ON-VEHICLE SERVICE
AT-221
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AT
15. Remove bolts A, B and C from control valve with TCM.
16. Remove control valve with TCM from transmission case.
CAUTION:
When removing, be careful with the manual valve notch and
manual plate height. Remove it vertically.
17. Remove A/T fluid temperature sensor 2 with bracket from con-
trol valve with TCM.
18. Remove bracket from A/T fluid temperature sensor 2.
19. Remove O-ring from A/T assembly harness connector.
Bolt symbol Length [mm (in)] Number of bolts
A42(1.65) 5
B55(2.17) 6
C40(1.57) 1
SCIA5139E
SCIA5142E
SCIA5301E
SCIA5264E
SCIA5155E
AT-270
DISASSEMBLY
33. Disconnect revolution sensor connector.
CAUTION:
Be careful not to damage connector.
34. Straighten terminal clips to free revolution sensor harness.
35. Remove bolts A, B and C from control valve with TCM.
36. Remove control valve with TCM from transmission case.
CAUTION:
When removing, be careful with manual valve notch and
manual plate height. Remove it vertically.
37. Remove A/T fluid temperature sensor 2 with bracket from con-
trol valve with TCM.
SCIA5024E
SCIA7023E
Bolt symbol Length [mm (in)] Number of bolts
A 42 (1.65) 5
B 55 (2.17) 6
C 40 (1.57) 1
SCIA5025E
SCIA5260E
SCIA5301E
BL-1
BODY, LOCK & SECURITY SYSTEM
IBODY
CONTENTS
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SECTIONBL
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BODY, LOCK & SECURITY SYSTEM
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 4
Precautions for procedures with out cowl top cover..... 4
Precautions for Work ................................................ 4
Wiring Diagrams and Trouble Diagnosis .................. 4
PREPARATION ........................................................... 5
Commercial Service Tools ........................................ 5
SQUEAK AND RATTLE TROUBLE DIAGNOSES..... 6
Work Flow ................................................................ 6
CUSTOMER INTERVIEW ..................................... 6
DUPLICATE THE NOISE AND TEST DRIVE ....... 7
CHECK RELATED SERVICE BULLETINS ........... 7
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 7
REPAIR THE CAUSE ........................................... 7
CONFIRM THE REPAIR ....................................... 8
Generic Squeak and Rattle Troubleshooting ........... 8
INSTRUMENT PANEL .......................................... 8
CENTER CONSOLE ............................................. 8
DOORS ................................................................. 8
TRUNK .................................................................. 9
SUNROOF/HEADLINING ..................................... 9
SEATS ................................................................... 9
UNDERHOOD ....................................................... 9
Diagnostic Worksheet ............................................ 10
HOOD ....................................................................... 12
Fitting Adjustment .................................................. 12
LONGITUDINAL AND LATERAL CLEARANCE
ADJUSTMENT .................................................... 13
FRONT END HEIGHT ADJUSTMENT ............... 13
SURFACE HEIGHT ADJUSTMENT ................... 13
Removal and Installation of Hood Assembly .......... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
Removal and Installation of Hood Hinge ................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
Removal and Installation of Hood Lock Control ..... 15REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
Hood Lock Control Inspection ................................ 17
RADIATOR CORE SUPPORT .................................. 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSTALLATION ................................................... 19
FRONT FENDER ...................................................... 20
Removal and Installation ........................................ 20
REMOVAL ........................................................... 20
INSTALLATION ................................................... 20
POWER DOOR LOCK SYSTEM .............................. 21
Component Parts and Harness Connector Location... 21
KING CAB ........................................................... 21
DOUBLE CAB ..................................................... 22
System Description ................................................. 23
OUTLINE ............................................................. 24
CAN Communication System Description .............. 25
CAN Communication Unit ....................................... 25
Schematic ............................................................... 26
Wiring Diagram —D/LOCK— ................................. 27
Terminals and Reference Value for BCM ............... 34
CONSULT-II Function (BCM) ................................. 35
CONSULT-II BASIC OPERATION PROCEDURE
... 35
CONSULT-II APPLICATION ITEMS .................... 36
Work Flow ............................................................... 37
Trouble Diagnoses Chart by Symptom ................... 37
Check Power Supply and Ground Circuit ............... 37
Check Door Switch ................................................. 39
CHECK DOOR SWITCH (DOUBLE CAB) .......... 39
CHECK DOOR SWITCH (KING CAB) ................ 41
Check Key Switch ................................................... 43
Check Door Key Cylinder Switch (LHD Model Only)... 45
Check Front Door Lock Actuator (Driver Side) ....... 48
Check Front Door Lock Actuator (Passenger Side)... 49
Check Front Door Lock Actuator Switch ................. 50
Check Rear Door Lock Actuator LH (Double Cab
Model) ..................................................................... 50
Check Rear Door Lock Actuator RH (Double Cab
HOOD
BL-13
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LONGITUDINAL AND LATERAL CLEARANCE ADJUSTMENT
1. Remove the hood lock, loosen the hood hinge nuts and close the hood.
2. Adjust the lateral and longitudinal clearance, and open the hood to tighten the mounting bolts to the spec-
ified torque.
3. Install the hood lock temporarily, and align the hood striker and lock so that the centers of striker and lock
become vertical viewed from the front, by moving the hood lock laterally.
4. Tighten hood lock mounting bolts to the specified torque.
FRONT END HEIGHT ADJUSTMENT
1. Remove the hood lock and adjust the height by rotating the bumper rubber until the hood becomes 1 to1.5
mm (0.04 to 0.059 in) lower than the fender.
2. Temporarily tighten the hood lock, and position it by engaging it with the hood striker. Check the lock and
striker for looseness, and tighten the hood lock mounting bolts to the specified torque.
CAUTION:
Adjust right/left clearance between hood and each part to the following specification.
SURFACE HEIGHT ADJUSTMENT
1. Remove the hood lock, and adjust the surface height difference of hood, fender and headlamp according
to the fitting standard dimension, by rotating RH and LH bumper rubbers.
2. Install hood lock temporarily, and move hood lock laterally until the centers of striker and lock become ver-
tical when viewed from the front.
3. Check that the hood lock secondary latch is properly engaged with the secondary striker with hood's own
weight.
4. Check that the hood lock primary latch is securely engaged with the hood striker with hood's own weight
by dropping hood from approx. 200 mm (7.87) height.
CAUTION:
Do not drop hood from a height of 300 mm (11.81 in) or more.
5. Move hood lockup and down until striker smoothly engages the lock when the hood is closed.
6. When pulling the hood opener lever gently, make sure that front end of the hood rises by approximately 20
mm (0.79) and that hood striker and hood lock primary latch is disengaged. Also make sure that hood
opener returns to the original position.
7. After adjustment, tighten lock bolts to the specified torque.
CAUTION:
lAfter installing, apply touch-up paint (the body color) onto the head of the hinge mounting nuts.
lAdjust evenness between hood and each part to the following specification.
Portion Clearance
Hood - Front grille A - A (a) 3.7 - 8.3 mm (0.146 - 0.327 in)
Hood - Front fender B - B (c) 3.6 - 5.6 mm (0.142 - 0.220 in)
Hood - Headlamp C - C (e) 6.0 - 8.0 mm (0.236 - 0.315 in)
Portion R / L difference
Hood - Front grille A - A (a) Less than 2.2 mm (0.087 in)
Hood - Front fender B - B (c) Less than 1.0 mm (0.039 In)
Portion Surface height
Hood - Front grille A - A (b) -1.7 - 3.1 mm (-0.067 - 0.122 in)
Hood - Front fender B - B (d) -1.0 - 1.0 mm (-0.039 - 0.039 in)
Hood - Headlamp C - C (f) -1.3 - 2.7 mm (-0.051 - 0.106 in)
HOOD
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Hood Lock Control InspectionEIS00BQ1
CAUTION:
If the hood lock cable is bent or deformed, replace it.
1. Make sure that the hood lock secondary latch is properly engaged with the secondary striker with hood's
own weight.
2. Make sure that the hood lock primary latch is securely engaged with the hood striker with hood's own
weight by dropping it from approx. 200 mm (7.87 in) height.
CAUTION:
Do not drop hood from a height of 300 mm (11.81 in) or more.
3. When pulling hood opener lever gently, make sure that front end
of the hood rises by approximately 20 mm (0.79 in) and that
hood striker and hood lock primary latch are disengaged. Also
make sure that hood opener returns to the original position.
4. Install as static closing face of hood is 392 N·m (35 Kg-m, 253.0
ft-lb) ~ 441 N·m (45 Kg-m, 325.3 ft-lb).
5. Confirm hood lock is properly lubricated. If necessary, apply
grease at the point shown in the figure.
MIIB0639E
MIIB0640E
BL-118
DOOR
FRONT DOOR
Longitudinal Clearance and Surface Height Adjustment at Front End
1. Remove the front fender. Refer toBL-20, "Removal and Installation".
2. Loosen the hinge mounting bolts. Raise or lower the front door at rear end to adjust.
REAR DOOR
Longitudinal Clearance and Surface Height Adjustment at Front End
1. Remove the rear door hinge cover mounting clips, and remove the rear door hinge cover.
2. Loosen the rear door hinge mounting bolts.
3. Open the door, and raise or lower the rear end of the door to adjust.
CAUTION:
After installing, apply touch-up paint (the body color) onto the head of the hinge mounting nuts and
mounting bolts.
STRIKER ADJUSTMENT
Adjust the striker so that it becomes parallel with the lock insertion
direction.
Portion Clearance
Front fender- Front door outer A - A (a) 3.5 - 5.5 mm (0.138 - 0.217 in)
Front door outer - Rear door outer B - B (c) 3.5 - 5.5 mm (0.138 - 0.217 in)
Portion Surface height
Front fender- Front door outer A - A (b) - 1.0 - 1.0 mm (- 0.039 - 0.039 in)
Front door outer - Rear door outer B - B (d) - 1.0 - 1.0 mm (- 0.039 - 0.039 in)
: 16.7 N·m (1.7 kg-m, 12.4 ft-lb)
PIIB2804J
BL-120
DOOR
FRONT DOOR
Longitudinal Clearance and Surface Height Adjustment at Front End
1. Remove the front fender. Refer toBL-20, "Removal and Installation".
2. Loosen the hinge mounting bolts. Raise or lower the front door at rear end to adjust.
REAR DOOR
Longitudinal Clearance and Surface Height Adjustment at Front End
1. Remove the center pillar upper finisher. Refer toEI-35, "CENTER PILLAR UPPER FINISHER".
2. Loosen the lower hinge mounting bolts.
3. From inside the vehicle, loosen the upper hinge mounting nuts. Open the door, and raise or lower the rear
end of the door to adjust.
CAUTION:
After installing, apply touch-up paint (the body color) onto the head of the hinge mounting nuts and
mounting bolts.
STRIKER ADJUSTMENT
Adjust the striker so that it becomes parallel with the lock insertion
direction.
Removal and Installation of Front DoorEIS00B6A
CAUTION:
lWhen removing and installing the front door assembly, support the door with a jack and cloth to
protect the door and body.
lWhen removing and installing front door assembly, be sure to carry out the fitting adjustment
Refer toBL-117, "
Fitting Adjustment (King Cab)"andBL-119, "Fitting Adjustment (Double Cab)".
lCheck the hinge rotating part for poor lubrication. If necessary, apply “body grease”.
lAfter installing, apply touch-up paint (the body color) onto the head of the hinge mounting nuts.
lOperate with two workers, because of its heavy weight.
lAfter installing, check operation.
REMOVAL
1. Remove the front kicking plate and the dash side finisher. Refer toEI-33, "BODY SIDE TRIM".
Portion Clearance
Front fender- Front door outer A - A (a) 3.5 - 5.5 mm (0.138 - 0.217 in)
Front door outer - Rear door outer B - B (c) 3.5 - 5.5 mm (0.138 - 0.217 in)
Portion Surface height
Front fender- Front door outer A - A (b) - 1.0 - 1.0 mm (- 0.039 - 0.039 in)
Front door outer - Rear door outer B - B (d) - 1.0 - 1.0 mm (- 0.039 - 0.039 in)
: 16.7 N·m (1.7 kg-m, 12.4 ft-lb)
PIIB2804J
BR-6
BRAKE PEDAL
BRAKE PEDAL
PFP:46501
Inspection and AdjustmentEFS005SG
Play and clearance inspection between brake pedal and floor panel with pedal depressed.
lCheck brake pedal play.
lCheck brake pedal height from dash lower panel (1).
lAdjust height referring to the following specifications.
SFIA2743J
H1Brake pedal height
(From dash lower panel top surface)LHD
modelA/T182.1-192.1 mm
(7.17-7.56 in)
M/T174.7-184.7 mm
(6.88-7.27 in)
RHD
modelA/T171.2-181.2 mm
(6.74-7.13 in)
M/T164.1-174.1 mm
(6.46-6.85 in)
H
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Brake pedal depressed height
[Under a force of 490 N (50 kg, 110 lb) with engine
running]LHD model 120 mm (4.72 in) or more
RHD model 110 mm (4.33 in) or more
CClearance between bracket (3) and threaded end of the stop lamp
switch (2)0.74-1.96 mm
(0.0291-0.0772 in)
A Pedal play3-11 m m
(0.12-0.43 in)