body panel flange. 4) Apply primer 1 sunster #435-40 or equivalent to the rear window glass side bonding surface. The primer should extend 23 mm (0.9 in.) form end of the glass.
CAB 10-9 5) Apply the rear window glass seling adhesive 2 . If you are using an air gun, air pressure should be maintained at 147 294 kpa. After drying primer completely, apply a sealing adhesive (Sunstar #557 or equivalent) along the edge of the glass so that the sealing adhesive has a 20 mm (0.79 in.) junction at left corner of the base of the glass. Note: Open time (1 min. or more) should be set after application of the primer. Bonding shall be done within 5 minutes after the sealing adhesive has been applied. 6) Insert the glass supports into the panel and then push the glass against the panel to affix it in place. Wipe away any adhesive that oozes out around the edges. 7) Check that the rear window glass does not leak water.
10-10 CAB
FRONT DOOR ASSEMBLY

REMOVAL AND INSTALLATION
This illustration is based on RHD model
Removal Steps
L 1. Door harness L 2. Checker arm screw L 3. Lower hinge bolt 4. Upper hinge bolt 5. Door assembly
Installation Steps
5. Door assembly 4. Upper hinge bolt L 3. Lower hinge bolt L 2. Check arm screw 1. Door harness

1. Door Harness Remove the harness bracket and disconnect the door harness connectors.
CAB 10-11 2. Check Arm Screw
3. Lower Hinge Bolt Position a wood block under the door for protection and support the door assembly with hands at removal or installation.
Important Operations Installation

3. Lower Hinge Bolt; Hinge to Door Torque 34 (3.5/25) 2. Check Arm Screw; Check Arm to Body Torque 24 (2.4/17) N m (kgf m/lb ft)
N m (kgf m/lb ft)
10-12 CAB
DISASSEMBLY

RTW4A0LF000701
Disassembly Steps
L 1. Switch bezel/Window regulator handle L 2. Power window switch L 3. Bezel L 4. Door mirror cover L 5. Door trim panel L 6. Tweeter (Required Option) L 7. Door mirror assembly L 8. Outer waste seal L 9. Bracket L10. Speaker assembly L11. Waterproof sheet L12. Inside lever L13. Window glass L14. Window regulator/Power window regulator L 15. Glass run L 16. Glass run rear channel / Glass ran rear channel with Door lock control or Anti theft (EC) L 17. Door lock assembly/Door lock assembly with super lock L 18. Outside handle protector (EUROPE) L 19. Outside handle L 20. Door lock cylinder protector (EUROPE) L 21. Door lock cylinder / Door lock cylinder with door lock switch (EC) 22. Door harness assembly 23. Anti rattler
CAB 10-13
Important Operations
1. Switch Bezel/Window Regulator Handle Remove the 2 screws and disconnect the connectors.
To remove the regulator handle, remove the clip at the root of the handle by using wire.
2. Power Window Switch Remove the 3 screws. 3. Bezel Remove the screw.
4. Door Mirror Cover Pull out the upper clip, and then take out the cover upward. 5. Door Trim Panel Pull out the trim panel at the 8 clip positions (Power window type).
10-14 CAB Remove the 2 screws and pull out the trim panel at the 8 clip positions (Window regulator handle type).
6. Tweeter (Required option) Disconnect the tweeter harness connector and remove the 3 screws.
RTW3A0SH000701
7. Door Mirror Assembly Remove 3 fixing bolts and then remove the connector. 8. Outer Waste Seal
9. Bracket 10.Speaker Assembly Remove the fixing screw and then remove the connector. 11.Waterproof Sheet Take care not to damage the sheet when peeling it off. 12.Inside Lever Disconnect the door lock cables.
CAB 10-15 13.Window Glass Remove 2 bolts through the access hole and pull out the window glass upward. 14.Window Regulator/Power Window Regulator Remove the 4 fixing bolts and the 2 fixing nuts. Disconnect the power window motor connector. 15.Glass Run Pull it out from the door frame of the channel. 16.Glass Run Rear Channel Remove the bolt. Bolt is removed after removing door lock cylinder switch harness. (Expect EC)
17.Door Lock Assembly Disconnect the lock cable from the anti rattler. Remove the 3 fixing screws and the bolt. Disconnect the linkage at the outside handle and the lock cylinder. Disconnect the harness connector.
18.Outside Handle Protector (EUROPE) Remove the fixing bolt from the outside handle. 19.Outside Handle 20.Door Lock Cylinder Protector (EUROPE) Remove the fixing bolt from the outside handle. 21.Door Lock Cylinder Remove the 2 fixing bolts from the outside handle.
10-16 CAB
REASSEMBLY

RTW4A0LF000801
Reassembly Steps
1. Anti rattler 2. Door harness assembly L 3. Door lock cylinder / Door lock cylinder with door lock switch (EC) L 4. Door lock cylinder protector (EUROPE) L 5. Outside handle L 6. Outside handle protector (EUROPE) 7. Door lock assembly / Door lock assembly with super lock 8. Glass run rear channel / Glass ran rear channel with Door lock control or Anti theft (EC) 9. Glass run 10. Window regulator / Power window regulator L 11. Window glass 12. Inside lever 13. Waterproof sheet 14. Speaker assembly 15. Bracket 16. Outer waste seal 17. Door mirror assembly 18. Tweeter (Required option) 19. Door trim panel 20. Door mirror cover 21. Bezel 22. Power window switch L 23. Switch bezel / Window regulator handle
CAB 10-17
3. Door Lock Cylinder Tighten the door lock cylinder fixing bolts to the specified torque. Torque 9 (0.9/78) N m (kgf m/lb in)
4. Door Lock Cylinder Protector (EUROPE) Tighten the door lock cylinder protector fixing bolt to the specified torque. Torque 9 (0.9/78) 5. Outside Handle Tighten the outside handle fixing bolts to the specified torque. Torque 9 (0.9/78) 6. Outside Handle Protector (EUROPE) Tighten the outside handle protector fixing bolt to the specified torque. Torque 9 (0.9/78) 11.Window Glass Insert the window glass into position by tilting it as necessary, then set it against the channel of the window regulator. N m (kgf m/lb in) N m (kgf m/lb in) N m (kgf m/lb in)
Attach the window glass to the window regulator with the 2 bolts.
10-18 CAB 23.Window Regulator Handle Install the regulator handle as illustrated when closing the window glass.
CAB 10-19
ADJUSTMENT (FRONT)
Door Hinge
Door alignment can be obtained by moving door hinges. Prior to adjustment, remove the fender and set the door temporarily. Loosen hinge to door bolts when adjusting steps between the door and body. Loosen hinge to body bolts to adjust the clearance between the door and body.
Door Striker
Loosen the striker screws and adjust the position of the striker by holding a piece of wood against the striker and tapping it with a hammer. To obtain correct adjustment, move the position of the striker vertically so that the lower face of the dovetail becomes parallel to the striker.
10-20 CAB
REAR DOOR ASSEMBLY (CREW CAB)

Removal Steps
L 1. Door harness L 2. Checker arm screw L 3. Lower hinge bolt 4. Upper hinge bolt 5. Door assembly
Installation Steps
5. Door assembly 4. Upper hinge bolt L 3. Lower hinge bolt L 2. Check arm screw 1. Door harness

1. Door Harness Remove the center pillar lower trim cover and disconnect the door harness connector.
2. Check Arm Screw
CAB 10-21 3. Lower Hinge Bolt Position a wood block under the door for protection and support the door assembly with hands at removal or installation.

3. Lower Hinge Bolt; Hinge to Door Torque 34 (3.5/25) 2. Check Arm Screw; Check Arm to Body Torque 24 (2.4/17) N m (kgf m/lb ft)
N m (kgf m/lb ft)
10-22 CAB
DISASSEMBLY
RTW3A0LF000601
Disassembly Steps
L L L L L L L L L 1. Switch bezel/Window regulator handle 2. Power window switch 3. Bezel 4. Door trim panel 5. Bracket 6. Speaker assembly 7. Waterproof sheet 8. Inside lever 9. Outer waste seal L 10. Window regulator/Power window regulator L 11. Glass run rear channel L 12. Door lock assembly L 13. Glass run L 14. Window glass L 15. Outside handle 16. Door harness assembly 17. Anti rattler
CAB 10-23
1. Switch Bezel/Window Regulator Handle Remove the 2 screws and disconnect the connector.
RTW3A0SH000401
To remove the regulator handle, remove the clip at the root of the handle by using wire.
2. Power Window Switch Pry the 4 clip positions. 3. Bezel Remove the screw. 4. Door Trim Panel Pull out the trim panel at the 7 clip positions (Power window type).
RTQ3A0SH000501
Remove the 2 screws and pull out the trim panel at the 7 clip positions (Window regulator handle type).
10-24 CAB 5. Bracket 6. Speaker assembly Remove the fixing bolt and then remove the connector. 7. Waterproof Sheet Take care not to damage the sheet when peeling it off. 8. Inside Lever Disconnect the door lock cables. 9. Outer Waste Seal 10.Window Regulator/Power Window Regulator Remove the 2 bolts fixing the window glass through the access hole. Move the window glass upward and hold it with adhesive tape. Remove the 5 bolts fixing the window regulator. Disconnect the power window motor connector. 11.Glass Run Rear Channel Remove the bolt. 12.Door Lock Assembly Disconnect the lock cable from the anti rattler. Remove the 3 fixing screws and the bolt. Disconnect the linkage and harness connector. 13.Glass Run Remove the adhesive tape and move the window glass downward. Pull it out from the door frame of the channel. 14.Window Glass Pull out the window glass upward. 15.Outside Handle Remove the 2 fixing bolts.
CAB 10-25
REASSEMBLY
RTW3A0LF000701
Reassembly Steps
1. Anti rattler 2. Door harness assembly L 3. Outside handle 4. Window glass 5. Glass run 6. Door lock assembly 7. Glass run rear channel 8. Window regulator/Power window regulator 9. Outer waste seal 10. Inside lever 11. Waterproof sheet 12. Speaker assembly 13. Bracket 14. Door trim panel 15. Bezel 16. Power window switch L 17. Switch bezel/Window regulator handle
10-26 CAB
3. Outside Handle Tighten the outside handle fixing bolts to the specified torque. Torque 9 (0.9/78) N m (kgf m/lb in)
17.Window Regulator Handle Install the regulator handle as illustrated when closing the window glass.
CAB 10-27
ADJUSTMENT (REAR) Door Hinge

Door alignment can be obtained by moving door hinges. Prior to adjustment, set the door temporarily. Loosen hinge to door bolts when adjusting steps between the door and body. Loosen hinge to body bolts to adjust the clearance between the door and body.
Door Striker
Loosen the striker screws and adjust the position of the striker by holding a piece of wood against the striker and tapping it with a hammer. To obtain correct adjustment, move the position of the striker vertically so that the lower face of the dovetail becomes parallel to the striker.
10-28 CAB
INSTRUMENT PANEL
REMOVAL

RTW4A0LF001001
Disassembly Steps
L 1. Front console assembly L 2. Glove box L 3. Instrument panel driver lower cover assembly L 4. Driver knee bolster assembly L 5. Driver air bag L 6. Steering wheel/ steering cowl L 7. Meter cluster assembly 8. Dash side trim cover 9. Front pillar trim cover 10. Front cover 11. Side cover L 12. Instrument panel & Cross beam assembly
L 13. Ashtray case L 14. Center cluster assembly L 15. Control lever assembly 16. Storage box assembly L 17. Ashtray bracket 18. Meter assembly 19. Passenger lower bracket 20. Glove box cover L 21. Passenger air bag (if so equipped) L 22. Side ventilation grille L 23. Vent duct assembly/Defroster nozzle assembly 24. Instrument harness assembly L 25. Instrument panel L 26. Cross beam
CAB 10-29
1. Front Console Assembly Refer to Floor Consol in this section. 2. Glove Box Remove 2 fixing screws and pulling the handle.
3. Instrument Panel Driver Lower Cover Assembly 1) Remove the engine hood opener 2 fixing screws. 2) Remove the lower cover one fixing screw. 3) Pull out the cover (Stick type parking brake only). 4) Pull out the lower cover assembly.
4. Driver Knee Bolster Assembly Remove 4 fixing bolts. Caution: For precaution on installation or removal of SRS-air bag system, refer to section 9 Supplemental Restraint System (SRS) - AIR BAG 5. Driver Air Bag 6. Steering Wheel/Steering Cowl Refer to Section 3B STEERING COLUMN for steering lock assembly removal steps. 7. Meter Cluster Assembly Pull out the 4 clip positions.
10-30 CAB 12.Instrument Panel & Cross Beam Assembly 1) Remove the two bolts fixing the steering column to the cross beam and the two bolts fixing the brake pedal bracket to the cross beam.
2) Remove the two bolts fixing the parking brake bracket to the cross beam (Stick type parking brake only).
3) Disconnect the control cables at the blower unit and heater unit. Remove the front & side cover from the instrument panel. 4) Remove the fasteners fixing the instrument panel & cross beam assembly to the body panel.
5) Disconnect the instrument harness connectors.
CAB 10-31 13.Ashtray Case Pull out the ashtray case. 14.Center Cluster Assembly 1) Pull out the cluster at the 6 clip positions. 2) Disconnect the cigarette lighter, accessory socket, hazard switch and clock connectors. 15.Control Lever Assembly Remove the 2 fixing screws. 17.Ashtray Bracket Remove the 3 fixing screws and illumination connector. Caution: For precautions on installation or removal of SRS-air bag system, refer to section 9 "Supplemental Restraint System (SRS) - AIR BAG". 21.Passenger Air Bag Remove 2 fixing bolts, 2 fixing nuts and connector. 22.Side Ventilation Grille. Pull out the grilles and disconnect switch connector (Drivers side). 23.Vent Duct Assembly/Defroster Nozzle Assembly Refer to section 1 HVAC for defroster nozzle and ventilation duct removal steps. 25.Instrument Panel Remove the clip and 6 fixing bolts. 26.Cross Beam
10-32 CAB
INSTALLATION

RTW4A0LF001101
Installation Steps
1. Cross beam 2. Instrument panel 3. Instrument harness assembly 4. Vent duct assembly/Defroster nozzle assembly 5. Side ventilation grille 6. Passenger air bag 7. Glove box cover 8. Passenger lower bracket 9. Meter assembly 10. Ashtray bracket 11. Storage box assembly 12. Control lever assembly 13. Center cluster assembly 14. Ashtray case L 15. Instrument panel & Cross beam assembly 16. Side cover 17. Front cover 18. Front pillar trim cover 19. Dash side trim cover 20. Meter cluster assembly L 21. Steering wheel/Steering cowl 22. Driver air bag 23. Driver knee bolster assembly 24. Instrument panel driver lower cover assembly 25. Glove box 26. Front console assembly
CAB 10-33
15.Instrument Panel & Crass Beam Assembly 1) Tighten the 4 bolts fixing the cross beam and body panel to the specified torque. Torque N m (kgf m/lb ft) 19 (1.9/14) 2) A Bolt: Steering Column to Cross Beam Torque 20 (2.0/14) B Bolt: Pedal Bracket to Cross Beam Torque 15 (1.5/11) N m (kgf m/lb ft) N m (kgf m/lb ft)
3) C Bolt: Parking Brake Bracket to Cross Beam Torque 15 (1.5/11) N m (kgf m/lb ft)
21.Steering Wheel/Steering Cowl Tighten the steering wheel fixing nut to the specified truque. Torque 35 (3.6/26) N m (kgf m/lb ft)
10-34 CAB
FLOOR CONSOLE
745R300001
A/T Model
Removal Steps
L 1. Rear floor console (Bucket seat model only) L 2. Front floor console 3. A/T switch
Installation Steps
3. A/T switch 2. Front floor console 1. Rear floor console (Bucket seat model only)
CAB 10-35

1. Rear Floor Console (Bucket Seat Model Only) 1) Open the rear console lid and remove 2 screws. 2) Pull out the front part of rear console at the 2 clip positions. 2. Front Floor Console 1) Remove the 2 screws. 2) Pull out the rear part of front console at the 2 clip positions and disconnect the switch connecter. 3) Remove the front console by pull out it rear ward.
10-36 CAB
745r300002
M/T Model
Removal Steps
L 1. Rear floor console (Bucket seat model only) 2. Shift knob L 3. Front floor console
Installation Steps
3. Front floor console 2. Shift knob 1. Rear floor console (Bucket seat model only)
CAB 10-37

1. Rear Floor Console (Bucket Seat Model Only) 1) Open the rear console lid and remove 2 screws. 2) Pull out the front part of rear console at the 2 clip positions. 3. Front Floor Console 1) Remove the 2 screws. 2) Pull out the rear part of front console at the 2 clip positions. 3) Remove the front console by pull out it rear ward.
10-38 CAB
CONSOLE BOX (WITHOUT FLOOR CONSOLE)

RTW4A0MF000201
M/T Model
Removal Steps
1. Screw 2. Console box
Installation Steps
2. Console box 1. Screw
CAB 10-39
HEADLINING
EXTEND CAB Model
Removal Steps
L L L L 1. Interior trim panels 2. Sunvisor/Sunvisor holder 3. Spot light 4. Assist grip 5. Hole cover L 6. Coat hook L 7. Dome light L 8. Headlining
Installation Steps
8. Headlining 7. Dome light 6. Coat hook 5. Hole cover 4. Assist grip 3. Spot light 2. Sunvisor/Sunvisor holder 1. Interior trim panels
10-40 CAB

RTW3A0LF001101
REGULAR CAB Model
Removal Steps
L 1. Interior trim panels L 2. Sunvisor/Sunvisor holder L 4. Assist grip 5. Hole cover L 7. Dome light L 8. Headlining
Installation Steps
8. Headlining 7. Dome light 5. Hole cover 4. Assist grip 2. Sunvisor/Sunvisor holder 1. Interior trim panels
CAB 10-41

RTW3A0LF001001
CREW CAB Model
Removal Steps
L L L L 1. Interior trim panels 2. Sunvisor/Sunvisor holder 3. Spot light 4. Assist grip 5. Hole cover L 6. Coat hook L 7. Dome light L 8. Headlining
Installation Steps
8. Headlining 7. Dome light 6. Coat hook 5. Hole cover 4. Assist grip 3. Spot light 2. Sunvisor/Sunvisor holder 1. Interior trim panels
10-42 CAB

1. Interior Trim Panels Refer to Interior Trim Panels in this section. 2. Sunvisor/Sunvisor Holder 1) Remove the 2 screws fixing the sunvisor. 2) Remove the screw fixing the sunvisor holder. 3. Spot Light Pull out the spot light and disconnect the connector.
4. Assist Grip Remove the 2 fixing screw.
6. Coat Hook Open the cover and remove the fixing screw.
7. Dome Light 1) Remove the dome light lens and the fixing screws. 2) Disconnect the dome light connector.
CAB 10-43 8. Headlining Pull out the headlining with the retainer from roof rear header panel as direction of shown in the illustration. Note : Remove steps (2-7) can be removed from the headlining in any order.
10-44 CAB
INTERIOR TRIM PANELS

RTW3A0MF001301
EXTEND CAB Model
Removal Steps
1. Sill plate 2. Dash side trim cover L 3. Front pillar trim cover L 4. Rear upper cushion 5. Jack cover L 6. Rear end trim cover L 7. Rear speaker grille/Rear speaker L 8. Body side rear lower trim cover 9. Door finisher L10. Tongue side seat belt L11. Body side rear upper trim cover
Installation Steps
11. Body side rear upper trim cover L 10. Torque side seat belt 9. Door finisher 8. Body side rear lower trim cover 7. Rear speaker grille/Rear speaker L 6. Rear end trim cover 5. Jack cover 4. Rear upper cushion 3. Front pillar trim assembly 2. Dash side trim cover 1. Sill plate
CAB 10-45

3. Front Pillar Trim Cover Turn up the finisher and pry the trim cover clips free from the body panel. Then remove the trim cover by pulling upward at the lower part of it.
4. Rear Upper Cushion Slide the upper cushion upward to remove it. 6. Rear End Trim Cover Pry the trim cover clips free from the body panel, and slide the trim cover upward to remove it.
7. Rear Speaker Grille/Rear Speaker 1) Remove the rear speaker grille (1). 2) Remove the 3 screws fixing the rear speaker (2) and disconnect the connector (3).
8. Body Side Rear Lower Trim Cover Pry the trim cover clips free from the body panel.
10-46 CAB 10. Tongue Side Seat Belt 1) Pull out the adjuster knob. 2) Open the through ring anchor cover and remove the seat belt upper anchor bolt.
RTW3A0SH000301
11. Body Side Rear Upper Trim Cover Pry the trim cover clips free from the body panel.
CAB 10-47

10. Tongue Side Seat Belt Tighten the seat belt upper anchor bolt to the specified torque. Torque 40 (4.1/30) 6. Rear End Trim Cover Insert the hooks on the back upper portion of trim cover to the body panel. N m (kgf m/lb ft)
10-48 CAB
RTW40MF000301
REGULAR CAB Model
Removal Steps
L L L L L 1. Sill plate 2. Dash side trim cover 3. Body side rear lower trim cover 4. Door finisher 5. Front pillar trim cover 6. Rear end trim cover 7. Tongue side seat belt 8. Body side rear upper trim cover
Installation Steps
8. Body side rear upper trim cover L 7. Tongue side seat belt L 6. Rear end trim cover 5. Front pillar trim cover 4. Door finisher 3. Body side rear lower trim cover 2. Dash side trim cover 1. Sill plate
CAB 10-49

5. Front Pillar Trim Cover Turn up the finisher and pry the trim cover clips free from the body panel. Then remove the trim cover by pulling upward at the lower part of it.
6. Rear End Trim Cover Pry the trim cover clips free from the body panel, and slide the trim cover upward to remove it.
7. Tongue Side Seat Belt 1) Pull out the adjuster knob. 2) Open the through ring anchor cover and remove the seat belt upper anchor bolt.
RTW3A0SH000301
10-50 CAB 8. Body Side Rear Upper Trim Cover Pry the trim cover clips free from the body panel.

7. Tongue Side Seat Belt Tighten the seat belt upper anchor bolt to the specified torque. Torque 40 (4.1/30) 6. Rear End Trim Cover Insert the hooks on the back upper portion of trim cover to the body panel. N m (kgf m/lb ft)
CAB 10-51
RTW4A0MF000401
CREW CAB Model
Removal Steps
L 1. Front sill plate/Rear sill plate 2. Dash side trim cover L 3. Front pillar trim cover L 4. Center pillar lower trim cover 5. Front door finisher 6. Cover L 7. Rear end trim cover L 8. Body side rear lower trim cover 9. Rear door finisher L10. Front tongue side seat belt L11. Center pillar upper trim cover 12. Rear tongue side seat belt L 13. Body side rear upper trim cover
Installation Steps
13. Body side rear upper trim cover L 12. Rear tongue side seat belt 11. Center pillar upper trim cover L10. Front tongue side seat belt 9 Rear door finisher 8. Body side rear lower trim cover L 7. Rear end trim cover 6. Cover 5. Front door finisher 4. Center pillar lower trim cover 3. Front pillar trim cover 2. Dash side trim cover 1. Front sill plate/Rear sill plate
10-52 CAB

1. Front Sill Plate/Rear Sill Plate Pull out the 4 clip positions (Front). Pull out the 2 clip positions (Rear).
3. Front Pillar Trim Cover Turn up the finisher and pry the trim cover clips free from the body panel. Then remove the trim cover by pulling upward a the lower part of it.
4. Center Pillar Lower Trim Cover Pry the trim cover lips free from the body panel.
7. Rear End Trim Cover Pry the trim cover clips free from the body panel, and slide the trim cover upward to remove it.
10.Front Tongue Side Seat Belt
CAB 10-53 1) Pull out the adjuster knob. 2) Open the through ring anchor cover and remove the seat belt upper anchor bolt.
RTW3A0SH000301
11.Center Pillar Upper Trim Cover Pry the trim cover clips free from the body panel.
13.Body Side Rear Upper Trim Cover Pry the trim cover clips free from the body panel.

12. Rear Tongue Side Seat Belt Tighten the seat belt upper anchor bolt to the specified torque. Torque 40 (4.1/30) N m (kgf m/lb ft)
10-54 CAB 10. Front Tongue Side Seat Belt Tighten the seat belt upper anchor bolt to the specified torque. Torque 40 (4.1/30) N m (kgf m/lb ft)
7. Rear End Trim Cover Insert the hooks on the back upper portion of trim cover to the body panel.
CAB 10-55
FUEL FILLER LID OPENER LEVER/CABLE

REMOVAL (REGULAR CAB RHD MODEL)
686R300015
Removal Steps
L 1. Front sill plate L 2. Fuel filler lid opener cover L 3. Fuel filler lid opener lever 4. Rear wheel housing extension panel L 5. Fuel filler lid cable assembly
10-56 CAB

REMOVAL (EXTEND CAB RHD MODEL)
686R300016
Removal Steps
CAB 10-57

REMOVAL (REGULAR CAB LHD MODEL)
RTW4A0LF000101
Removal Steps
10-58 CAB

REMOVAL (EXTEND CAB LHD MODEL)
RTW4A0LF000201
Removal Steps
CAB 10-59

1. Front Sill Plate Pull out the 4 clip positions.
2. Fuel Filler Lid Opener Cover Pull out the 3 clip positions.
3. Fuel Filler Lid Opener Lever Remove the 2 opener fixing bolts and disconnect the cable.
5. Fuel Filler Lid Cable Assembly Remove some fixing clips, turn the cable holder on the side of recess in 90 counterclockwise and remove it from the recess. Pull out the grommet to frontward of vehicle and remove the cable assembly.
10-60 CAB

REMOVAL (CREW CAB RHD MODEL)
686R300010
Removal Steps
L 1. Front sill plate L 2. Rear sill plate 3. Center pillar lower trim cover L 4. Fuel filler lid opener cover L 5. Fuel filler lid opener lever 6. Rear wheel housing extension panel L 7. Fuel filler lid cable assembly
CAB 10-61

REMOVAL (CREW CAB LHD MODEL)
RTW4A0LF000301
Removal Steps
L 1. Front sill plate L 2. Rear sill plate 3. Center pillar lower trim cover L 4. Fuel filler lid opener cover L 5. Fuel filler lid opener lever 6. Rear wheel housing extension panel L 7. Fuel filler lid cable assembly
10-62 CAB

1. Front Sill Plate Pull out 4 clip positions. 2. Rear Sill Plate Pull out 2 clip positions.
4. Fuel Filler Lid Opener Cover Pull out the 3 clip positions.
5. Fuel Filler Lid Opener Lever Remove the 2 opener fixing bolts and disconnect the cable.
7. Fuel Filler Lid Cable Assembly Remove some fixing clips, turn the cable holder on the side of recess in 90 counterclockwise and remove it from the recess. Pull out the grommet to frontward of vehicle and remove the cable assembly.
CAB 10-63
INSTALLATION (REGULAR CAB RHD MODEL)
686R300017
Installation Steps
L 1. Fuel filler lid cable assembly 2. Rear wheel housing extension panel 3. Fuel filler lid opener lever 4. Fuel filler lid opener cover 5. Front sill plate
10-64 CAB
INSTALLATION (EXTEND CAB RHD MODEL)
686R300019
Installation Steps
CAB 10-65
INSTALLATION (CREW CAB RHD MODEL)
686R300013
Installation Steps
L 1. Fuel filler lid cable assembly 2. Rear wheel housing extension panel 3. Fuel filler lid opener lever 4. Fuel filler lid opener cover 5. Center pillar lower trim cover 6. Rear sill plate 7. Front sill plate
10-66 CAB
INSTALLATION (REGULAR CAB LHD MODEL)
RTW4A0LF000401
Installation Steps
CAB 10-67
INSTALLATION (EXTEND CAB LHD MODEL)
RTW4A0LF000501
Installation Steps
10-68 CAB
INSTALLATION (CREW CAB LHD MODEL)
RTW4A0LF000601
Installation Steps
L 1. Fuel filler lid cable assembly 2. Rear wheel housing extension panel 3. Fuel filler lid opener lever 4. Fuel filler lid opener cover 5. Center pillar lower trim cover 6. Rear sill plate 7. Front sill plate
CAB 10-69

1. Fuel Filler Lid Cable Assembly Install the cable holder of cable assembly to the recess and push the grommet in to the back panel. Fix the clips to the pointed places. Note: To install, follow the removal steps in the reverse order, noting the following points. Do not make extreme curve on the cable. Install the cable from inside of the cab.
10-70 CAB
QUARTER GLASS (EXTEND CAB)

RTW4A0MF000101
Removal Steps
L 1. Body side rear trim covers 2. Hinge/Faster 3. Quarter glass 4. Weather strip
Installation Steps
L 4. Weather strip 3. Quarter glass 2. Hinge/Faster 1. Body side rear trim covers

1. Body Side Rear Trim Covers Refer to Interior Trim Panels in this section.
Important Operation Installation

4. Weather Strip Install the weather strip by aligning to corners with white mark to the upper coners on the body panel.
CAB 10-71
FRONT SEAT
RTW3A0MF000301
Removal Steps
L 1. Front cover 2. Rear cover 3. Bolt L 4. Seat assembly L 5. Side seat belt buckle/Pretensioner seat belt/Center seat belt 6. Seat adjuster
Installation Steps
6. Seat adjuster L 5. Side seat belt buckle/Pretensioner seat belt/Center seat belt 4. Seat assembly L 3. Bolt 2. Rear cover 1. Front cover
10-72 CAB

1. Front Cover While pushing the cover downward, pull it. 4. Seat Assembly Disconnect the seat belt warning harness connector (Drivers side only). 5. Side Seat Belt Buckle/Pretensioner Seat Belt/Center Seat Belt Remove the seat belt fixing screw and the warning harness connector clip (Bucket seat model).
Remove the pretensioner seat belt fixing screw and the warning harness connector (With pretensioner seat belt model).
RTW4A0SH000101-X
Remove the seat belt fixing screws and the warning harness connector clip (Bench seat model).
24.jpg

5. Buckle Side Seat Belt/Pretensioner Seat Belt/Center Seat Belt Tighten the seat belt fixing screws to the specified torque. Torque 40 (4.1 / 30) N m (kgf m/lb ft)
CAB 10-73 3. Bolt: Seat Assembly to Floor Panel The fixing procedure of a bolt (1) Front inboard (2) Front outboard (3) Rear inboard (4) Rear inboard Torque 40 (4.1 / 30)
N m (kgf m/lb ft)
10-74 CAB
REAR SEAT (CREW CAB)

RTW3A0SF000101
Removal Steps
L 1. Nut 2. Rear seat assembly
Installation Steps
2. Rear seat assembly L 1. Nut

1. Nut Pull the strap to release the seat back lock and fold down the seat back.

1. Nut Torque 40 (4.1 / 30) N m (kgf m/lb ft)
CAB 10-75
JUMP SEAT (EXTEND CAB)

RTW3A0MF001201
Removal Steps
1. Cover 2. Bolt 3. Jump seat assembly 4. Storage box
Installation Steps
4. Storage box 3. Jump seat assembly L 2. Bolt 1. Cover

2. Bolt Bolt Torque 40 (4.1 / 30) N m (kg m/lb ft)
10-76 CAB
FRONT SEAT BELT

REMOVAL AND INSTALLATION (TONGUE SIDE SEAT BELT)
Removal Steps
1. Body side rear lower trim cover 2. Lower anchor bolt L 3. Knob L 4. Upper anchor bolt 5. Retractor fixing bolt 6. Body side rear upper trim cover 7. Adjustable shoulder anchor fixing bolts
Installation Steps
L 7. Adjustable shoulder anchor fixing bolts 6. Body side rear upper trim cover L 5. Retractor fixing bolt L 4. Upper anchor bolt 3. Knob L 2. Lower anchor bolt 1. Body side rear lower trim cover
CAB 10-77

3. Knob Pull out the knob. 4. Upper anchor bolt Open the through ring anchor cover and remove the seat belt upper anchor bolt.
RTW3A0SH000301

7. Adjustable shoulder anchor fixing bolts Bolt torque N m (kgf m/lb ft) 40 (4.1 / 30) 5. Retractor fixing bolt Bolt torque 40 (4.1 / 30) 4. Upper anchor bolt Bolt torque 40 (4.1 / 30) 2. Lower anchor bolt Bolt torque 40 (4.1 / 30) N m (kgf m/lb ft) N m (kgf m/lb ft) N m (kgf m/lb ft)
10-78 CAB
REMOVAL AND INSTALLATION (SIDE SEAT BELT BUCKLE/PRETENSIONER SEAT BELT/ CENTER SEAT BELT)
RTW3A0MF000401
Removal Steps
L 1. Front seat assembly L 2. Side seat belt buckle/Pretensioner seat belt/Center seat belt
Installation Steps
L 2. Side seat belt buckle/Pretensioner seat belt/Center seat belt L 1. Front seat assembly
CAB 10-79

1. Front Seat Assembly Refer to Front Seat in this section. 2. Side Seat Belt Buckle/Pretensioner Seat Belt/Center Seat Belt Remove the seat belt fixing screw and the warning harness connector clip (Bucket seat model).
Remove the pretensioner seat belt fixing screw and the warning harness connector (With pretensioner seat belt model).
RTW4A0SH000101-X
Remove the seat belt fixing screws and the warning harness connector clip (Bench seat model).
24.jpg

2. Side Seat Belt Buckle/Pretensioner Seat Belt /Center Seat Belt Tighten the seat belt fixing screws to the specified torque. Torque 40 (4.1 / 30) 1. Front Seat Assembly Tighten the seat assembly fixing bolts to the specified torque. Torque 40 (4.1 / 30) N m (kgf m/lb ft) N m (kgf m/lb ft)
10-80 CAB
REAR SEAT BELT (CREW CAB)

Removal Steps
1. Body side rear lower trim cover 2. Lower anchor bolt L 3. Knob L 4. Upper anchor bolt 5. Retractor fixing bolt 6. Body side rear upper trim cover 7. Adjustable shoulder anchor fixing bolts
Installation Steps
L 7. Adjustable shoulder anchor fixing bolts 6. Body side rear upper trim cover L 5. Retractor fixing bolt L 4. Upper anchor bolt 3. Knob L 2. Lower anchor bolt 1. Body side rear lower trim cover
CAB 10-81

3. Knob Pull out the knob. 4. Upper anchor bolt Open the through ring anchor cover and remove the seat belt upper anchor bolt.
RTW3A0SH000301

7. Adjustable shoulder anchor fixing bolts Bolt torque N m (kgf m/lb ft) 40 (4.1 / 30) 5. Retractor fixing bolt Bolt torque 40 (4.1 / 30) 4. Upper anchor bolt Bolt torque 40 (4.1 / 30) 2. Lower anchor bolt Bolt torque 40 (4.1 / 30) N m (kgf m/lb ft) N m (kgf m/lb ft) N m (kgf m/lb ft)
10-82 CAB
REMOVAL AND INSTALLATION (REAR CENTER SEAT BELT/REAR SEAT BELT BACKLE)
RTW3A0LF000901
Removal Steps
1. Nut 2. Rear seat belt buckle L 3. Cover L 4. Rear end trim cover 5. Bolt 6. Rear center seat belt
Installation Steps
L 6. Rear center seat belt L 5. Bolt 4. Rear end trim cover 3. Cover 2. Rear seat belt buckle L 1. Nut
CAB 10-83

3. Cover Pry the lower portion of the cover and remove it.
RTW3A0SH000601
4. Rear End Trim Cover Refer to Interior Trim Panels in this section.

6. Rear center seat belt Install the seat belt webbing through the through ring on the back panel as shown in the illustration.
RTW3A0SH001601
5. Bolt: Rear Center Seat Belt to Floor Panel Torque N m (kgf m/lb ft) 40 (4.1 / 30) 1. Nut: Rear Seat Assembly/Rear Seat Belt Buckle to Floor Panel Torque N m (kgf m/lb ft) 40 (4.1 / 30)
10-84 CAB
REAR SEAT BELT (EXTEND CAB)

RTW3A0MF000701
Removal Steps
L 1. Body side rear lower trim cover 2. Lower anchor bolt L 3. Upper anchor bolt 4. Retractor fixing bolt
Installation Steps
L 4. Retractor fixing bolt L 3. Upper anchor bolt L 2. Lower anchor bolt 1. Body side rear lower trim cover
CAB 10-85

1. Body side rear lower trim cover Refer to Interior Trim Panels in this section.. 3. Upper anchor bolt Open the through ring anchor cover and remove the seat belt upper anchor bolt
RTW3A0SH000301

4. Retractor fixing bolt Bolt torque 40 (4.1 / 30) 3. Upper anchor bolt Bolt torque 40 (4.1 / 30) 2. Lower anchor bolt Bolt torque 40 (4.1 / 30) N m (kgf m/lb ft) N m (kgf m/lb ft) N m (kgf m/lb ft)
10-86 CAB
REMOVAL AND INSTALLATION (REAR SEAT BELT BACKLE)
RTW3A0SF000201
Removal Steps
L 1. Cover 2. Bolt 3. Rear seat belt buckle
Installation Steps
3. Rear seat belt buckle L 2. Bolt 1. Cover

1. Cover Refer to Jump Seat (Extend Cab) in this section.
2. Bolt: Jump Seat Assembly/Rear Seat Belt Buckle to Floor Panel Torque N m (kgf m/lb ft) 40 (4.1 / 30)
CAB 10-87
FRONT WHEEL EXTENTION

Removal Steps
1. Screw L 2. Front wheel extension
Installation Steps
2. Front wheel extension 1. Screw

2. Front Wheel Extension pull out the 5 clip positions
10-88 CAB
REAR WHEEL EXTENTION

RTW4A0MF000501
Removal Steps
1. Screw L 2. Rear wheel extension
Installation Steps
2. Rear wheel extension 1. Screw

2. Rear Wheel Extension Pull out the 6 clip positions (Extend cab) Pull out the 5 clip positions (Crew cab)
CAB 10-89
TAIL GATE ASSEMBLY

CENTER PULL HANDLE MODEL
Removal Steps
Installation Steps
L 7. Tail gate lock striker L 6. Tail gate hinge L 5. Tail gate 4. Tail gate link L 3. Tail gate lock assembly L 2. Outside handle assembly 1. Hole cover plate
1. Hole cover plate L 2. Outside handle assembly 3. Tail gate lock assembly 4. Tail gate link L 5. Tail gate 6. Tail gate hinge 7. Tail gate lock striker
10-90 CAB

2. Outside Handle Assembly Disconnect the lock link and remove the 2 fixing bolts. 5. Tail Gate 1) Removing the tailgate assembly may require two people. 2) Remove the tailgate hinge fixing bolts.

7. Tail Gate Lock Striker Tighten the lock striker fixing bolts to the specified torque. Torque 15 (1.5 / 11) 6. Tail Gate Hinge Tighten the hinge fixing bolts to the specified torque. C: Bolt Torque 40 (4.1 / 30) 5. Tail Gate 1) A: Bolts Torque 13 (1.3 / 113) 2) B: Bolt Torque 25 (2.5 / 18) 3) Check the tailgate and rear body. a. Clearance: 5.0 mm (0.20 in.) b. Height (Step): Flush c. Height (Step): Flush 3. Tail Gate Lock Assembly Tighten the lock assembly fixing bolts to the specified torque. Torque 15 (1.5 / 11) 2. Outside Handle Assembly Tighten the outside handle assembly fixing bolts to the specified torque and if remove the key cylinder (if equipped) tighten it to the specified torque. Torque 9 (0.9 / 78) N m(kgf m/lb in) N m(kgf m/lb ft) N m(kgf m/lb in) N m(kgf m/lb in) N m(kgf m/lb ft) N m(kgf m/lb ft)
No. TFCAB-WE-0431

Workshop Manual: TF Series

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Workshop Manual: TF Series

Hochgeladen von

Copyright:

Verfügbare Formate

WORKSHOP MANUAL

Important Operations - Removal

Important Operations - Installation

40 mm (1.57 in) 52 mm (2.05 in)

REAR WINDOW ASSEMBLY

Important Operation - Removal

Important Operation - Installation

FRONT DOOR ASSEMBLY

This illustration is based on RHD model

Important Operations - Removal

CAB 10-11 2. Check Arm Screw

Important Operations Installation

N m (kgf m/lb ft)

This illustration is based on RHD model

This illustration is based on RHD model

REAR DOOR ASSEMBLY (CREW CAB)

Important Operations - Removal

2. Check Arm Screw

Important Operations Installation

N m (kgf m/lb ft)

ADJUSTMENT (REAR) Door Hinge

This illustration is based on RHD model

5) Disconnect the instrument harness connectors.

This illustration is based on RHD model

Important Operations - Removal

REMOVAL AND INSTALLATION

Important Operations - Removal

CONSOLE BOX (WITHOUT FLOOR CONSOLE)

This illustration is based on RHD model

EXTEND CAB Model

REMOVAL AND INSTALLATION

This illustration is based on RHD model

REGULAR CAB Model

REMOVAL AND INSTALLATION

This illustration is based on RHD model

CREW CAB Model

Important Operations - Removal

4. Assist Grip Remove the 2 fixing screw.

INTERIOR TRIM PANELS

EXTEND CAB Model

Important Operations - Removal

Important Operations - Installation

REMOVAL AND INSTALLATION

REGULAR CAB Model

Important Operations - Removal

Important Operations - Installation

REMOVAL AND INSTALLATION

CREW CAB Model

Important Operations - Removal

10.Front Tongue Side Seat Belt

Important Operations - Installation

FUEL FILLER LID OPENER LEVER/CABLE

FUEL FILLER LID OPENER LEVER/CABLE

FUEL FILLER LID OPENER LEVER/CABLE

FUEL FILLER LID OPENER LEVER/CABLE

Important Operations - Removal

FUEL FILLER LID OPENER LEVER/CABLE

FUEL FILLER LID OPENER LEVER/CABLE

Important Operations - Removal

INSTALLATION (REGULAR CAB RHD MODEL)

INSTALLATION (EXTEND CAB RHD MODEL)

INSTALLATION (CREW CAB RHD MODEL)

INSTALLATION (REGULAR CAB LHD MODEL)