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FUEL FILLER LID OPENERDLK-249
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1. Remove fuel mounting pin (1).
2. Remove mounting TORX bolts, and then remove fuel filler lid.
3. Remove luggage side lower finisher LH. Refer to INT-36, "
LUGGAGE SIDE LOWER FINISHER :
Removal and Installation".
4. Disconnect woofer connector.
5. Remove woofer mounting bolts, and then remove woofer.
6. Rotate lock nut counterclockwise, and then remove lock nut.
7. Push fuel filler lid lock actuator behind the vehicle, while pushing the pawl.
8. Disconnect harness connector and remove fuel filler lid lock actuator.
9. Pull and remove lock & rod assembly forward, while pushing the pawls.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
After installation, check fuel filler li d assembly open/close, lock/unlock operation.
After installation, apply touch-up paint (the body color) onto the head of fuel filler lid mounting
screws.
JMKIA5270ZZ
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DLK-250
< REMOVAL AND INSTALLATION >
KEY CYLINDER
KEY CYLINDER
GLOVE BOX LID KEY CYLINDER
GLOVE BOX LID KEY CYLINDER : Removal and InstallationINFOID:0000000006226112
REMOVAL
1. Remove glove box assembly. Refer to IP-14, "Removal and Installation".
2. Insert mechanical key (1) into glove box lid lock cylinder (2).
3. Set glove box lid release handle (3) to the pulled-up status.
4. Rotate mechanical key and turn glove box lid key cylinder to the lock position.
5. Press tumbler stopper (1) into glove box lid lock cylinder (2) using a hook and pick tool (A), and then remove mechanical key
(3) and glove box lid lock cylinder together from glove box lid
release handle (4).
NOTE:
When removing glove box lid lock cylinder, write a short note
describing its position against glove box lid release handle.
6. Remove sleeve (3) from glove box lid release handle, and then install sleeve to glove box lid lock cylinder.
NOTE:
When removing sleeve, write a short note describing its position
against glove box lid release handle.
CAUTION:
Never pull out mechanical key (1) from glove box lid lock
cylinder (2) while sl eeve is uninstalled. Otherwise, tumbler
(4) pops out of glove box lid lock cylinder.
INSTALLATION
Note the following item, and then install in the reverse order of removal.
CAUTION:
After installation, check glove box assem bly open/close, lock/unlock operation.
JMKIA5490ZZ
JMKIA5491ZZ
JMKIA5819ZZ
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CAB MOUNTING INSULATORDLK-251
< REMOVAL AND INSTALLATION >
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CAB MOUNTING INSULATOR
Exploded ViewINFOID:0000000006226113
Removal and InstallationINFOID:0000000006226114
REMOVAL
1. Set the vehicle position for lifting body assembly using a 2-pole lift. 1. Remove side step. Refer to EXT-45, "
Removal and Installation".
2. For replacing cab mounting insulator, separate body assembly and frame assembly. Because sepa-
rating operation lifts only body assembly, determine the vehicle position by aligning the position of
body side sill portion and arm of 2-pole lift.
CAUTION:
Never lift up by body side sill using 2-pole lift before separating body assembly from frame
assembly. Otherwise, body may be damaged.
2. Set arm of 2-pole lift to lifting point of frame assembly. Refer to GI-33, "
2-Pole Lift".
3. Preparation.
1. Cab mounting insulator (1st) 2. Cab mounting insulator (2nd and 5th)3. Washer
4. Cab mounting insulator (3rd) 5. Cab mo unting insulator (4th) 6. Frame assembly
Refer to GI-4, "
Components" for symbols in the figure.
JMKIA5271GB
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DLK-252
< REMOVAL AND INSTALLATION >
CAB MOUNTING INSULATOR
Drain brake fluid from brake line. Refer to BR-10, "Draining".
Release fuel pressure. Refer to EC-153, "
Work Procedure".
Disconnect both battery cables. Refer to PG-164, "
Removal and Installation".
Drain engine coolant from radiator. Refer to CO-8, "
Draining".
Discharge refrigerant from A/C circuit. Refer to HA-20, "
Recycle Refrigerant".
Drain power steering fluid from reservoir tank.
4. Remove parts relating to connection of body assembly and frame assembly. Tire and wheel: Refer to WT-64, "
Removal and Installation" (with TPMS).
Front fender protector (LH and RH): Refer to EXT-23, "
FENDER PROTECTOR : Removal and Installa-
tion".
Front bumper: Refer to EXT-13, "
Removal and Installation".
Radiator core support upper: Refer to DLK-220, "
Removal and Installation".
Fan shroud: Refer to CO-16, "
Removal and Installation".
Battery and battery case: Refer to PG-164, "
Removal and Installation".
Air cleaner case (upper and lower): Refer to EM-27, "
Removal and Installation".
Engine cover: Refer to EM-25, "
Removal and Installation".
Rear wheel house protector (LH and RH): EXT-24, "
REAR WHEEL HOUSE PROTECTOR : Removal
and Installation".
Rear bumper: Refer to EXT-17, "
Removal and Installation".
Fuel filler tube: Remove to FL-8, "
Exploded View".
Spare tire
Towing hook bracket.
5. Separate parts relating to connection of body assembly and frame assembly. Vehicle front
Disconnect ICC sensor connector. (models with ICC) Refer to CCS-176, "
Removal and Installation".
Remove radiator upper hose and radiator lower hose from radiator assembly. Refer to CO-13,
"Exploded View".
Remove A/T fluid cooler hose B and A/T fluid cooler hose E from A/T fluid cooler tubes. Refer to TM-
202, "Exploded View".
Remove power steering return hose from oil cooler, and then power steering return hose clamp bolt from frame assembly. Refer to ST-54, "
Exploded View".
Remove power steering suction hose from reservoir tank. Refer to ST-54, "
Exploded View".
CAUTION:
Never spill power steering fluid in engine room.
Remove A/C low-presser flexible hose from A/C low-presser pipe. Refer to HA-35, "
LOW-PRESSURE
FLEXIBLE HOSE : Removal and Installation".
Remove A/C hi-presser flexible hose from condenser. Refer to HA-34, "
HIGH-PRESSURE FLEXIBLE
HOSE : Removal and Installation".
Remove all engine Control Harness connectors, har ness clips and others that are connected to the
body assembly side of the engine room. (engine room LH and RH side). Refer to PG-148, "
Engine Con-
trol Harness".
NOTE:
Separate harness connectors from ECM (engine control module). Refer to EC-10, "
General Precau-
tions".
CAUTION:
When pulling out harnesses, never damage harnesses or connectors.
After temporarily securing connectors, cover th em with vinyl or similar material to protect
against adhesion of foreign materials.
Disconnect engine room harness connectors and remo ve harness clips from engine assembly (engine
RH side). Refer to PG-146, "
Engine Room Harness".
Remove heater hoses from front water outlet tube (engine room RH side). Refer to HA-33, "
Exploded
View".
Disconnect front wheel sensor connectors (LH and RH). Refer to BRC-134, "
FRONT WHEEL SENSOR
: Exploded View".
Disconnect fuel feed tube and EVAP hos e (front wheel well LH side).
Remove steering lower shaft from steering gear side assembly. Refer to ST-37, "
Removal and Installa-
tion"
CAUTION:
Spiral cable may be cut if steering wheel turns while separating steering column assembly and
steering gear assembly.
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CAB MOUNTING INSULATORDLK-253
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Remove brake tube from connector (front wheel well LH and RH side). Refer to BR-22, "FRONT :
Exploded View"
Vehicle center side
Remove A/T control cable from manual lever. Refer to TM-178, "
Removal and Installation".
Separate parking brake rear cable (LH and RH) from parking brake front cable. Refer to PB-5, "
Removal
and Installation".
Remove engine room harness connector (frame assembly RH center side). Refer to PG-146, "
Engine
Room Harness"
- Remove harness connector protector.
- Disconnect chassis harness connector from engine room harness connector.
- Remove harness bracket bolt, and then remove engi ne room harness connector from frame assembly.
Vehicle rear side
Remove EVAP hose (canister side).
Remove rear final drive breather hose from air breather tube (body side). Refer to DLN-201, "
Removal
and Installation".
Disconnect body harness connector from chassis harness connectors (frame assembly LH rear side).
Refer to PG-150, "
Body Harness"
6. Set safety stand to frame assembly. Release arm of 2-pole lift.
7. Remove cab mounting insulator bolts.
8. Set arm of 2-pole lift to body side sill portion of body.
9. Slowly lift 2-pole lift.
CAUTION:
Check that there is no inte rference with the vehicle.
Check that all connection points are disconnected.
10. Remove cab mounting insulator.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
Before starting engine, check oil/fl uid levels including engine coolant and engine oil. If levels are
less than the required quantity, fill to the specified level. Refer to MA-10, "
Fluids and Lubricants".
Warm up engine thoroughly to check that there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
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DLK-254
< REMOVAL AND INSTALLATION >
DOOR SWITCH
DOOR SWITCH
Removal and InstallationINFOID:0000000006226115
REMOVAL
Remove the door switch mounting bolt, and then remove door switch.
INSTALLATION
Install in the reverse order of removal.
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DOOR REQUEST SWITCHDLK-255
< REMOVAL AND INSTALLATION >
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DOOR REQUEST SWITCH
DRIVER SIDE
DRIVER SIDE : Remova l and InstallationINFOID:0000000006226116
REMOVAL
Remove the driver side outside handle. Refer to DLK-241, "OUTSIDE HANDLE : Removal and Installation".
INSTALLATION
Install in the reverse order of removal.
PASSENGER SIDE
PASSENGER SIDE : Removal and InstallationINFOID:0000000006226117
REMOVAL
Remove the passenger side outside handle. Refer to DLK-241, "OUTSIDE HANDLE : Removal and Installa-
tion".
INSTALLATION
Install in the reverse order of removal.
BACK DOOR
BACK DOOR : Removal and InstallationINFOID:0000000006226118
REMOVAL
Remove the back door finisher. Refer to INT-39, "Removal and Installation".
INSTALLATION
Install in the reverse order of removal.
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DLK-256
< REMOVAL AND INSTALLATION >
INSIDE KEY ANTENNA
INSIDE KEY ANTENNA
INSTRUMENT CENTER
INSTRUMENT CENTER : Removal and InstallationINFOID:0000000006226119
REMOVAL
1. Remove the cluster lid C. Refer to IP-14, "Removal and Installation".
2. Remove the inside key antenna (instrument cente r) mounting screw, and then remove inside key antenna
(instrument center).
INSTALLATION
Install in the reverse order of removal.
CONSOLE
CONSOLE : Removal and InstallationINFOID:0000000006226120
REMOVAL
1. Remove the console rear finisher. Refer to IP-29, "Removal and Installation".
2. Remove the inside key antenna (console) mounting screw, and then remove inside key antenna (con- sole).
INSTALLATION
Install in the reverse order of removal.
LUGGAGE ROOM
LUGGAGE ROOM : Removal and InstallationINFOID:0000000006226121
REMOVAL
1. Remove the second seat seatback. Refer to SE-126, "SEATBACK : Disassembly and Assembly".
2. Remove the inside key antenna (luggage room) mounting clip, and then remove inside ke\
y antenna (lug- gage room).
INSTALLATION
Install in the reverse order of removal.
Revision: 2010 May2011 QX56