Body Repair: Section

BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY
SECTION BRM BODY REPAIR

B
E
CONTENTS
KING CAB FOR THAILAND .........................................................32 F
FOR THAILAND : Undercoating ..............................32
VEHICLE INFORMATION ............................. 6 FOR THAILAND : Stone Guard Coat ......................33
FOR THAILAND : Body Sealing ..............................35 G
BODY EXTERIOR PAINT COLOR ..................... 6
Body Exterior Paint Color ....................................... 6 FOR AUSTRALIA AND NEW ZEALAND ..................40
FOR AUSTRALIA AND NEW ZEALAND : Under-
PRECAUTION ............................................... 8 coating .....................................................................41 H
FOR AUSTRALIA AND NEW ZEALAND : Stone
PRECAUTIONS ................................................... 8 Guard Coat ..............................................................41
Precautions for Removing Battery Terminal ............. 8 FOR AUSTRALIA AND NEW ZEALAND : Body I
REPAIRING HIGH STRENGTH STEEL .............. 9 Sealing .....................................................................43
High Strength Steel (HSS) ........................................ 9 BODY CONSTRUCTION .................................. 49
J
PREPARATION ........................................... 13 FOR THAILAND .........................................................49
FOR THAILAND : Body Construction ......................49
REPAIRING MATERIAL ....................................13
Foam Repair ........................................................... 13 FOR AUSTRALIA AND NEW ZEALAND ..................50 BRM
FOR AUSTRALIA AND NEW ZEALAND : Body
BODY COMPONENT PARTS ............................15 Construction ............................................................51
FOR THAILAND ........................................................ 15 L
REPLACEMENT OPERATIONS ....................... 53
FOR THAILAND : Underbody Component Parts .... 15 Description ...............................................................53
FOR THAILAND : Body Component Parts .............. 16
FOR THAILAND : Rear Body Component Parts .... 18 FOR THAILAND .........................................................54 M
FOR THAILAND : Frame Component Parts ........... 20 FOR THAILAND : Radiator Core Support ...............55
FOR THAILAND : Hoodledge ..................................55
FOR AUSTRALIA AND NEW ZEALAND .................. 23
FOR THAILAND : Hoodledge (Partial Replace- N
ment) .......................................................................56
body Component Parts ........................................... 23
FOR THAILAND : Front Pillar ..................................57
FOR THAILAND : Outer Sill (Partial Replacement)
Component Parts .................................................... 24 O
....61
FOR AUSTRALIA AND NEW ZEALAND : Rear
FOR THAILAND : Outer Sill ....................................62
Body Component Parts ........................................... 26
FOR THAILAND : Rear Cab Pillar ...........................62
FOR AUSTRALIA AND NEW ZEALAND : Frame P
FOR THAILAND : Back Panel .................................65
Component Parts .................................................... 28
FOR THAILAND : Rear Body Fender ......................66
REMOVAL AND INSTALLATION ............... 32 FOR THAILAND : Rear Crossmember ....................67
FOR THAILAND : Crush Horn .................................68
CORROSION PROTECTION .............................32 FOR THAILAND : Roof ............................................70
Description .............................................................. 32
FOR AUSTRALIA AND NEW ZEALAND ..................70
Revision: August 2015 BRM-1 D23

FOR AUSTRALIA AND NEW ZEALAND : Radia- DOUBLE CAB
tor Core Support ..................................................... 71
FOR AUSTRALIA AND NEW ZEALAND : Hoo- VEHICLE INFORMATION ......................... 113
dledge ..................................................................... 71
FOR AUSTRALIA AND NEW ZEALAND : Hoo- BODY EXTERIOR PAINT COLOR ................... 113
dledge (Partial Replacement) ................................. 72 Body Exterior Paint Color ................................... 113
FOR AUSTRALIA AND NEW ZEALAND : Front
Pillar ........................................................................ 73
PRECAUTION ........................................... 115
FOR AUSTRALIA AND NEW ZEALAND : Outer PRECAUTIONS ................................................ 115
Sill (Partial Replacement) ....................................... 77 Precautions for Removing Battery Terminal ......... 115
FOR AUSTRALIA AND NEW ZEALAND :
Outer Sill ................................................................ 78 REPAIRING HIGH STRENGTH STEEL ........... 116
FOR AUSTRALIA AND NEW ZEALAND : Rear High Strength Steel (HSS) .................................... 116
Cab Pillar ................................................................ 78
FOR AUSTRALIA AND NEW ZEALAND : Back PREPARATION ......................................... 120
Panel ...................................................................... 81
FOR AUSTRALIA AND NEW ZEALAND : Rear REPAIRING MATERIAL ................................... 120
Body Fender ........................................................... 82 Foam Repair ......................................................... 120
FOR AUSTRALIA AND NEW ZEALAND : Rear BODY COMPONENT PARTS .......................... 122
Crossmember ......................................................... 83
FOR AUSTRALIA AND NEW ZEALAND : Crush LHD .......................................................................... 122
Horn ........................................................................ 84 LHD : Underbody Component Parts ..................... 122
FOR AUSTRALIA AND NEW ZEALAND : Roof ..... 86 LHD : Body Component Parts ............................... 123
LHD : Rear Body Component Parts ...................... 125
SERVICE DATA AND SPECIFICATIONS LHD : Frame Component Parts ............................ 127
(SDS) ........................................................... 87
FOR THAILAND ...................................................... 132
BODY ALIGNMENT ........................................... 87 FOR THAILAND : Underbody Component Parts . 132
FOR THAILAND : Body Component Parts ........... 134
FOR THAILAND ........................................................ 87 FOR THAILAND : Rear Body Component Parts ... 136
FOR THAILAND : Body Center Marks .................... 87 FOR THAILAND : Frame Component Parts ......... 138
FOR THAILAND : Description ................................ 88
FOR THAILAND : Engine Compartment ................ 88 EXCEPT FOR THAILAND ....................................... 141
FOR THAILAND : Underbody ................................. 90 EXCEPT FOR THAILAND : Underbody Compo-
FOR THAILAND : Passenger Compartment nent Parts .............................................................. 141
(Windshield and Door Opening) ............................. 93 EXCEPT FOR THAILAND : Body Component
FOR THAILAND : Passenger Compartment (Rear Parts ...................................................................... 142
Window Opening) ................................................... 94 EXCEPT FOR THAILAND : Rear Body Compo-
FOR THAILAND : Rear Body ................................. 96 nent Parts .............................................................. 144
EXCEPT FOR THAILAND : Frame Component
FOR AUSTRALIA AND NEW ZEALAND ................. 98 Parts ...................................................................... 146
Center Marks .......................................................... 98 REMOVAL AND INSTALLATION ............. 152
FOR AUSTRALIA AND NEW ZEALAND : De-
scription .................................................................. 99 CORROSION PROTECTION ........................... 152
FOR AUSTRALIA AND NEW ZEALAND : Engine Description ............................................................ 152
Compartment .........................................................100
LHD .......................................................................... 152
LHD : Undercoating .............................................. 152
body .......................................................................101
LHD : Stone Guard Coat ....................................... 153
FOR AUSTRALIA AND NEW ZEALAND : Pas-
LHD : Body Sealing ............................................... 155
senger Compartment (Windshield and Door
Opening) ................................................................103 FOR THAILAND ...................................................... 160
FOR AUSTRALIA AND NEW ZEALAND : Pas- FOR THAILAND : Undercoating ........................... 161
senger Compartment (Rear Window Opening) .....105 FOR THAILAND : Stone Guard Coat .................... 161
FOR AUSTRALIA AND NEW ZEALAND : Rear FOR THAILAND : Body Sealing ........................... 163
Body ......................................................................107
FOR AUSTRALIA AND NEW ZEALAND ............... 168
LOCATION OF PLASTIC PARTS ................... 110 FOR AUSTRALIA AND NEW ZEALAND : Under-
Precautions for Plastics .........................................110 coating .................................................................. 169
Location of Plastic Parts ........................................111

FOR AUSTRALIA AND NEW ZEALAND : Stone FOR THAILAND : Rear Crossmember .................. 229
Guard Coat ............................................................ 169 FOR THAILAND : Crush Horn ............................... 230 A
FOR AUSTRALIA AND NEW ZEALAND : Body FOR THAILAND : Roof (Normal Roof Models) ..... 232
Sealing .................................................................. 171
FOR AUSTRALIA AND NEW ZEALAND ................ 233
EXCEPT FOR THAILAND, AUSTRALIA AND FOR AUSTRALIA AND NEW ZEALAND : Radia- B
NEW ZEALAND ....................................................... 176 tor Core Support .................................................... 233
EXCEPT FOR THAILAND, AUSTRALIA AND FOR AUSTRALIA AND NEW ZEALAND : Hoo-
NEW ZEALAND : Undercoating ............................ 177 dledge .................................................................... 234 C
EXCEPT FOR THAILAND, AUSTRALIA AND FOR AUSTRALIA AND NEW ZEALAND : Hoo-
NEW ZEALAND : Stone Guard Coat .................... 177 dledge (Partial Replacement) ................................ 235
EXCEPT FOR THAILAND, AUSTRALIA AND FOR AUSTRALIA AND NEW ZEALAND : Front D
NEW ZEALAND : Body Sealing ............................ 179 Pillar ....................................................................... 235
FOR AUSTRALIA AND NEW ZEALAND : Center
BODY CONSTRUCTION .................................. 185 Pillar ....................................................................... 239
FOR AUSTRALIA AND NEW ZEALAND : Outer E
LHD .......................................................................... 185
Sill (Partial Replacement) ...................................... 241
LHD : Body Construction ....................................... 185
FOR AUSTRALIA AND NEW ZEALAND :
FOR THAILAND ...................................................... 186 Outer Sill ............................................................... 242 F
FOR THAILAND : Body Construction ................... 187 FOR AUSTRALIA AND NEW ZEALAND : Rear
Cab Pillar ............................................................... 243
FOR AUSTRALIA AND NEW ZEALAND ................ 188 FOR AUSTRALIA AND NEW ZEALAND : Back G
FOR AUSTRALIA AND NEW ZEALAND : Body Panel ..................................................................... 246
Construction .......................................................... 189 FOR AUSTRALIA AND NEW ZEALAND : Rear
Body Fender .......................................................... 247
EXCEPT FOR THAILAND, AUSTRALIA AND H
FOR AUSTRALIA AND NEW ZEALAND : Rear
NEW ZEALAND ....................................................... 190
Crossmember ........................................................ 248
EXCEPT FOR THAILAND, AUSTRALIA AND
FOR AUSTRALIA AND NEW ZEALAND : Crush
NEW ZEALAND : Body Construction .................... 191
Horn ....................................................................... 249 I
REPLACEMENT OPERATIONS ...................... 193 FOR AUSTRALIA AND NEW ZEALAND : Roof
Description ............................................................ 193 (Normal Roof Models) ........................................... 251
FOR AUSTRALIA AND NEW ZEALAND : Roof J
LHD .......................................................................... 194 (Sunroof Models) ................................................... 252
LHD : Radiator Core Support ................................ 195
LHD : Hoodledge ................................................... 195 EXCEPT FOR THAILAND AND AUSTRALIA
LHD : Hoodledge (Partial Replacement) ............... 196 (RHD) ....................................................................... 252 BRM
LHD : Front Pillar ................................................... 197 EXCEPT FOR THAILAND AND AUSTRALIA
LHD : Center Pillar ................................................ 201 (RHD) : Radiator Core Support ............................. 253
LHD : Outer Sill (Partial Replacement) ................. 203 EXCEPT FOR THAILAND AND AUSTRALIA L
LHD : Outer Sill .................................................... 204 (RHD) : Hoodledge ................................................ 253
LHD : Rear Cab Pillar ............................................ 205 EXCEPT FOR THAILAND AND AUSTRALIA
LHD : Back Panel .................................................. 208 (RHD) : Hoodledge (Partial Replacement) ............ 254
M
LHD : Rear Body Fender ....................................... 209 EXCEPT FOR THAILAND AND AUSTRALIA
LHD : Rear Crossmember ..................................... 210 (RHD) : Front Pillar ................................................ 255
LHD : Crush Horn .................................................. 211 EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Center Pillar .............................................. 259 N
LHD : Roof (Normal Roof Models) ........................ 213
EXCEPT FOR THAILAND AND AUSTRALIA
FOR THAILAND ...................................................... 214 (RHD) : Outer Sill (Partial Replacement) ............... 261
FOR THAILAND : Radiator Core Support ............. 214 EXCEPT FOR THAILAND AND AUSTRALIA O
FOR THAILAND : Hoodledge ............................... 215 (RHD) : Outer Sill .................................................. 262
FOR THAILAND : Hoodledge (Partial Replace- EXCEPT FOR THAILAND AND AUSTRALIA
ment) ..................................................................... 216 (RHD) : Rear Cab Pillar ......................................... 263 P
FOR THAILAND : Front Pillar ............................... 216 EXCEPT FOR THAILAND AND AUSTRALIA
FOR THAILAND : Center Pillar ............................. 220 (RHD) : Back Panel ............................................... 266
FOR THAILAND : Outer Sill (Partial Replacement) EXCEPT FOR THAILAND AND AUSTRALIA
.. 222 (RHD) : Rear Body Fender .................................... 267
FOR THAILAND : Outer Sill ................................. 223 EXCEPT FOR THAILAND AND AUSTRALIA
FOR THAILAND : Rear Cab Pillar ........................ 224 (RHD) : Rear Crossmember .................................. 268
FOR THAILAND : Back Panel ............................... 227
FOR THAILAND : Rear Body Fender ................... 228

EXCEPT FOR THAILAND AND AUSTRALIA FOR THAILAND ...................................................... 311
(RHD) : Crush Horn ...............................................269 FOR THAILAND : Underbody Component Parts . 311
EXCEPT FOR THAILAND AND AUSTRALIA FOR THAILAND : Body Component Parts ........... 312
(RHD) : Roof (Normal Roof Models) ......................271 FOR THAILAND : Rear Body Component Parts ... 314
FOR THAILAND : Frame Component Parts ......... 316
SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 272 EXCEPT FOR THAILAND ....................................... 319
EXCEPT FOR THAILAND : Underbody Compo-
BODY ALIGNMENT ......................................... 272 nent Parts .............................................................. 319
EXCEPT FOR THAILAND : Body Component
LHD ..........................................................................272 Parts ...................................................................... 320
LHD : Body Center Marks ......................................272 EXCEPT FOR THAILAND : Rear Body Compo-
LHD : Description ..................................................273 nent Parts .............................................................. 322
LHD : Engine Compartment ..................................273 EXCEPT FOR THAILAND : Frame Component
LHD : Underbody ...................................................275 Parts ...................................................................... 324
LHD : Passenger Compartment (Windshield and
Door Opening) .......................................................277 REMOVAL AND INSTALLATION ............. 328
LHD : Passenger Compartment (Rear Window
Opening) ................................................................281 CORROSION PROTECTION ........................... 328
LHD : Rear Body ...................................................282 Description ............................................................ 328
RHD ..........................................................................284 FOR THAILAND ...................................................... 328

RHD : Body Center Marks .....................................284 FOR THAILAND : Undercoating ........................... 328
RHD : Description ..................................................285 FOR THAILAND : Stone Guard Coat .................... 329
RHD : Engine Compartment ..................................286 FOR THAILAND : Body Sealing ........................... 331
RHD : Underbody ..................................................287
FOR AUSTRALIA AND NEW ZEALAND ............... 336
RHD : Passenger Compartment (Windshield and
Door Opening) .......................................................289
coating .................................................................. 337
RHD : Passenger Compartment (Rear Window
FOR AUSTRALIA AND NEW ZEALAND : Stone
Opening) ................................................................293
Guard Coat ........................................................... 337
RHD : Rear Body ...................................................294
LOCATION OF PLASTIC PARTS ................... 297 Sealing .................................................................. 339
Precautions for Plastics .........................................297
EXCEPT FOR THAILAND, AUSTRALIA AND
LHD ..........................................................................297 NEW ZEALAND ...................................................... 344
LHD : Location of Plastic Parts ..............................298 EXCEPT FOR THAILAND, AUSTRALIA AND
NEW ZEALAND : Undercoating ............................ 345
RHD ..........................................................................299 EXCEPT FOR THAILAND, AUSTRALIA AND
RHD : Location of Plastic Parts .............................300 NEW ZEALAND : Stone Guard Coat .................... 345
SINGLE CAB EXCEPT FOR THAILAND, AUSTRALIA AND
NEW ZEALAND : Body Sealing ............................ 347
VEHICLE INFORMATION .......................... 302
BODY CONSTRUCTION .................................. 353
BODY EXTERIOR PAINT COLOR .................. 302
Body Exterior Paint Color ....................................302 FOR THAILAND ...................................................... 353
FOR THAILAND : Body Construction ................... 353
PRECAUTION ............................................ 304
EXCEPT FOR THAILAND ....................................... 354
PRECAUTIONS ............................................... 304 EXCEPT FOR THAILAND : Body Construction .... 355
Precautions for Removing Battery Terminal ..........304
REPLACEMENT OPERATIONS ...................... 357
REPAIRING HIGH STRENGTH STEEL .......... 305 Description ............................................................ 357
High Strength Steel (HSS) .....................................305
FOR THAILAND ...................................................... 358
PREPARATION .......................................... 309 FOR THAILAND : Radiator Core Support ............. 359
FOR THAILAND : Hoodledge ............................... 359
REPAIRING MATERIAL .................................. 309 FOR THAILAND : Hoodledge (Partial Replace-
Foam Repair ..........................................................309 ment) ..................................................................... 360
FOR THAILAND : Front Pillar ............................... 361
BODY COMPONENT PARTS ......................... 311 FOR THAILAND : Outer Sill (Partial Replacement)
. 365

FOR THAILAND : Outer Sill ................................. 366 EXCEPT FOR THAILAND AND AUSTRALIA
FOR THAILAND : Rear Cab Pillar ........................ 367 (RHD) : Hoodledge (Partial Replacement) ............ 395 A
FOR THAILAND : Back Panel ............................... 370 EXCEPT FOR THAILAND AND AUSTRALIA
FOR THAILAND : Rear Body Fender ................... 371 (RHD) : Front Pillar ................................................ 396
FOR THAILAND : Rear Crossmember ................. 373 EXCEPT FOR THAILAND AND AUSTRALIA B
FOR THAILAND : Crush Horn .............................. 374 (RHD) : Outer Sill (Partial Replacement) ............... 399
FOR THAILAND : Roof ......................................... 375 EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Outer Sill .................................................. 400
FOR AUSTRALIA AND NEW ZEALAND ................ 376 EXCEPT FOR THAILAND AND AUSTRALIA C
FOR AUSTRALIA AND NEW ZEALAND : Radia- (RHD) : Rear Cab Pillar ......................................... 401
tor Core Support .................................................... 376 EXCEPT FOR THAILAND AND AUSTRALIA
FOR AUSTRALIA AND NEW ZEALAND : Hoo- (RHD) : Back Panel ............................................... 404 D
dledge ................................................................... 377 EXCEPT FOR THAILAND AND AUSTRALIA
FOR AUSTRALIA AND NEW ZEALAND : Hoo- (RHD) : Rear Body Fender .................................... 405
dledge (Partial Replacement) ................................ 378 EXCEPT FOR THAILAND AND AUSTRALIA
FOR AUSTRALIA AND NEW ZEALAND : Front E
(RHD) : Rear Crossmember .................................. 407
Pillar ...................................................................... 378 EXCEPT FOR THAILAND AND AUSTRALIA
FOR AUSTRALIA AND NEW ZEALAND : Outer (RHD) : Crush Horn ............................................... 408
Sill (Partial Replacement) ...................................... 382 EXCEPT FOR THAILAND AND AUSTRALIA F
FOR AUSTRALIA AND NEW ZEALAND : (RHD) : Roof .......................................................... 409
Outer Sill ............................................................... 383
FOR AUSTRALIA AND NEW ZEALAND : Rear SERVICE DATA AND SPECIFICATIONS G
Cab Pillar ............................................................... 384 (SDS) .......................................................... 411
FOR AUSTRALIA AND NEW ZEALAND : Back
Panel ..................................................................... 387 BODY ALIGNMENT ........................................ 411
H
FOR AUSTRALIA AND NEW ZEALAND : Rear Body Center Marks ................................................ 411
Body Fender .......................................................... 388 Description ............................................................. 412
FOR AUSTRALIA AND NEW ZEALAND : Rear Engine Compartment ............................................. 412
Crossmember ........................................................ 390 Underbody ............................................................. 414 I
FOR AUSTRALIA AND NEW ZEALAND : Crush Passenger Compartment (Windshield and Door
Horn ...................................................................... 391 Opening) ................................................................ 416
FOR AUSTRALIA AND NEW ZEALAND : Roof .. 392 Passenger Compartment (Rear Window Opening) J
.. 418
Rear Body .............................................................. 420
(RHD) ....................................................................... 393
EXCEPT FOR THAILAND AND AUSTRALIA LOCATION OF PLASTIC PARTS .................. 423 BRM
(RHD) : Radiator Core Support ............................. 393 Precautions for Plastics ......................................... 423
EXCEPT FOR THAILAND AND AUSTRALIA Location of Plastic Parts ........................................ 424
(RHD) : Hoodledge ................................................ 394 L

BODY EXTERIOR PAINT COLOR
< VEHICLE INFORMATION > [KING CAB]
VEHICLE INFORMATION
Body Exterior Paint Color INFOID:0000000011680921
FOR THAILAND
JSKIA5724ZZ
Color code BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1
Dark Dark
Description Orange Black Gray Silver White White
Brown Blue
Component
Paint type note 2PM 2PM 2S 2FPM 2M 3P 2P S
Standard
× × × × × × × –
clear coat
Chromium
Cr Cr Cr Cr Cr Cr Cr Cr
Door mirror plate
Material color – – – – – – – –
Chromium
Front grille plate
Silver K23 K23 K23 K23 K23 K23 K23 K23
Front bumper fascia Body color BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1
Tail gate handle Material color – – – – – – – –

Chromium
Door outside handle plate
Upper and
Lower fin- Material color – – – – – – – –
isher
Rear
bumper Rear
bumper Chromium
reinforce- plate
ment
NOTE:
• S: 1-Coat solid
• 2M: 2-Coat Metallic
• 2P: 2-Coat pearl
• 2S: 2-Coat solid

< VEHICLE INFORMATION > [KING CAB]
• 2PM: 2-Coat Pearl metallic
• 2FPM: 2-Coat Iron pearl metallic A
FOR AUSTRALIA
B
F
JSKIA5724ZZ
Color code BAX6 BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1 G
Dark Dark
Description Red Orange Black Gray Silver White White
Brown Blue
Component H
Paint type note 2S 2PM 2PM 2S 2FPM 2M 3P 2P S
Standard
× × × × × × × × –
clear coat
I
Chromium
Cr Cr Cr Cr Cr Cr Cr Cr Cr
Door mirror plate
Material color – – – – – – – – –
J
Chromium
Front grille plate
Silver K23 K23 K23 K23 K23 K23 K23 K23 K23
BRM
Front bumper fascia Body color BAX6 BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1
Tail gate handle Material color – – – – – – – – –

L
Chromium
Material color – – – – – – – – –
M
Upper and
Lower fin- Material color – – – – – – – – –
isher
Rear N
bumper Rear
bumper Chromium
reinforce- plate
ment
O
NOTE:
• S: 1-Coat solid
• 2M: 2-Coat Metallic P
• 2FPM: 2-Coat Iron pearl metallic

PRECAUTIONS
< PRECAUTION > [KING CAB]
PRECAUTION
PRECAUTIONS
Precautions for Removing Battery Terminal INFOID:0000000011667139
• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the Intelligent
Key or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied
even after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed
time.
• When disconnecting the 12V battery terminal, turn off the ACC
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE:
SEF289H
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to instruction described below.
1. Open the hood.
2. Turn ignition switch to the ON position.
3. Turn ignition switch to the OFF position with the driver side door opened.
4. Get out of the vehicle and close the driver side door.
5. Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.
D4D engine : 20 minutes YS23DDT : 4 minutes

HRA2DDT : 12 minutes YS23DDTT : 4 minutes
K9K engine : 4 minutes ZD30DDTi : 60 seconds
M9R engine : 4 minutes ZD30DDTT : 60 seconds
R9M engine : 4 minutes
V9X engine : 4 minutes
YD25DDTi : 2 minutes
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
6. Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

REPAIRING HIGH STRENGTH STEEL
A
High Strength Steel (HSS) INFOID:0000000011667140
High strength steel is used for body panels in order to reduce vehicle weight. B
Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:
Tensile strength Major applicable parts

C
• 4th cab mounting crossmember
(Rear floor assembly component part)
• Rear floor side reinforcement
(Rear floor assembly component part) D
• Inner sill wheelhouse
(Inner sill extension assembly component part)
• Front seat mounting rear crossmember
(Front floor assembly component part) E
• Center pillar crossmember
(Front floor assembly component part)
• Side member outrigger
(Front floor assembly component part) F
• 2nd body mounting member
• Inner sill
G
(Inner front sill assembly component part)
• Lower dash reinforcement
(Lower dash complete component part)
• Upper hoodledge H
(Hoodledge assembly component part)
• Lower hoodledge
(Lower hoodledge component part)
• Hoodledge reinforcement extension I
• Lower battery support bracket
440 - 780 MPa (Lower hoodledge component part)
• Lower battery bracket J
• Side radiator core stay
(Side radiator core support component part)
• Front roof rail
BRM
(Front roof rail component part)
• Upper inner front pillar
• Inner lock pillar assembly L
• Upper front pillar hinge brace
(Outer front pillar reinforcement component part)
• Outer sill reinforcement
• Outer side roof rail reinforcement M
• Outer lock pillar reinforcement
• Lower rear panel reinforcement
(Back panel assembly component part)
• Upper front door hinge reinforcement N
(Front door assembly component part)
• Lower front door hinge reinforcement
• Outer rear door seat belt reinforcement O
(Rear door assembly component part)
• 4th floor bolster
(4th floor bolster assembly component part)
• 3rd floor bolster
P
(3rd floor bolster assembly component part)


• Inner front side member
(Frame assembly component part)
• Outer front side member
• Outer rear side member
• Inner center side member
• Front bumper crossmember assembly
• Front suspension rear crossmember assembly
• 4th crossmember
440 - 780 MPa
• Diagonal member complete
• Upper rear engine mounting crossmember
(Rear engine mounting crossmember complete component part)
• Rear fuel tank crossmember
(7th crossmember component part)
• Spare wheel cross reinforcement
(Spare wheel crossmember assembly component part)
• Outer front side member extension
(Front side member extension assembly component part)
• Inner front side member extension
Read the following precautions when repairing HSS:

1. Additional points to consider
• The repair of reinforcements (such as side members) by heat-
ing is not recommended, because it may weaken the compo-
nent. When heating is unavoidable, never heat HSS parts
above 550°C (1,022°F).
Verify heating temperature with a thermometer.
(Crayon-type and other similar type thermometer are appropri-
ate.)
PIIA0115E
• When straightening body panels, use caution in pulling any HSS panel. Because HSS is very strong,
pulling may cause deformation in adjacent sections of the body. In this case, increase the number of
measuring points, and carefully pull the HSS panel.
• When cutting HSS panels, avoid gas (torch) cutting if possible.
Instead, use a saw to avoid weakening surrounding areas due
to heat. If gas (torch) cutting is unavoidable, allow a minimum
margin of 50 mm (1.97 in).
PIIA0117E

• When welding HSS panels, use spot welding whenever possi-
ble in order to minimize weakening surrounding areas due to A
heat.
If spot welding is impossible, use MIG. welding. Do not use
gas (torch) for welding because it is inferior in welding
B
strength.
PIIA0144E
D
• Spot welding on HSS panels is harder than that of an ordinary
steel panel.
Therefore, when cutting spot welds on a HSS panel, use a low E
speed high torque drill (1,000 to 1,200 rpm) to increase drill bit
durability and facilitate the operation.
F
G
PIIA0145E
2. Precautions in spot welding HSS H

This work should be performed under standard working condi-
tions. Always note the following when spot welding HSS:
• The electrode tip diameter must be sized properly according to
I
the metal thickness.
PIIA0146E BRM
• The panel surfaces must fit flush to each other, leaving no

gaps. L
PIIA0147E

• Follow the specifications for the proper welding pitch.
Unit: mm (in)
Thickness (T) Minimum pitch (L)
0.6 (0.024) 10 (0.39) or more
0.8 (0.031) 12 (0.47) or more
1.0 (0.039) 18 (0.71) or more
1.2 (0.047) 20 (0.79) or more
1.6 (0.063) 27 (1.06) or more
1.8 (0.071) 31 (1.22) or more
JSKIA0781ZZ

REPAIRING MATERIAL
< PREPARATION > [KING CAB]
PREPARATION A
REPAIRING MATERIAL
Foam Repair INFOID:0000000011667141
B
During factory body assembly, foam insulators are installed in certain body panels and locations around the
vehicle. Use the following procedure(s) to replace any factory-installed foam insulators.
C
URETHANE FOAM APPLICATIONS
Use commercially available Urethane foam for sealant (foam material) repair of material used on vehicle.
D
<Urethane foam for foaming agent> 3M™ Automix™ Flexible Foam 08463 or equiva-
lent
Read instructions on product for fill procedures. E
Example of foaming agent filling operation procedure
1. Fill procedures after installation of service part.
a. Eliminate foam material remaining on vehicle side. F
b. Clean area after eliminating form insulator and foam material.
c. Install service part.
G
d. Insert nozzle into hole near fill area and fill foam material or fill enough to close gap with the service part.
BRM
L
JSKIA0129GB
Urethane foam
M
Nozzle insert hole
: Vehicle front
2. Fill procedures before installation of service part. N

a. Eliminate foam material remaining on vehicle side.
b. Clean area after eliminating foam insulator and foam material.
O
c. Fill foam material on wheelhouse outer side.

REPAIRING MATERIAL
Urethane foam
Fill while avoiding flange area
: Vehicle front
NOTE:
Fill enough to close gap with service part while avoiding flange
area.
d. Install service part.
NOTE: JSKIA0130GB
Refer to label for information on working times.

BODY COMPONENT PARTS
A
FOR THAILAND
FOR THAILAND : Underbody Component Parts INFOID:0000000011667143
B
Refer to parts catalogue for the replacement parts.
BRM
JSKIA5725ZZ

AT models MT models
: Both sided anti-corrosive precoated steel sections

: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections
Both sided
Tensile strength anti-corrosive
No. Parts name
(MPa) precoated
steel sections
Rear floor assembly 440 —
Inner sill extension assembly (RH & LH) 440 ×
Front floor assembly 590 —
Inner front sill assembly (RH & LH) 590 ×
Cowl top assembly Under 440 ×
Upper dash assembly Under 440 ×
Side dash (RH & LH) under 440 —
Lower dash complete 440 —
Upper rear hoodledge (RH & LH) Under 440 ×
Hoodledge assembly (RH & LH) 440 ×
Lower hoodledge (RH & LH) 440 ×
Side radiator core support (RH & LH) 440 ×

NOTE:
• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part.
FOR THAILAND : Body Component Parts INFOID:0000000011667144

BRM
JSKIA5726ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections
Roof Under 440 —
Front roof rail 590 —
Roof bow No.1 Under 440 —
Rear roof rail Under 440 —
Hood Under 440 ×
Front fender (RH & LH) Under 440 ×
Upper inner front pillar (RH & LH) 590 —
Inner lock pillar assembly (RH & LH) 440 —
Outer front pillar reinforcement (RH & LH) 590 —
Outer sill reinforcement (RH & LH) 590 ×
Front fender bracket assembly (RH & LH) Under 440 ×
Outer side roof rail reinforcement (RH & LH) 590 —
Outer lock pillar reinforcement (RH & LH) 590 —
Outer front side body (RH & LH) Under 440 ×
Back panel assembly Under 440 ×
Front door assembly (RH & LH) 590 ×
Outer front door panel (RH & LH) Under 440 ×
Rear door assembly (RH & LH) 590 ×
Outer rear door panel (RH & LH) Under 440 ×

NOTE:
FOR THAILAND : Rear Body Component Parts INFOID:0000000011848201

BRM
JSKIA5727ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections
Rear gate assembly Under 440 ×
Fuel filler lid assembly Under 440 ×
Rear body assembly Refer to No. −

Center floor panel Under 440 ×
Side panel assembly (RH & LH) Under 440 ×
Rear body tail floor bolster assembly Under 440 ×
4th floor bolster assembly 440 ×
3rd floor bolster assembly 440 ×
Floor bolster assembly Under 440 ×
1st floor bolster assembly Under 440 ×
Header panel frame assembly Under 440 ×
Header panel assembly Under 440 ×

NOTE:
FOR THAILAND : Frame Component Parts INFOID:0000000011680922

BRM
JSKIA5728ZZ
P
4WD models 2WD models

Both sided
No. Parts name
(MPa) precoated
steel sections
Frame assembly Refer to No. −
Front bumper crossmember assembly 540 —
2nd crossmember Under 440 —
Front suspension rear crossmember assembly 440 —
4th crossmember 540 —
Diagonal member complete 540 —
Rear engine mounting crossmember complete 440 —
Fuel tank crossmember assembly Under 440 —
Fuel tank cover bracket assembly (RH) Under 440 —
Fuel tank cover bracket assembly (LH) Under 440 —
Torsion crossmember assembly Under 440 —
Spare wheel crossmember assembly 440 —
Front side member extension assembly (RH & LH) 540 —
1st cab mounting bracket (RH & LH) Under 440 —
Front suspension cross reinforcement (RH & LH) Under 440 —
Front suspension bracket assembly (RH & LH) Under 440 —
Front brake hose bracket (RH & LH) Under 440 —
Front bound bumper bracket assembly (RH & LH) Under 440 —
2nd cab mounting bracket (RH & LH) Under 440 —
Lower front link mounting bracket assembly (RH & LH) Under 440 —
Engine mounting bracket assembly (RH & LH) Under 440 —
4th crossmember gusset (RH & LH) Under 440 —
Rear spring front bracket assembly (RH & LH) Under 440 —
3rd cab mounting bracket (RH & LH) Under 440 —
1st rear body mounting bracket (RH & LH) Under 440 —
2nd rear body mounting bracket (RH & LH) Under 440 —
Rear bound bumper bracket assembly (RH & LH) Under 440 —
Rear shock absorber bracket assembly (RH & LH) Under 440 —
ABS sensor bracket (RH & LH) Under 440 —
Crossmember collar (RH & LH) Under 440 —
Rear spring rear bracket assembly (RH & LH) Under 440 —
Rear brake hose bracket Under 440 —
4th rear body mounting bracket (RH & LH) Under 440 —
Crossmember gusset (RH & LH) Under 440 —
NOTE:

• Tensile strength column shows the largest strength value of a part in the component part. A
FOR AUSTRALIA AND NEW ZEALAND
FOR AUSTRALIA AND NEW ZEALAND : Underbody Component Parts INFOID:0000000011853122
B
C
BRM
JSKIA5729ZZ

AT models MT models

Both sided
No. Parts name
(MPa) precoated
steel sections

NOTE:
FOR AUSTRALIA AND NEW ZEALAND : Body Component Parts INFOID:0000000011853123

BRM
JSKIA5730ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections
Roof Under 440 —
Hood Under 440 ×

NOTE:
FOR AUSTRALIA AND NEW ZEALAND : Rear Body Component Parts INFOID:0000000011863868

BRM
JSKIA5727ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections

1st floor bolster assembly Under 440 ×

NOTE:
FOR AUSTRALIA AND NEW ZEALAND : Frame Component Parts INFOID:0000000011863869

BRM
JSKIA5728ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections
NOTE:

BRM

CORROSION PROTECTION
< REMOVAL AND INSTALLATION > [KING CAB]
REMOVAL AND INSTALLATION

Description INFOID:0000000011680946
To provide improved corrosion prevention, the following anti-corrosive measures have been implemented in
NISSAN production plants. When repairing or replacing body panels, it is necessary to use the same anti-cor-
rosive measures.
ANTI-CORROSIVE PRECOATED STEEL (GALVANNEALED STEEL)
To improve repairability and corrosion resistance, a new type of anti-
corrosive precoated steel sheet has been adopted replacing conven-
tional zinc-coated steel sheet.
Galvannealed steel is electroplated and heated to form Zinc-iron
alloy, which provides excellent and long term corrosion resistance
with cationic electrodeposition primer.
SIIA2294E
Nissan Genuine Service Parts are fabricated from galvannealed steel. Therefore, it is recommended that
GENUINE NISSAN PARTS or equivalent be used for panel replacement to maintain the anti-corrosive perfor-
mance built into the vehicle at the factory.
PHOSPHATE COATING TREATMENT AND CATIONIC ELECTRODEPOSITION PRIMER
A phosphate coating treatment and a cationic electrodeposition
primer, which provide excellent corrosion protection, are employed
on all body components.
CAUTION:
Confine paint removal during welding operations to an absolute
minimum.
PIIA0095E
Nissan Genuine Service Parts are also treated in the same manner. Therefore, it is recommended that GENU-
INE NISSAN PARTS or an equivalent be used for panel replacement to maintain anti-corrosive performance
built into the vehicle at the factory.
FOR THAILAND
FOR THAILAND : Undercoating INFOID:0000000011680948
The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chip-
ping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoat-
ing which is rust resistant, soundproof, vibration-proof, shock-resistant, adhesive, and durable.
PRECAUTIONS IN UNDERCOATING
1. Never apply undercoating to any place unless specified (such as the areas above the muffler and three
way catalyst that are subjected to heat).
2. Never undercoat the exhaust pipe or other parts that become hot.
3. Never undercoat rotating parts.
4. Apply bitumen wax after applying undercoating.
5. After putting seal on the vehicle, put undercoating on it.

JSKIA5733ZZ F
: Undercoated areas
: Sealed portions G
FOR THAILAND : Stone Guard Coat INFOID:0000000011680950
To prevent damage caused by stones, the lower outer body panel (fender, door, etc.) have an additional layer H
of Stone Guard Coating over the ED primer coating. When replacing or repairing these panels, apply Stone
Guard coating to the same portions as before. Use a coating which is rust preventive, durable, shock-resistant
and has a long shelf life. I
CAB
BRM

JSKIA5735ZZ
: Stone guard coated portions
REAR BODY

JSKIA5736ZZ
BRM

L
FOR THAILAND : Body Sealing INFOID:0000000011680952
The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas M
should be smooth and free from cuts or gaps. Care should be taken not to apply an excess amount of sealant
and not to allow other unaffected parts to come into contact with the sealant.
CAB N

JSKIA5737ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA7248ZZ
P
: Vehicle front
: Sealed portions

JSKIA5739ZZ
: Sealed portions
REAR BODY

BRM
N
JSKIA5741ZZ
: Vehicle front O
: Sealed portions

JSKIA5742ZZ
Without rear skirt panel models With rear skirt panel models
: Vehicle front
: Sealed portions

FOR AUSTRALIA AND NEW ZEALAND : Undercoating INFOID:0000000011863884
A
ing which is rust resistant, soundproof, vibration-proof, shock-resistant, adhesive, and durable. B
way catalyst that are subjected to heat). C
4. Apply bitumen wax after applying undercoating. D
E
J
JSKIA5733ZZ
: Undercoated areas
: Sealed portions BRM
FOR AUSTRALIA AND NEW ZEALAND : Stone Guard Coat INFOID:0000000011863885
L
To prevent damage caused by stones, the lower outer body panel (fender, door, etc.) have an additional layer
and has a long shelf life. M
CAB
N

JSKIA5735ZZ
REAR BODY

JSKIA5736ZZ
BRM

L
FOR AUSTRALIA AND NEW ZEALAND : Body Sealing INFOID:0000000011688026
CAB N

JSKIA5749ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA7249ZZ
P
: Vehicle front
: Sealed portions

JSKIA5739ZZ
: Sealed portions
REAR BODY

BRM
N
JSKIA5741ZZ
: Vehicle front O
: Sealed portions

JSKIA5742ZZ
: Vehicle front
: Sealed portions

BODY CONSTRUCTION
BODY CONSTRUCTION
A
FOR THAILAND
FOR THAILAND : Body Construction INFOID:0000000011681252
B
BRM
JSKIA5755ZZ
Outer side body Upper front pillar hinge brace Upper inner front pillar
Weld nut Side dash Upper dash

BODY CONSTRUCTION
Upper rear hoodledge Lower front pillar reinforcement Lower dash
Front fender bracket Lower front pillar bulkhead Front floor
Inner sill Outer sill reinforcement Front seat mounting front cross-
member
Outer front seat mounting front 2nd crossmember extension Outer side roof rail reinforcement
bracket
Roof 1st roof bow Inner front side roof rail
Inner lock pillar Upper outer lock pillar reinforcement 4th cab mounting crossmember
Inner sill wheelhouse Rear seat mounting bracket Outer rear seat mounting bracket
Rear floor Hinge brace Lower outer lock pillar reinforcement

BODY CONSTRUCTION
FOR AUSTRALIA AND NEW ZEALAND : Body Construction INFOID:0000000011853121
BRM
P
JSKIA5756ZZ
Outer side body Upper front pillar hinge brace Upper outer front pillar
Upper inner front pillar Weld nut Inner front pillar reinforcement
Side dash Upper dash Upper rear hoodledge
Lower front pillar reinforcement Lower dash Front fender bracket

BODY CONSTRUCTION
Lower front pillar bulkhead Front floor Inner sill
Outer sill reinforcement Front seat mounting front cross- Outer front seat mounting front
member bracket
2nd crossmember extension Outer side roof rail reinforcement Roof
1st roof bow Inner front side roof rail Inner lock pillar
Seat belt anchor bracket Inner rear pillar reinforcement Upper outer lock pillar reinforcement
4th cab mounting crossmember Inner sill wheelhouse Rear seat mounting bracket
Outer rear seat mounting bracket Rear floor Hinge brace
Lower outer lock pillar reinforcement

REPLACEMENT OPERATIONS
A
• This section is prepared for technicians who have attained a high level of skill and experience in repairing B
collision-damaged vehicles and also use modern service tools and equipment. Persons unfamiliar with body
repair techniques should not attempt to repair collision-damaged vehicles by using this section.
• Technicians are also encouraged to read the Body Repair Manual (Fundamentals) in order to ensure that the
original functions and quality of the vehicle are maintained. The Body Repair Manual (Fundamentals) con- C
tains additional information, including cautions and warnings, that are not including in this manual. Techni-
cians should refer to both manuals to ensure proper repair.
• Please note that this information is prepared for worldwide usage, and as such, certain procedures might not D
apply in some regions or countries.
The symbols used in this section for welding operations are shown below.
Symbol marks Description
E
F
2-spot welds
G
JSKIA0049ZZ
H
JSKIA0053ZZ
3-spot welds
I
JSKIA0050ZZ
BRM
JSKIA0054ZZ L
MIG plug weld
For 3 panels plug weld method
M
JSKIA0051ZZ
N
JSKIA0055ZZ
MIG seam weld / Point weld

P
JSKIA0052ZZ JSKIA0056ZZ

• Front pillar butt joint can be determined anywhere within shaded
area as shown in the figure. The best location for the butt joint is at
position A due to the construction of the vehicle.
PIIA0150E
• Determine cutting position and record distance from the locating

indent. Use this distance when cutting the service part. Cut outer
front pillar over 60 mm (2.36 in) above the inner front pillar cut
position.
JSKIA0104GB
• Prepare a cutting jig to make outer pillar easier to cut. Also, this will
permit the service part to be accurately cut at the joint position.
JSKIA0105GB
• An example of cutting operation using a cutting jig is as per the fol-

lowing.
1. Mark cutting lines.
A: Cut position of outer pillar
B: Cut position of inner pillar
2. Align cutting line with notch on jig. Clamp jig to pillar.
3. Cut outer pillar along groove of jig (at position A).
4. Remove jig and cut remaining portions.
5. Cut inner pillar at position B in same manner.
PIIA0153E
FOR THAILAND

FOR THAILAND : Radiator Core Support INFOID:0000000011667155
BRM
JSKIA5626ZZ O
: Vehicle front
: Weld the parts onto the back of the component part. P
Replacement part
z Side radiator core support
FOR THAILAND : Hoodledge INFOID:0000000011667156
Work after radiator core support is removed.

JSKIA5627ZZ
: Vehicle front
: Weld the parts onto the back of the component part.
Replacement part
z Hoodledge assembly z Upper rear hoodledge
View D: Before installing upper rear hoodledge

FOR THAILAND : Hoodledge (Partial Replacement) INFOID:0000000011667157

BRM
N
JSKIA5628GB
Unit: mm (in) O
Replacement part
z Lower hoodledge
P
FOR THAILAND : Front Pillar INFOID:0000000011667160
Work after upper rear hoodledge is removed.

JSKIA5633GB
Body sealing Urethane foam

Unit: mm (in)
: Vehicle front
Replacement part
z Outer front side body z Outer front pillar reinforcement z Side dash
z Upper inner front pillar z Front fender bracket assembly

BRM
N
JSKIA5634GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P
: N·m (kg-m, ft-lb)
View B: Before installing outer front side body and outer front pillar reinforcement

JSKIA5635GB
Body sealing
Unit: mm (in)
: Vehicle front

FOR THAILAND : Outer Sill (Partial Replacement) INFOID:0000000011667162
BRM
JSKIA5644GB O
Unit: mm (in)
: Vehicle front P
Replacement part
z Outer front side body

FOR THAILAND : Outer Sill INFOID:0000000011667163
JSKIA5647GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part
z Outer front side body z Front fender bracket assembly
FOR THAILAND : Rear Cab Pillar INFOID:0000000011667164
Work after back panel is removed.

BRM
N
JSKIA5652GB
Urethane foam O
Unit: mm (in)
: Vehicle front
Replacement part P

JSKIA5653GB
Urethane foam
Unit: mm (in)
: Vehicle front

FOR THAILAND : Back Panel INFOID:0000000011667165
BRM
JSKIA5658GB O
Body sealing
Unit: mm (in) P
: Vehicle front
: Welding method, the number of welding points, and the tightening torque apply to both side of the vehicle.
: Sealing portion apply to both side of the vehicle.
: N·m (kg-m, in-lb)
Replacement part
z Back panel assembly

FOR THAILAND : Rear Body Fender INFOID:0000000011667166
JSKIA5661GB
: Vehicle front
Replacement part
z Side panel assembly

BRM
N
JSKIA5662GB
: Vehicle front O
P
FOR THAILAND : Rear Crossmember INFOID:0000000011667167
Work after rear body fender is removed.

JSKIA5667GB
: Vehicle front
: Welding method and the number of welding points apply to both side of the vehicle.
Replacement part
z Rear body tail floor bolster assembly
FOR THAILAND : Crush Horn INFOID:0000000011667168
CAUTION:

Create the reinforcing sheet from the redundant area of service parts for butt welding area.
Weld the reinforcing sheet on the back of butt welding area, and then perform butt welding. A
After welding, apply anti-corrosive wax on the reinforcing sheet-welded area.
BRM
O
JSKIA5669GB
Front side member closing bracket Reinforcing sheet

P
Unit: mm (in)
: Vehicle front
Replacement part
z Front side member extension as-
sembly
View A: Before installing front side member closing bracket and outer front side member extension

View B: Before installing front side member closing bracket
FOR THAILAND : Roof INFOID:0000000011667371
JSKIA5670ZZ
Body sealing
: Vehicle front
Replacement part
z Roof z Roof bow No.1 z Roof bow No.2

FOR AUSTRALIA AND NEW ZEALAND : Radiator Core Support INFOID:0000000011854129
BRM
JSKIA5626ZZ O
: Vehicle front
Replacement part
FOR AUSTRALIA AND NEW ZEALAND : Hoodledge INFOID:0000000011854130

JSKIA5627ZZ
: Vehicle front
Replacement part

FOR AUSTRALIA AND NEW ZEALAND : Hoodledge (Partial Replacement)
INFOID:0000000011854131

BRM
N
JSKIA5628GB
Unit: mm (in) O
Replacement part
z Lower hoodledge
P
FOR AUSTRALIA AND NEW ZEALAND : Front Pillar INFOID:0000000011854132

JSKIA7376GB

Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA7377GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

JSKIA5632GB

Unit: mm (in)
: Vehicle front
View J: Before installing upper inner front pillar, outer front side body and outer front pillar reinforcement
View N: Before installing outer front side body

FOR AUSTRALIA AND NEW ZEALAND : Outer Sill (Partial Replacement) INFOID:0000000011854133
BRM
JSKIA5644GB O
Unit: mm (in)
: Vehicle front P
Replacement part

FOR AUSTRALIA AND NEW ZEALAND : Outer Sill INFOID:0000000011854134
JSKIA7379GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part
FOR AUSTRALIA AND NEW ZEALAND : Rear Cab Pillar INFOID:0000000011854135

BRM
N
JSKIA5652GB
Urethane foam O
Unit: mm (in)
: Vehicle front
Replacement part P

JSKIA5653GB
Urethane foam
Unit: mm (in)
: Vehicle front

FOR AUSTRALIA AND NEW ZEALAND : Back Panel INFOID:0000000011854136
BRM
JSKIA5658GB O
Body sealing
Unit: mm (in) P
: Vehicle front
: Welding method, the number of welding points, and the tightening torque apply to both side of the vehicle.
Replacement part

FOR AUSTRALIA AND NEW ZEALAND : Rear Body Fender INFOID:0000000011854137
JSKIA5661GB
: Vehicle front
Replacement part

BRM
N
JSKIA5662GB
: Vehicle front O
P
FOR AUSTRALIA AND NEW ZEALAND : Rear Crossmember INFOID:0000000011854138

JSKIA5667GB
: Vehicle front
Replacement part
FOR AUSTRALIA AND NEW ZEALAND : Crush Horn INFOID:0000000011854139
CAUTION:

BRM
O
JSKIA5669GB

P
Unit: mm (in)
: Vehicle front
Replacement part
sembly

FOR AUSTRALIA AND NEW ZEALAND : Roof INFOID:0000000011854140
JSKIA5670ZZ
Body sealing
: Vehicle front
Replacement part

BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS) [KING CAB]
SERVICE DATA AND SPECIFICATIONS (SDS) A

BODY ALIGNMENT
FOR THAILAND
B
FOR THAILAND : Body Center Marks INFOID:0000000011681384
A mark is placed on each part of the body to indicate the vehicle center. When repairing the vehicle frame C
(members, pillars, etc.) damaged by an accident which it enables more accurate and effective repair by using
these marks together with body alignment specifications.
D
BRM
JSKIA5758ZZ
P
: Vehicle front
Unit: mm (in)
Points Portion Marks
A Front roof Embossment
B Cowl top Hole 10×12 (0.39×0.47)
C Center pillar crossmember Hole 12×14 (0.47×0.55)

BODY ALIGNMENT
D Back panel Indent
E Rear roof Indent
FOR THAILAND : Description INFOID:0000000011681305
• All dimensions indicated in the figures are actual.

• When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself
to make sure there is no free play.
• When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
• Measurements should be taken at the center of the mounting holes.
• An asterisk (*) following the value at the measuring point indicates that the measuring point on the other side
is symmetrically the same value.
• The coordinates of the measurement points are the distances measured from the standard line of ″X″, ″Y″
and ″Z″.
• ″Z″: Imaginary base line [300 mm (11.81 in) below datum line (″0Z″ at design plan)]
JSKIA0073GB
Vehicle center Front axle center Imaginary base line
FOR THAILAND : Engine Compartment INFOID:0000000011681306
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.

BODY ALIGNMENT
I
JSKIA5075GB
Unit: mm (in)
J
MEASUREMENT POINTS
BRM

BODY ALIGNMENT
JSKIA5076ZZ
: Vehicle front
Unit: mm (in)
Point Material Point Material

Cowl top hole center of center positioning mark Upper radiator core support hole center φ11
10×12 (0.39×0.47) (0.43)
Hood hinge installing hole center φ11 (0.43) Side radiator core stay hole center φ12 (0.47)
Upper hoodledge hole center φ12 (0.47) — —
FOR THAILAND : Underbody INFOID:0000000011681307
MEASUREMENT
vehicle.
The following figure shows a bottom view and a side view of the vehicle.

BODY ALIGNMENT
BRM
JSKIA5759GB
P
Unit: mm (in)
MEASUREMENT POINTS

BODY ALIGNMENT
JSKIA5869ZZ
: Vehicle front
Unit: mm (in)
Coordinates Coordinates
Points Remarks Points Remarks
X Y Z X Y Z
±426.0 −528.0 275.0 Hole 14×16 ±570.0 2085.0 100.0
Hole φ8 (0.31)
(±16.772) (−20.787) (10.827) (0.55×0.63) (±22.441) (82.086) (3.937)
±518.0 −483.0 405.0 Hole φ32 ±553.0 4173.0 337.0 Hole 17×18
(±20.394) (−19.016) (15.945) (1.26) (±21.772) (164.291) (13.268) (0.67×0.71)
±437.0 90.0 178.0 Hole φ10 ±484.0 −47.0 513.0 Hole φ52
(±17.205) (3.543) (7.008) (0.39) (±19.055) (−1.850) (20.197) (2.05)
±474.0 804.0 100.0 Hole φ16
– – – – –
(±18.661) (31.653) (3.937) (0.63)

BODY ALIGNMENT
FOR THAILAND : Passenger Compartment (Windshield and Door Opening)
INFOID:0000000011681308 A
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the B
vehicle.
BRM
JSKIA5079GB
Unit: mm (in)
L
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo

M
- 1386 (54.57) - 1339 (52.72) - 878 (34.57)*
- 1639 (64.53)* - 1628 (64.09)* - 1584 (62.36)
- 1960 (77.17)* - 1487 (58.54) - 1729 (68.07)* N
- 2062 (81.18)* - 1487 (58.54) - 1768 (69.61)*
- 1453 (57.20) - 1336 (52.60)* - 1616 (63.62) O

- 2042 (80.39)* - 1263 (49.72)* - 1777 (69.96)*
- 1483 (58.39) - 1257 (49.49)* - 1734 (68.27)*

P
- 2291 (90.20)* - 1237 (48.70)* - 1604 (63.15)
- 2096 (82.52)* - 995 (39.17)* - 1604 (63.15)
MEASUREMENT POINTS

BODY ALIGNMENT
JSKIA5080ZZ
: Vehicle front
Unit: mm (in)
Cowl top hole center of center positioning mark

Front pillar indent
10×12 (0.39×0.47)
Roof flange end of center positioning mark Rear pillar indent
Center pillar crossmember hole center of center

Outer side body joggle
positioning mark 12×14 (0.47×0.55)
Outer side body indent Door hinge installing hole center φ12 (0.47)
FOR THAILAND : Passenger Compartment (Rear Window Opening) INFOID:0000000011681309
MEASUREMENT

BODY ALIGNMENT
vehicle. A
JSKIA5081GB
J
Unit: mm (in)
MEASUREMENT POINTS BRM

BODY ALIGNMENT
JSKIA5082ZZ
: Vehicle front

Roof indent of center positioning mark Back panel indent of center positioning mark
Outer side body joggle — —
FOR THAILAND : Rear Body INFOID:0000000011681310
MEASUREMENT
vehicle.

BODY ALIGNMENT
I
JSKIA5083GB
Unit: mm (in)
J
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo BRM
- 549 (21.61)* - 1492 (58.74)* - 1370 (53.94)*
MEASUREMENT POINTS L

BODY ALIGNMENT
JSKIA5084ZZ
: Vehicle front
Unit: mm (in)

Outer side panel hole center
Inner rear strut reinforcement hole center φ14
: φ14 (0.55)
(0.55)
: φ10 (0.39)

FOR AUSTRALIA AND NEW ZEALAND : Body Center Marks INFOID:0000000011688217
A mark is placed on each part of the body to indicate the vehicle center. When repairing the vehicle frame

BODY ALIGNMENT
BRM
L
JSKIA5760ZZ
: Vehicle front M
Unit: mm (in)
N
B Cowl top Hole 10×12 (0.39×0.47)
C Center pillar crossmember Hole 12×14 (0.47×0.55) O
D Back panel Indent
E Rear roof Indent
P
FOR AUSTRALIA AND NEW ZEALAND : Description INFOID:0000000011688225


BODY ALIGNMENT
and ″Z″.
JSKIA0073GB
FOR AUSTRALIA AND NEW ZEALAND : Engine Compartment INFOID:0000000011688226
MEASUREMENT
vehicle.
JSKIA5075GB

BODY ALIGNMENT
Unit: mm (in) A
MEASUREMENT POINTS
B
J
JSKIA5076ZZ
: Vehicle front BRM

Unit: mm (in)

L
10×12 (0.39×0.47) (0.43)
M
FOR AUSTRALIA AND NEW ZEALAND : Underbody INFOID:0000000011688228

N
MEASUREMENT
O
vehicle.

BODY ALIGNMENT
JSKIA5759GB
Unit: mm (in)
MEASUREMENT POINTS

BODY ALIGNMENT
BRM
L
JSKIA5869ZZ
: Vehicle front M
Unit: mm (in)
Points Remarks Points Remarks N
X Y Z X Y Z
±426.0 −528.0 275.0 Hole 14×16 ±570.0 2085.0 100.0
Hole φ8 (0.31)
(±16.772) (−20.787) (10.827) (0.55×0.63) (±22.441) (82.086) (3.937) O
±518.0 −483.0 405.0 Hole φ32 ±553.0 4173.0 337.0 Hole 17×18
(±20.394) (−19.016) (15.945) (1.26) (±21.772) (164.291) (13.268) (0.67×0.71)
±437.0 90.0 178.0 Hole φ10 ±484.0 −47.0 513.0 Hole φ52 P
(±17.205) (3.543) (7.008) (0.39) (±19.055) (−1.850) (20.197) (2.05)
±474.0 804.0 100.0 Hole φ16
– – – – –
(±18.661) (31.653) (3.937) (0.63)
FOR AUSTRALIA AND NEW ZEALAND : Passenger Compartment (Windshield and

BODY ALIGNMENT
Door Opening) INFOID:0000000011688221
MEASUREMENT
vehicle.
JSKIA5761GB
Unit: mm (in)
«The others»
Unit: mm (in)
- 1386 (54.57) - 1339 (52.72) - 878 (34.57)*
- 1639 (64.53)* - 1628 (64.09)* - 1584 (62.36)
- 1960 (77.17)* - 1487 (58.54) - 1729 (68.07)*
- 2062 (81.18)* - 1487 (58.54) - 1768 (69.61)*
- 1453 (57.20) - 1336 (52.60)* - 1616 (63.62)
- 2042 (80.39)* - 1263 (49.72)* - 1777 (69.96)*
- 1483 (58.39) - 1257 (49.49)* - 1734 (68.27)*
- 2291 (90.20)* - 1237 (48.70)* - 1604 (63.15)
- 2096 (82.52)* - 995 (39.17)* - 1604 (63.15)
MEASUREMENT POINTS

BODY ALIGNMENT
BRM
L
JSKIA5762ZZ
: Vehicle front M
Unit: mm (in)
Point Material Point Material N

Front pillar indent
10×12 (0.39×0.47)
O
Center pillar crossmember hole center of center

Outer side body joggle
positioning mark 12×14 (0.47×0.55)
P
FOR AUSTRALIA AND NEW ZEALAND : Passenger Compartment (Rear Window

BODY ALIGNMENT
Opening) INFOID:0000000011688229
MEASUREMENT
vehicle.
JSKIA5081GB
Unit: mm (in)
MEASUREMENT POINTS

BODY ALIGNMENT
I
JSKIA5082ZZ
: Vehicle front J

Roof indent of center positioning mark Back panel indent of center positioning mark BRM
FOR AUSTRALIA AND NEW ZEALAND : Rear Body INFOID:0000000011688230

L
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the M
vehicle.

BODY ALIGNMENT
JSKIA5083GB
Unit: mm (in)
«The others»
Unit: mm (in)
- 549 (21.61)* - 1492 (58.74)* - 1370 (53.94)*
MEASUREMENT POINTS

BODY ALIGNMENT
I
JSKIA5084ZZ
: Vehicle front J
Unit: mm (in)

BRM
: φ14 (0.55)
(0.55)
: φ10 (0.39)
L

LOCATION OF PLASTIC PARTS
Precautions for Plastics INFOID:0000000011667169
Heat resisting
Abbre- Resistance to gasoline and
Material name temperature Other cautions
viation solvents
°C (°F)
Gasoline and most solvents are
PE Polyethylene 60 (140) harmless if applied for a very Flammable
short time (wipe out quickly).
ABS Acrylonitrile Butadiene Styrene 80 (176) Avoid gasoline and solvents. —
AES Acrylonitrile Ethylene Styrene 80 (176) ↑ —
EPM/ Ethylene Propylene (Diene) co-
80 (176) harmless if applied for a very Flammable
EPDM polymer
PS Polystyrene 80 (176) Avoid solvents. Flammable
Poisonous gas is emitted
PVC Poly Vinyl Chloride 80 (176) harmless if applied for a very
when burned.
TPO Thermoplastic Olefine 80 (176) ↑ Flammable
AAS Acrylonitrile Acrylic Styrene 85 (185) Avoid gasoline and solvents. —
PMMA Poly Methyl Methacrylate 85 (185) ↑ —
EVAC Ethylene Vinyl Acetate 90 (194) ↑ —
Flammable, avoid bat-
PP Polypropylene 90 (194) harmless if applied for a very
tery acid.
PUR Polyurethane 90 (194) Avoid gasoline and solvents. —
UP Unsaturated Polyester 90 (194) ↑ Flammable
ASA Acrylonitrile Styrene Acrylate 100 (212) ↑ Flammable
PPE Poly Phenylene Ether 110 (230) ↑ —
TPU Thermoplastic Urethane 110 (230) ↑ —
PBT+ Poly Butylene Terephthalate +
120 (248) ↑ Flammable
PC Polycarbonate
PC Polycarbonate 120 (248) ↑ —
POM Poly Oxymethylene 120 (248) ↑ Avoid battery acid.
Avoid immersing in wa-
PA Polyamide 140 (284) ↑
ter.
PBT Poly Butylene Terephthalate 140 (284) ↑ —
PAR Polyarylate 180 (356) ↑ —
PET Polyethylene terephthalate 180 (356) ↑ —
PEI Polyetherimide 200 (392) ↑ —
CAUTION:
• When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics (influence of heat
and solvent) and remove them if necessary or take suitable measures to protect them.
• Plastic parts should be repaired and painted using methods suiting the materials, characteristics.

Location of Plastic Parts INFOID:0000000011667170
JSKIA5763ZZ
I
Component Material Component Material
PC + PET +
Body PP Escutcheon
Glass fiber J
Door mirror
Tailgate
(Manual Base PA + Glass fiber Chrome PC + ABS
handle
type) Handle PC + PET +
Lower cover ASA Black BRM
Glass fiber
Body ASA With rear Lens PMMA
body mod-
Door mirror Under body ASA els Housing ASA L
Rear combi-
(Electrical
Chrome ABS nation lamp Without rear Lens PMMA
type)
Garnish body mod-
Black ASA els Housing PP
M
Lens PC Lens PMMA
Front combination lamp High mount stop lamp
Housing PP Housing ABS + ASA
Outer ABS Door outside molding PVC + Stainless N
Front grille
Inner ASA Chrome PC + ABS
Door outside handle
Front bumper fascia PP + EPM Black PC + PET O
Front bumper finisher ABS Upper and Lower finisher PP
Rear
bumper Rear bumper reinforce-
Lens Glass Steel
ment P
Front fog lamp
PBT + ASA +
Housing Lens PC
Glass fiber License plate lamp
Front fender protector PP Housing PC

Mudguard PP + EPDM
Lens PMMA – – –
Side turn signal lamp
Housing PC + ABS
JSKIA5764ZZ

Back pillar garnish PP Instrument panel PP
Lens PC Glove box PP
Room lamp Housing PP Cluster lid C PC + ABS
Knob PP Cluster lid C lower PP
Rear door finisher PP Instrument side finisher PC + ABS
Switch finisher PP Console body PP
Map lamp
Console PP Console box PP
Lid box PC + ABS Center con- Console finisher PC + ABS
sole
Front pillar garnish PP Outer ABS
Console lid
Cluster lid A PP Inner PP

< VEHICLE INFORMATION > [DOUBLE CAB]
VEHICLE INFORMATION A
B
FOR AUSTRALIA
C
JSKIA5767ZZ
H
Color code BAX6 BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1
Dark Dark
Description Red Orange Black Gray Silver White White
Brown Blue
Component I
Paint type note 2S 2PM 2PM 2S 2FPM 2M 3P 2P S
Standard
× × × × × × × × –
clear coat J
Chromium
Door mirror plate
Material color – – – – – – – – – BRM
Chromium
Front grille plate
Silver K23 K23 K23 K23 K23 K23 K23 K23 K23 L
Front bumper fascia Body color BAX6 BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1
Tail gate handle Material color – – – – – – – – –

M
Chromium
Material color – – – – – – – – – N
Upper and
Rear
Lower fin- Material color – – – – – – – – –
bumper
isher
O
Rear
bumper Chromium
reinforce- plate
ment P
NOTE:
• S: 1-Coat solid

< VEHICLE INFORMATION > [DOUBLE CAB]
EXCEPT FOR AUSTRALIA
JSKIA5767ZZ
Color code BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1
Dark Dark
Brown Blue
Component
Paint type note 2PM 2PM 2S 2FPM 2M 3P 2P S
Standard
× × × × × × × –
clear coat
Chromium
Door mirror plate
Front Chromium
grille plate
Silver K23 K23 K23 K23 K23 K23 K23 K23
Tail gate handle Material color – – – – – – – –

Chromium
Upper and
Lower fin- Material color – – – – – – – –
isher
Rear
bumper Rear
bumper Chromium
reinforce- plate
ment
NOTE:
• S: 1-Coat solid

PRECAUTIONS
< PRECAUTION > [DOUBLE CAB]
PRECAUTION A
PRECAUTIONS
B
even after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed C
time.
power before disconnecting the 12V battery terminal, observing D
NOTE:
switch is turned OFF and ignition power supply is stopped. If the E
• For vehicles with the 2-batteries, be sure to connect the main bat- F
NOTE:
SEF289H
main battery and sub battery disconnected, then DTC may be detected. G
NOTE:
The removal of 12V battery may cause a DTC detection error. H
1. Open the hood. I
4. Get out of the vehicle and close the driver side door. J
D4D engine : 20 minutes YS23DDT : 4 minutes BRM

L
M
CAUTION:
N
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC. O

High strength steel is used for body panels in order to reduce vehicle weight.

• 4th cab mounting crossmember
• Rear floor side reinforcement
• Inner sill wheelhouse
(Inner sill extension assembly component part)
• Inner sill
(Lower dash complete component part)
• Upper hoodledge
• Lower hoodledge
• Hoodledge reinforcement extension
• Lower battery support bracket
• Lower battery bracket
• Side radiator core stay
• Front roof rail
• Upper inner front pillar
• Inner lock pillar assembly
• Outer side roof rail reinforcement
• Lower rear panel reinforcement
• Upper front door hinge reinforcement
• Lower front door hinge reinforcement
• Inner center pillar assembly
• Center pillar hinge brace assembly
• 3rd floor bolster

Tensile strength Major applicable parts A

B
• Inner center side member C
440 - 780 MPa
• 4th crossmember D
• Rear fuel tank crossmember E
• Outer front side member extension F
G

1. Additional points to consider H
above 550°C (1,022°F). I
ate.) J
BRM
PIIA0115E
• When straightening body panels, use caution in pulling any HSS panel. Because HSS is very strong, L
Instead, use a saw to avoid weakening surrounding areas due M
N
PIIA0117E
P

ble in order to minimize weakening surrounding areas due to
heat.
strength.
PIIA0144E

steel panel.
Therefore, when cutting spot welds on a HSS panel, use a low
PIIA0145E
2. Precautions in spot welding HSS

PIIA0146E

gaps.
PIIA0147E

Unit: mm (in) A
0.6 (0.024) 10 (0.39) or more
0.8 (0.031) 12 (0.47) or more B
1.0 (0.039) 18 (0.71) or more
1.2 (0.047) 20 (0.79) or more
1.6 (0.063) 27 (1.06) or more C
1.8 (0.071) 31 (1.22) or more
JSKIA0781ZZ
BRM

REPAIRING MATERIAL
< PREPARATION > [DOUBLE CAB]
PREPARATION
REPAIRING MATERIAL
lent
Read instructions on product for fill procedures.
JSKIA0129GB
Urethane foam
Nozzle insert hole
: Vehicle front
2. Fill procedures before installation of service part.


REPAIRING MATERIAL
A
Urethane foam
: Vehicle front B
NOTE:
area. C
NOTE: JSKIA0130GB
Refer to label for information on working times. D
BRM

LHD
LHD : Underbody Component Parts INFOID:0000000011681549
JSKIA5768ZZ

AT models MT models A
: Both sided anti-corrosive steel and HSS sections B
Both sided
Tensile strength anti-corrosive C
No. Parts name
(MPa) precoated
steel sections
Rear floor assembly 440 — D
Front floor assembly 590 — E


F

G
Hoodledge assembly (RH & LH) 440 × H

Side radiator core support (RH & LH) 440 × I

NOTE:
• Tensile strength column shows the largest strength value of a part in the component part. J
LHD : Body Component Parts INFOID:0000000011681550
Refer to parts catalogue for the replacement parts. BRM

JSKIA5769ZZ


Both sided A
No. Parts name
(MPa) precoated
steel sections
B
Roof Under 440 —
Roof bow No.1 Under 440 — C

Center roof bow Under 440 — D


E
Hood Under 440 ×

F
Inner center pillar assembly (RH & LH) 590 —
Inner lock pillar assembly (RH & LH) 440 — G
Outer sill reinforcement (RH & LH) 590 × H


I
Center pillar hinge brace assembly (RH & LH) 590 —

J

BRM
Rear door assembly (RH & LH) 590 × L

NOTE:
M
LHD : Rear Body Component Parts INFOID:0000000011853879 N

O

JSKIA5770ZZ
Leaf rigid type suspension models 5 Link suspension models


Both sided A
No. Parts name
(MPa) precoated
steel sections
B
Rear body assembly Refer to No. − C

Side panel assembly (RH & LH) Under 440 × D


E

F

NOTE: G
H
LHD : Frame Component Parts INFOID:0000000011681551

I
LEAF RIGID TYPE SUSPENSION MODELS
BRM

JSKIA5771ZZ

Both sided A
No. Parts name
(MPa) precoated
steel sections
B
2nd crossmember Under 440 — C

4th crossmember 540 — D


E

F
Torsion crossmember assembly Under 440 — G
Front side member extension assembly (RH & LH) 540 — H


I

J
BRM
4th crossmember gusset (RH & LH) Under 440 — L

Rear spring front bracket assembly (RH & LH) Under 440 — M
4th cab mounting bracket (RH & LH) Under 440 —
N

O
Rear spring rear bracket assembly (RH & LH) Under 440 — P
NOTE:

5 LINK SUSPENSION MODELS
JSKIA5775ZZ

Both sided A
No. Parts name
(MPa) precoated
steel sections
B
2nd crossmember Under 440 — C

4th crossmember 540 — D


E

F
Torsion crossmember assembly (Front) Under 440 — G
Torsion crossmember assembly (Rear) Under 440 —
Spare wheel crossmember assembly 440 — H


I

J

BRM
Engine mounting bracket assembly (RH & LH) Under 440 — L

3rd cab mounting bracket (RH & LH) Under 440 — M

Lower mounting bracket (RH & LH) Under 440 —

N
Rear bound bumper bracket (RH & LH) Under 440 —

O
Panhard rod reinforcement Under 440 —
Crossmember collar (Front RH & LH) Under 440 — P

Crossmember collar (Rear RH & LH) Under 440 —
Rear stabilizer mounting bracket (RH & LH) Under 440 —
Rear suspension mounting bracket assembly (RH & LH) Under 440 —

Both sided
No. Parts name
(MPa) precoated
steel sections
Rear brake hose bracket (RH & LH) Under 440 —
Panhard rod mounting bracket assembly Under 440 —
NOTE:
FOR THAILAND

BRM
JSKIA5772ZZ
P
AT models MT models


Both sided
No. Parts name
(MPa) precoated
steel sections

NOTE:

BRM
JSKIA5773ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections
Roof Under 440 —
Center roof bow Under 440 —
Hood Under 440 ×

NOTE:

BRM
JSKIA5774ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections


NOTE:

BRM
JSKIA5771ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections
NOTE:

EXCEPT FOR THAILAND
EXCEPT FOR THAILAND : Underbody Component Parts INFOID:0000000011853933
B
C
BRM
JSKIA5776ZZ

AT models MT models

Both sided
No. Parts name
(MPa) precoated
steel sections

NOTE:
EXCEPT FOR THAILAND : Body Component Parts INFOID:0000000011853990

BRM
JSKIA5777ZZ
P
Normal roof models Sunroof models


Both sided
No. Parts name
(MPa) precoated
steel sections
Roof Under 440 —
Center roof bow Under 440 —
Roof assembly Under 440 —
Hood Under 440 ×

NOTE:
EXCEPT FOR THAILAND : Rear Body Component Parts INFOID:0000000011853991

BRM
JSKIA5778ZZ
P
Leaf rigid type suspension models 5 Link suspension models Without guard frame models
With guard frame models


Both sided
No. Parts name
(MPa) precoated
steel sections


NOTE:
EXCEPT FOR THAILAND : Frame Component Parts INFOID:0000000011866667

LEAF RIGID TYPE SUSPENSION MODELS

BRM
JSKIA5771ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections
NOTE:

5 LINK SUSPENSION MODELS
B
BRM
JSKIA5775ZZ

Both sided
No. Parts name
(MPa) precoated
steel sections
Torsion crossmember assembly (Front) Under 440 —
Torsion crossmember assembly (Rear) Under 440 —
Lower mounting bracket (RH & LH) Under 440 —
Rear bound bumper bracket (RH & LH) Under 440 —
Panhard rod reinforcement Under 440 —
Crossmember collar (Front RH & LH) Under 440 —
Crossmember collar (Rear RH & LH) Under 440 —
Rear stabilizer mounting bracket (RH & LH) Under 440 —
Rear suspension mounting bracket assembly (RH & LH) Under 440 —

Both sided
Tensile strength anti-corrosive A
No. Parts name
(MPa) precoated
steel sections
Rear brake hose bracket (RH & LH) Under 440 — B
Panhard rod mounting bracket assembly Under 440 —
C
D
NOTE:
E
BRM

< REMOVAL AND INSTALLATION > [DOUBLE CAB]

rosive measures.
SIIA2294E
CAUTION:
minimum.
PIIA0095E
LHD
LHD : Undercoating INFOID:0000000011681554

JSKIA5779ZZ F
: Undercoated areas
: Sealed portions G
LHD : Stone Guard Coat INFOID:0000000011681555
CAB
BRM

JSKIA5781ZZ
REAR BODY

JSKIA5782ZZ
BRM

L
LHD : Body Sealing INFOID:0000000011688256
CAB N

JSKIA5783ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA7250ZZ
P
: Vehicle front
: Sealed portions

JSKIA5785ZZ
: Sealed portions
REAR BODY

BRM
N
JSKIA5787ZZ
: Vehicle front O
: Sealed portions

JSKIA5788ZZ
: Vehicle front
: Sealed portions
FOR THAILAND

A
E
J
JSKIA5791ZZ
: Undercoated areas
L
CAB
N

JSKIA5793ZZ
REAR BODY

JSKIA5782ZZ
BRM

L
CAB N

JSKIA5795ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA7251ZZ
P
: Vehicle front
: Sealed portions

JSKIA5785ZZ
: Sealed portions
REAR BODY

BRM
N
JSKIA5787ZZ
: Vehicle front O
: Sealed portions

JSKIA5788ZZ
: Vehicle front
: Sealed portions

A
E
J
JSKIA5791ZZ
: Undercoated areas
L
CAB
N

JSKIA5793ZZ
REAR BODY

JSKIA5782ZZ
BRM

L
CAB N

JSKIA5795ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA7252ZZ
P
: Vehicle front
: Sealed portions

JSKIA5785ZZ
: Sealed portions
REAR BODY

BRM
N
JSKIA5787ZZ
: Vehicle front O
: Sealed portions

JSKIA5788ZZ
: Vehicle front
: Sealed portions
EXCEPT FOR THAILAND, AUSTRALIA AND NEW ZEALAND

EXCEPT FOR THAILAND, AUSTRALIA AND NEW ZEALAND : Undercoating
INFOID:0000000011854125 A
1. Never apply undercoating to any place unless specified (such as the areas above the muffler and three C
3. Never undercoat rotating parts. D
E
J
JSKIA5791ZZ
: Undercoated areas BRM

: Sealed portions
EXCEPT FOR THAILAND, AUSTRALIA AND NEW ZEALAND : Stone Guard Coat L
INFOID:0000000011854126
of Stone Guard Coating over the ED primer coating. When replacing or repairing these panels, apply Stone M
and has a long shelf life.
CAB N

JSKIA5793ZZ
REAR BODY

JSKIA5782ZZ
BRM

L
EXCEPT FOR THAILAND, AUSTRALIA AND NEW ZEALAND : Body Sealing
INFOID:0000000011854128
CAB N

JSKIA5795ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA7253ZZ
P
: Vehicle front
: Sealed portions

JSKIA5785ZZ
: Sealed portions
REAR BODY

BRM
N
JSKIA5787ZZ
: Vehicle front O
: Sealed portions

JSKIA5788ZZ
: Vehicle front
: Sealed portions

BODY CONSTRUCTION
BODY CONSTRUCTION
A
LHD
LHD : Body Construction INFOID:0000000011681557
B
BRM
JSKIA5809ZZ
Upper inner front pillar Weld nut Side dash

BODY CONSTRUCTION
Upper dash Upper rear hoodledge Lower front pillar reinforcement
Lower dash Front fender bracket Lower front pillar bulkhead
Front floor Inner sill Outer sill reinforcement
Front seat mounting front cross- Outer front seat mounting front 2nd crossmember extension
member bracket
Outer side roof rail reinforcement Roof 1st roof bow
Inner front side roof rail Assist grip bracket Anchor plate
Upper inner center pillar Upper center pillar hinge brace Lower inner center pillar
Lower hinge plate Lower center pillar hinge brace Rear floor
Inner sill wheelhouse Inner lock pillar Upper lock pillar belt anchor
Upper outer lock pillar reinforcement Back panel Lower outer lock pillar reinforcement
FOR THAILAND

BODY CONSTRUCTION
BRM
P
JSKIA5810ZZ

BODY CONSTRUCTION
member
Outer front seat mounting front 2nd crossmember extension Outer side roof rail reinforcement
bracket
Roof 1st roof bow Inner front side roof rail
Assist grip bracket Anchor plate Upper inner center pillar
Upper center pillar hinge brace Lower inner center pillar Lower hinge plate
Lower center pillar hinge brace Rear floor Inner sill wheelhouse
Inner lock pillar Upper lock pillar belt anchor Upper outer lock pillar reinforcement
Back panel Lower outer lock pillar reinforcement

BODY CONSTRUCTION
FOR AUSTRALIA AND NEW ZEALAND : Body Construction INFOID:0000000011854176
BRM
P
JSKIA5811ZZ

BODY CONSTRUCTION
member bracket
1st roof bow Inner front side roof rail Assist grip bracket
Anchor plate Upper inner center pillar Upper center pillar hinge brace
Lower inner center pillar Lower hinge plate Lower center pillar hinge brace
Rear floor Inner sill wheelhouse Inner lock pillar
Upper lock pillar belt anchor Upper outer lock pillar reinforcement Back panel

BODY CONSTRUCTION
EXCEPT FOR THAILAND, AUSTRALIA AND NEW ZEALAND : Body Construction
INFOID:0000000011854177 A
BRM
P
JSKIA5812ZZ
Upper inner front pillar Weld nut Side dash
Upper dash Upper rear hoodledge Lower front pillar reinforcement
Lower dash Front fender bracket Lower front pillar bulkhead

BODY CONSTRUCTION
Front floor Inner sill Outer sill reinforcement
Front seat mounting front cross- Outer front seat mounting front 2nd crossmember extension
member bracket
Outer side roof rail reinforcement Roof 1st roof bow
Inner front side roof rail Assist grip bracket Anchor plate
Upper inner center pillar Upper center pillar hinge brace Lower inner center pillar
Lower hinge plate Lower center pillar hinge brace Rear floor
Inner sill wheelhouse Inner lock pillar Upper lock pillar belt anchor
Upper outer lock pillar reinforcement Back panel Lower outer lock pillar reinforcement

A
E
F
2-spot welds
G
JSKIA0049ZZ
H
JSKIA0053ZZ
3-spot welds
I
JSKIA0050ZZ
BRM
JSKIA0054ZZ L
MIG plug weld
M
JSKIA0051ZZ
N
JSKIA0055ZZ

P

PIIA0150E

position.
JSKIA0104GB
JSKIA0105GB

lowing.
PIIA0153E
LHD

LHD : Radiator Core Support INFOID:0000000011830704
BRM
JSKIA5626ZZ O
: Vehicle front
Replacement part
LHD : Hoodledge INFOID:0000000011830705

JSKIA5627ZZ
: Vehicle front
Replacement part

LHD : Hoodledge (Partial Replacement) INFOID:0000000011830706

BRM
N
JSKIA5629GB
Relay box bracket O

Unit: mm (in)
: Vehicle front
Replacement part P
z Lower hoodledge
View B: Before installing relay box bracket

LHD : Front Pillar INFOID:0000000011830707

JSKIA5636GB

Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5637GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

JSKIA5638GB

Unit: mm (in)
: Vehicle front
View M: Before installing outer front side body

LHD : Center Pillar INFOID:0000000011667194
BRM
JSKIA5642GB O
Unit: mm (in)
: Vehicle front P
Replacement part
z Outer front side body z Center pillar hinge brace assembly z Inner center pillar assembly

JSKIA5643GB
Unit: mm (in)
: Vehicle front
View B: Before installing outer front side body

LHD : Outer Sill (Partial Replacement) INFOID:0000000011667195
BRM
JSKIA5645GB O
Unit: mm (in)
: Vehicle front P
Replacement part

LHD : Outer Sill INFOID:0000000011667196
JSKIA5648GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5649GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P
LHD : Rear Cab Pillar INFOID:0000000011667197

JSKIA5654GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5655GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

LHD : Back Panel INFOID:0000000011667198
JSKIA5659GB
Body sealing
Unit: mm (in)
: Vehicle front
: Welding method, the number of welding points, and the distance in the figure apply to both side of the vehicle.
Replacement part

LHD : Rear Body Fender INFOID:0000000011667199
BRM
JSKIA5663GB O
: Vehicle front
Replacement part

JSKIA5664GB
: Vehicle front
LHD : Rear Crossmember INFOID:0000000011830708

BRM
N
JSKIA5667GB
: Vehicle front O
P
Replacement part
LHD : Crush Horn INFOID:0000000011830709
CAUTION:

Weld the reinforcing sheet on the back of butt welding area, and then perform butt welding.
JSKIA5669GB

Unit: mm (in)
: Vehicle front
Replacement part
sembly

A
LHD : Roof (Normal Roof Models) INFOID:0000000011667372
BRM
O
JSKIA5671ZZ
Body sealing P
: Vehicle front
Replacement part
z Center roof bow z Roof bow No.3

FOR THAILAND
JSKIA5626ZZ
: Vehicle front
Replacement part

A
BRM
O
JSKIA5627ZZ
: Vehicle front
P
Replacement part

JSKIA5628GB
Unit: mm (in)
Replacement part
z Lower hoodledge

BRM
N
JSKIA5633GB
Body sealing Urethane foam O

Unit: mm (in)
: Vehicle front
Replacement part P

JSKIA5634GB
Urethane foam
Unit: mm (in)
: Vehicle front

BRM
N
JSKIA5635GB
Body sealing O
Unit: mm (in)
: Vehicle front
P

FOR THAILAND : Center Pillar INFOID:0000000011854763
JSKIA5642GB
Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5643GB
Unit: mm (in) O
: Vehicle front

P

JSKIA5645GB
Unit: mm (in)
: Vehicle front
Replacement part

BRM
JSKIA5648GB O
Urethane foam
Unit: mm (in) P
: Vehicle front
Replacement part

JSKIA5649GB
Urethane foam
Unit: mm (in)
: Vehicle front

BRM
N
JSKIA5654GB
Urethane foam O
Unit: mm (in)
: Vehicle front
Replacement part P

JSKIA5655GB
Urethane foam
Unit: mm (in)
: Vehicle front

BRM
JSKIA5659GB O
Body sealing
Unit: mm (in) P
: Vehicle front
Replacement part

JSKIA5663GB
: Vehicle front
Replacement part

BRM
N
JSKIA5664GB
: Vehicle front O
P

JSKIA5667GB
: Vehicle front
Replacement part
CAUTION:

BRM
O
JSKIA5669GB

P
Unit: mm (in)
: Vehicle front
Replacement part
sembly

FOR THAILAND : Roof (Normal Roof Models) INFOID:0000000011854771
JSKIA5671ZZ
Body sealing
: Vehicle front
Replacement part

A
BRM
JSKIA5626ZZ
P
: Vehicle front
Replacement part

JSKIA5627ZZ
: Vehicle front
Replacement part

INFOID:0000000011854789 A
B
BRM
O
JSKIA5628GB
Unit: mm (in) P
Replacement part
z Lower hoodledge

JSKIA7376GB

Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA7377GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

JSKIA5632GB

Unit: mm (in)
: Vehicle front

FOR AUSTRALIA AND NEW ZEALAND : Center Pillar INFOID:0000000011854791
BRM
JSKIA7378GB O
Unit: mm (in)
: Vehicle front P
Replacement part

JSKIA5643GB
Unit: mm (in)
: Vehicle front

BRM
JSKIA5645GB O
Unit: mm (in)
: Vehicle front P
Replacement part

JSKIA7380GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5649GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

JSKIA5654GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5655GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

JSKIA5659GB
Body sealing
Unit: mm (in)
: Vehicle front
Replacement part

BRM
JSKIA5663GB O
: Vehicle front
Replacement part

JSKIA5664GB
: Vehicle front

BRM
N
JSKIA5667GB
: Vehicle front O
P
Replacement part
CAUTION:

JSKIA5669GB

Unit: mm (in)
: Vehicle front
Replacement part
sembly

A
FOR AUSTRALIA AND NEW ZEALAND : Roof (Normal Roof Models) INFOID:0000000011854799
BRM
O
JSKIA5671ZZ
Body sealing P
: Vehicle front
Replacement part

FOR AUSTRALIA AND NEW ZEALAND : Roof (Sunroof Models) INFOID:0000000011854800
JSKIA5672ZZ
Body sealing
: Vehicle front
Replacement part
z Roof assembly z Roof bow No.3
EXCEPT FOR THAILAND AND AUSTRALIA (RHD)

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Radiator Core Support
INFOID:0000000011854801 A
BRM
O
JSKIA5626ZZ
: Vehicle front
P
Replacement part
EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Hoodledge INFOID:0000000011854802

JSKIA5627ZZ
: Vehicle front
Replacement part

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Hoodledge (Partial Replace-
ment) INFOID:0000000011854803

BRM
N
JSKIA5628GB
Unit: mm (in) O
Replacement part
z Lower hoodledge
P
EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Front Pillar INFOID:0000000011854804

JSKIA5639GB

Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5640GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

JSKIA5641GB

Unit: mm (in)
: Vehicle front

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Center Pillar INFOID:0000000011854805
BRM
JSKIA5642GB O
Unit: mm (in)
: Vehicle front P
Replacement part

JSKIA5643GB
Unit: mm (in)
: Vehicle front

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Outer Sill (Partial Replacement)
INFOID:0000000011854806 A
BRM
O
JSKIA5645GB
Unit: mm (in)
P
: Vehicle front
Replacement part

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Outer Sill INFOID:0000000011854807
JSKIA5648GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5649GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P
EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Cab Pillar INFOID:0000000011854808

JSKIA5654GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5655GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Back Panel INFOID:0000000011854809
JSKIA5659GB
Body sealing
Unit: mm (in)
: Vehicle front
Replacement part

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Body Fender INFOID:0000000011854810
BRM
JSKIA5663GB O
: Vehicle front
Replacement part

JSKIA5664GB
: Vehicle front
EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Crossmember INFOID:0000000011854811

BRM
N
JSKIA5667GB
: Vehicle front O
P
Replacement part
EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Crush Horn INFOID:0000000011854812
CAUTION:

JSKIA5669GB

Unit: mm (in)
: Vehicle front
Replacement part
sembly

A
EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Roof (Normal Roof Models)
INFOID:0000000011854813
BRM
JSKIA5671ZZ
P
Body sealing
: Vehicle front
Replacement part

BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS) [DOUBLE CAB]
SERVICE DATA AND SPECIFICATIONS (SDS)

BODY ALIGNMENT
LHD
LHD : Body Center Marks INFOID:0000000011681878
JSKIA5815ZZ
: Vehicle front
Unit: mm (in)
B Cowl top Hole 10×12 (0.39×0.47)

BODY ALIGNMENT
A
C Back panel Indent
D Rear roof Indent
LHD : Description INFOID:0000000011688548

B

• When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself C
D
and ″Z″. E
J
JSKIA0073GB

BRM
LHD : Engine Compartment INFOID:0000000011185721
MEASUREMENT L
vehicle.
M

BODY ALIGNMENT
JSKIA5816GB
Unit: mm (in)
MEASUREMENT POINTS

BODY ALIGNMENT
I
JSKIA5817ZZ
: Vehicle front J
Unit: mm (in)

BRM
10×12 (0.39×0.47) (0.43)
L
LHD : Underbody INFOID:0000000011688550

M
MEASUREMENT
vehicle. N

BODY ALIGNMENT
JSKIA5818GB
Unit: mm (in)
MEASUREMENT POINTS

BODY ALIGNMENT
BRM
L
JSKIA5869ZZ
: Vehicle front M
Unit: mm (in)
X Y Z X Y Z
±426.0 −528.0 275.0 Hole 14×16 ±570.0 2085.0 100.0
Hole φ8 (0.31)
(±16.772) (−20.787) (10.827) (0.55×0.63) (±22.441) (82.086) (3.937) O
±518.0 −483.0 405.0 Hole φ32 ±553.0 4173.0 337.0 Hole 17×18
(±20.394) (−19.016) (15.945) (1.26) (±21.772) (164.291) (13.268) (0.67×0.71)
±437.0 90.0 178.0 Hole φ10 ±484.0 −47.0 513.0 Hole φ52 P
(±17.205) (3.543) (7.008) (0.39) (±19.055) (−1.850) (20.197) (2.05)
±474.0 804.0 100.0 Hole φ16
– – – – –
(±18.661) (31.653) (3.937) (0.63)
LHD : Passenger Compartment (Windshield and Door Opening) INFOID:0000000011185723
MEASUREMENT

BODY ALIGNMENT
vehicle.
JSKIA5819GB
Unit: mm (in)
«The others»

BODY ALIGNMENT
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo A

- 1374 (54.09) - 1609 (63.35)* - 794 (31.26)
- 1649 (64.92)* - 1480 (58.27) - 899 (35.39) B

- 1563 (61.54)* - 1787 (70.35)* - 1052 (41.42)*
- 1746 (68.74)* - 1602 (63.07)* - 822 (32.36)*

C
- 1453 (57.20) - 1352 (53.23) - 681 (26.81)*
- 1673 (65.87)* - 1621 (63.82)* - 1353 (53.27)*

D
- 1483 (58.39) - 1423 (56.02) - 1226 (48.27)*
- 1917 (75.47)* - 1481 (58.31) - 1008 (39.68)*
- 1720 (67.72)* - 997 (39.25) - 1584 (62.36) E
- 1368 (53.86) - 1077 (42.40) - 1131 (44.53)*
- 1645 (64.76)* - 862 (33.94) - 1193 (46.97)* F

- 1458 (57.40) - 958 (37.72) - 1616 (63.62)
- 1489 (58.62) - 827 (32.56) - 1188 (46.77)*

G
- 1369 (53.90) - 928 (36.54) - 1122 (44.17)*
- 1639 (64.53)* - 1120 (44.09) - 1602 (63.07)

H
- 1536 (60.47)* - 1191 (46.89) - 1630 (64.17)
- 1730 (68.11)* - 915 (36.02) — —
- 1446 (56.93) - 1006 (39.61) — — I
MEASUREMENT POINTS
J
BRM

BODY ALIGNMENT
JSKIA5820ZZ
: Vehicle front
Unit: mm (in)

Center pillar indent
10×12 (0.39×0.47)
Front seat mounting front crossmember hole

Roof flange end of center positioning mark
center φ7 (0.28)
Outer side body joggle Center pillar crossmember hole center φ12 (0.47)
Front pillar indent — —

BODY ALIGNMENT
LHD : Passenger Compartment (Rear Window Opening) INFOID:0000000011185724
A
MEASUREMENT
vehicle. B
JSKIA5821GB
BRM
Unit: mm (in)

BODY ALIGNMENT
JSKIA5093ZZ
: Vehicle front

LHD : Rear Body INFOID:0000000011688580
MEASUREMENT
vehicle.

BODY ALIGNMENT
I
JSKIA5094GB
Unit: mm (in)
J
«The others»
Unit: mm (in)
- 549 (21.61)* - 1492 (58.74)* - 1370 (53.94)*

BODY ALIGNMENT
JSKIA5095ZZ
: Vehicle front
Unit: mm (in)

: φ14 (0.55)
(0.55)
: φ10 (0.39)
RHD
RHD : Body Center Marks INFOID:0000000011688529

BODY ALIGNMENT
BRM
L
JSKIA5823ZZ
: Vehicle front M
Unit: mm (in)
N
B Cowl top Hole 10×12 (0.39×0.47)
C Back panel Indent O
D Rear roof Indent
RHD : Description INFOID:0000000011688530 P


BODY ALIGNMENT
and ″Z″.
JSKIA0073GB
RHD : Engine Compartment INFOID:0000000011688531
MEASUREMENT
vehicle.
JSKIA5086GB

BODY ALIGNMENT
Unit: mm (in) A
MEASUREMENT POINTS
B
J
JSKIA5087ZZ
: Vehicle front BRM

Unit: mm (in)

L
10×12 (0.39×0.47) (0.43)
M
RHD : Underbody INFOID:0000000011688532

N
MEASUREMENT
O
vehicle.

BODY ALIGNMENT
JSKIA5818GB
Unit: mm (in)
MEASUREMENT POINTS

BODY ALIGNMENT
BRM
L
JSKIA5869ZZ
: Vehicle front M
Unit: mm (in)
X Y Z X Y Z
±426.0 −528.0 275.0 Hole 14×16 ±570.0 2085.0 100.0
Hole φ8 (0.31)
(±16.772) (−20.787) (10.827) (0.55×0.63) (±22.441) (82.086) (3.937) O
±518.0 −483.0 405.0 Hole φ32 ±553.0 4173.0 337.0 Hole 17×18
(±20.394) (−19.016) (15.945) (1.26) (±21.772) (164.291) (13.268) (0.67×0.71)
±437.0 90.0 178.0 Hole φ10 ±484.0 −47.0 513.0 Hole φ52 P
(±17.205) (3.543) (7.008) (0.39) (±19.055) (−1.850) (20.197) (2.05)
±474.0 804.0 100.0 Hole φ16
– – – – –
(±18.661) (31.653) (3.937) (0.63)
RHD : Passenger Compartment (Windshield and Door Opening) INFOID:0000000011688533
MEASUREMENT

BODY ALIGNMENT
vehicle.
JSKIA5090GB
Unit: mm (in)
«The others»

BODY ALIGNMENT
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo A

- 1374 (54.09) - 1609 (63.35)* - 794 (31.26)
- 1649 (64.92)* - 1480 (58.27) - 899 (35.39) B

- 1563 (61.54)* - 1787 (70.35)* - 1052 (41.42)*
- 1746 (68.74)* - 1602 (63.07)* - 822 (32.36)*

C
- 1453 (57.20) - 1352 (53.23) - 681 (26.81)*
- 1673 (65.87)* - 1621 (63.82)* - 1353 (53.27)*

D
- 1483 (58.39) - 1423 (56.02) - 1226 (48.27)*
- 1917 (75.47)* - 1481 (58.31) - 1008 (39.68)*
- 1720 (67.72)* - 997 (39.25) - 1584 (62.36) E
- 1368 (53.86) - 1077 (42.40) - 1131 (44.53)*
- 1645 (64.76)* - 862 (33.94) - 1193 (46.97)* F

- 1458 (57.40) - 958 (37.72) - 1616 (63.62)
- 1489 (58.62) - 827 (32.56) - 1188 (46.77)*

G
- 1369 (53.90) - 928 (36.54) - 1122 (44.17)*
- 1639 (64.53)* - 1120 (44.09) - 1602 (63.07)

H
- 1536 (60.47)* - 1191 (46.89) - 1630 (64.17)
- 1730 (68.11)* - 915 (36.02) — —
- 1446 (56.93) - 1006 (39.61) — — I
MEASUREMENT POINTS
J
BRM

BODY ALIGNMENT
JSKIA5091ZZ
: Vehicle front
Unit: mm (in)

Center pillar indent
10×12 (0.39×0.47)
Front seat mounting front crossmember hole

Roof flange end of center positioning mark
center φ7 (0.28)
Front pillar indent — —

BODY ALIGNMENT
RHD : Passenger Compartment (Rear Window Opening) INFOID:0000000011688534
A
MEASUREMENT
vehicle. B
JSKIA5092GB
BRM
Unit: mm (in)

BODY ALIGNMENT
JSKIA5093ZZ
: Vehicle front

RHD : Rear Body INFOID:0000000011688535
MEASUREMENT
vehicle.

BODY ALIGNMENT
I
JSKIA5094GB
Unit: mm (in)
J
«The others»
Unit: mm (in)
- 549 (21.61)* - 1492 (58.74)* - 1370 (53.94)*

BODY ALIGNMENT
JSKIA5095ZZ
: Vehicle front
Unit: mm (in)

: φ14 (0.55)
(0.55)
: φ10 (0.39)

A
B
Heat resisting
viation solvents
°C (°F)
C
ABS Acrylonitrile Butadiene Styrene 80 (176) Avoid gasoline and solvents. — D
E
EPDM polymer
F
when burned.
TPO Thermoplastic Olefine 80 (176) ↑ Flammable G
H
tery acid. I
UP Unsaturated Polyester 90 (194) ↑ Flammable J
BRM
PC Polycarbonate
L
Avoid immersing in wa- M
ter.
PAR Polyarylate 180 (356) ↑ — N
O
CAUTION:
P
LHD

LHD : Location of Plastic Parts INFOID:0000000011681877
JSKIA5824ZZ

PC + PET +
Body PP Escutcheon
Glass fiber
Door mirror
Tailgate
handle
Lower cover ASA Black
Glass fiber
body mod-
Door mirror Under body ASA els Housing ASA
Rear combi-
(Electrical
type)
Garnish body mod-
Lens PC Lens PMMA

Outer ABS Door outside molding PVC + Stainless
Front grille
Door outside handle
Front bumper fascia PP + EPM Black PC + PET
Rear
Lens Glass Steel
ment
Front fog lamp
PBT + ASA +
Housing Lens PC

A
Mudguard PP + EPDM
Housing PC + ABS B
JSKIA5825ZZ
J
BRM
Knob PP Cluster lid C lower PP L
Center pillar garnish PP Instrument side finisher PC + ABS

Switch finisher PP Console body PP M
Map lamp
sole
N
Console lid
RHD O

RHD : Location of Plastic Parts INFOID:0000000011688592
JSKIA5824ZZ

PC + PET +
Body PP Escutcheon
Glass fiber
Door mirror
Tailgate
handle
Lower cover ASA Black
Glass fiber
body mod-
Rear combi-
(Electrical
type)
Garnish body mod-
Lens PC Lens PMMA

Front grille
Door outside handle
Rear
Lens Glass Steel
ment
Front fog lamp
PBT + ASA +
Housing Lens PC

A
Mudguard PP + EPDM
Housing PC + ABS B
JSKIA5827ZZ
J
BRM
Knob PP Cluster lid C lower PP L
Center pillar garnish PP Instrument side finisher PC + ABS

Switch finisher PP Console body PP M
Map lamp
sole
N
Console lid

< VEHICLE INFORMATION > [SINGLE CAB]
VEHICLE INFORMATION
FOR THAILAND AND AUSTRALIA
JSKIA5830ZZ
Color code BK21 BK23 BQM1

Description Gray Silver White
Component Paint type note 2FPM 2M S
Standard
× × –
clear coat
Chromium
Cr Cr Cr
Door mirror plate
Material color – – –
Chromium
Cr Cr Cr
Front grille plate
Silver K23 K23 K23
Front bumper fascia Body color BK21 BK23 BQM1
Chromium
Cr Cr Cr
Material color – – –
Upper and
Lower fin- Material color – – –
isher
Rear
bumper Rear
bumper Chromium
Cr Cr Cr
reinforce- plate
ment
NOTE:
• S: 1-Coat solid

< VEHICLE INFORMATION > [SINGLE CAB]
E
JSKIA5830ZZ
Color code BCAQ BEAU BG42 BK21 BK23 BQX1 BRAA BQM1 F
Dark Dark
Brown Blue
Component
Paint type note 2PM 2PM 2S 2FPM 2M 3P 2P S G
Standard
× × × × × × × –
clear coat
Chromium H
Door mirror plate
Chromium I
Front grille plate
Silver K23 K23 K23 K23 K23 K23 K23 K23
J
Chromium
BRM
Upper and
Lower fin- Material color – – – – – – – – L
isher
Rear
bumper Rear
bumper Chromium
Cr Cr Cr Cr Cr Cr Cr Cr M
reinforce- plate
ment
NOTE:
• S: 1-Coat solid N
• 2S: 2-Coat solid O
• 2FPM: 2-Coat Iron pearl metallic P

PRECAUTIONS
< PRECAUTION > [SINGLE CAB]
PRECAUTION
PRECAUTIONS
even after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed
time.
power before disconnecting the 12V battery terminal, observing
NOTE:
switch is turned OFF and ignition power supply is stopped. If the
• For vehicles with the 2-batteries, be sure to connect the main bat-
NOTE:
SEF289H
main battery and sub battery disconnected, then DTC may be detected.
NOTE:
The removal of 12V battery may cause a DTC detection error.
1. Open the hood.
4. Get out of the vehicle and close the driver side door.
D4D engine : 20 minutes YS23DDT : 4 minutes

CAUTION:
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

A
High strength steel is used for body panels in order to reduce vehicle weight. B

C
(Front floor assembly component part) D
(Front floor assembly component part) E
• Inner sill
(Lower dash complete component part) F
• Upper hoodledge
• Lower hoodledge
G
• Hoodledge reinforcement extension
• Lower battery support bracket H
• Lower battery bracket
• Side radiator core stay I
• Front roof rail
• Upper inner front pillar J
• Inner lock pillar assembly
BRM
• Outer side roof rail reinforcement
• Lower rear panel reinforcement L
• Upper front door hinge reinforcement
• Lower front door hinge reinforcement M
• 3rd floor bolster N


• Inner center side member
• 4th crossmember
440 - 780 MPa
• Rear fuel tank crossmember
• Outer front side member extension

1. Additional points to consider
above 550°C (1,022°F).
ate.)
PIIA0115E
• When straightening body panels, use caution in pulling any HSS panel. Because HSS is very strong,
Instead, use a saw to avoid weakening surrounding areas due
PIIA0117E

ble in order to minimize weakening surrounding areas due to A
heat.
B
strength.
PIIA0144E
D
steel panel.
Therefore, when cutting spot welds on a HSS panel, use a low E
F
G
PIIA0145E
2. Precautions in spot welding HSS H

I
PIIA0146E BRM

gaps. L
PIIA0147E

Unit: mm (in)
0.6 (0.024) 10 (0.39) or more
0.8 (0.031) 12 (0.47) or more
1.0 (0.039) 18 (0.71) or more
1.2 (0.047) 20 (0.79) or more
1.6 (0.063) 27 (1.06) or more
1.8 (0.071) 31 (1.22) or more
JSKIA0781ZZ

REPAIRING MATERIAL
< PREPARATION > [SINGLE CAB]
PREPARATION A
REPAIRING MATERIAL
B
C
D
lent
Read instructions on product for fill procedures. E
a. Eliminate foam material remaining on vehicle side. F
G
BRM
L
JSKIA0129GB
Urethane foam
M
Nozzle insert hole
: Vehicle front
2. Fill procedures before installation of service part. N

O

REPAIRING MATERIAL
Urethane foam
: Vehicle front
NOTE:
area.
NOTE: JSKIA0130GB
Refer to label for information on working times.

A
FOR THAILAND
B
BRM
JSKIA5831ZZ


Both sided
No. Parts name
(MPa) precoated
steel sections

NOTE:

BRM
JSKIA5832ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections
Roof Under 440 —
Hood Under 440 ×

NOTE:

BRM
JSKIA5833ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections

3rd floor bolster assembly (Rear) 440 ×
3rd floor bolster assembly (Front) 440 ×
1st floor bolster assembly 440 ×

NOTE:

BRM
JSKIA5834ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections
NOTE:

EXCEPT FOR THAILAND
EXCEPT FOR THAILAND : Underbody Component Parts INFOID:0000000011854752
B
C
BRM
JSKIA5835ZZ

AT models MT models

Both sided
No. Parts name
(MPa) precoated
steel sections

NOTE:
EXCEPT FOR THAILAND : Body Component Parts INFOID:0000000011854753

BRM
JSKIA5836ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections
Roof Under 440 —
Hood Under 440 ×

NOTE:
EXCEPT FOR THAILAND : Rear Body Component Parts INFOID:0000000011854754

BRM
JSKIA5837ZZ
P
Without guard frame models With guard frame models


Both sided
No. Parts name
(MPa) precoated
steel sections

3rd floor bolster assembly (Rear) 440 ×
3rd floor bolster assembly (Front) 440 ×
1st floor bolster assembly 440 ×

NOTE:
EXCEPT FOR THAILAND : Frame Component Parts INFOID:0000000011866984

BRM
JSKIA5834ZZ
P

Both sided
No. Parts name
(MPa) precoated
steel sections
NOTE:

BRM

< REMOVAL AND INSTALLATION > [SINGLE CAB]

rosive measures.
SIIA2294E
CAUTION:
minimum.
PIIA0095E
FOR THAILAND

JSKIA5839ZZ F
: Undercoated areas
: Sealed portions G
CAB
BRM

JSKIA5841ZZ
REAR BODY

JSKIA5842ZZ
BRM

L
CAB N

JSKIA5843ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA7254ZZ
P
: Vehicle front
: Sealed portions

JSKIA5845ZZ
: Sealed portions
REAR BODY

BRM
N
JSKIA5847ZZ
: Vehicle front O
: Sealed portions

JSKIA7255ZZ
: Vehicle front
: Sealed portions

A
E
J
JSKIA5839ZZ
: Undercoated areas
L
CAB
N

JSKIA5841ZZ
REAR BODY

JSKIA5842ZZ
BRM

L
CAB N

JSKIA5843ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA7256ZZ
P
: Vehicle front
: Sealed portions

JSKIA5845ZZ
: Sealed portions
REAR BODY

BRM
N
JSKIA5847ZZ
: Vehicle front O
: Sealed portions

JSKIA7255ZZ
: Vehicle front
: Sealed portions

EXCEPT FOR THAILAND, AUSTRALIA AND NEW ZEALAND : Undercoating
INFOID:0000000011854756 A
1. Never apply undercoating to any place unless specified (such as the areas above the muffler and three C
3. Never undercoat rotating parts. D
E
J
JSKIA5839ZZ
: Undercoated areas BRM

: Sealed portions
EXCEPT FOR THAILAND, AUSTRALIA AND NEW ZEALAND : Stone Guard Coat L
INFOID:0000000011854757
of Stone Guard Coating over the ED primer coating. When replacing or repairing these panels, apply Stone M
and has a long shelf life.
CAB N

JSKIA5841ZZ
REAR BODY

JSKIA5842ZZ
BRM

L
EXCEPT FOR THAILAND, AUSTRALIA AND NEW ZEALAND : Body Sealing
INFOID:0000000011688602
CAB N

JSKIA5843ZZ
: Vehicle front
: Sealed portions

BRM
JSKIA7257ZZ
P
: Vehicle front
: Sealed portions

JSKIA5845ZZ
: Sealed portions
REAR BODY

BRM
N
JSKIA5847ZZ
: Vehicle front O
: Sealed portions

JSKIA7255ZZ
: Vehicle front
: Sealed portions

BODY CONSTRUCTION
BODY CONSTRUCTION
A
FOR THAILAND
B
BRM
JSKIA5861ZZ

BODY CONSTRUCTION
member
Outer front seat mounting front 2nd crossmember extension Roof
bracket
Inner front side roof rail Upper lock pillar belt anchor Upper outer lock pillar reinforcement
Inner lock pillar Anchor plate Back panel
EXCEPT FOR THAILAND

BODY CONSTRUCTION
EXCEPT FOR THAILAND : Body Construction INFOID:0000000011854758
BRM
P
JSKIA5862ZZ

BODY CONSTRUCTION
member bracket
Inner front side roof rail Inner rear pillar reinforcement Upper lock pillar belt anchor
Upper outer lock pillar reinforcement Inner lock pillar Anchor plate
Back panel Lower outer lock pillar reinforcement

A
E
F
2-spot welds
G
JSKIA0049ZZ
H
JSKIA0053ZZ
3-spot welds
I
JSKIA0050ZZ
BRM
JSKIA0054ZZ L
MIG plug weld
M
JSKIA0051ZZ
N
JSKIA0055ZZ

P

PIIA0150E

position.
JSKIA0104GB
JSKIA0105GB

lowing.
PIIA0153E
FOR THAILAND

BRM
JSKIA5626ZZ O
: Vehicle front
Replacement part

JSKIA5627ZZ
: Vehicle front
Replacement part


BRM
N
JSKIA5628GB
Unit: mm (in) O
Replacement part
z Lower hoodledge
P

JSKIA5633GB

Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5634GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

JSKIA5635GB
Body sealing
Unit: mm (in)
: Vehicle front

BRM
JSKIA5646GB O
Unit: mm (in)
: Vehicle front P
Replacement part

JSKIA5650GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5651GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

JSKIA5656GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5657GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

JSKIA5660GB
Body sealing
Unit: mm (in)
: Vehicle front
Replacement part

BRM
JSKIA5665GB O
: Vehicle front
Replacement part

JSKIA5666GB
: Vehicle front

BRM
JSKIA5668GB O
: Vehicle front
: N·m (kg-m, ft-lb) P
Replacement part

CAUTION:
JSKIA5669GB

Unit: mm (in)
: Vehicle front

Replacement part
z Front side member extension as- A
sembly
View B: Before installing front side member closing bracket B
FOR THAILAND : Roof INFOID:0000000011667375
BRM
JSKIA5673ZZ
Body sealing
: Vehicle front

Replacement part
z Roof

JSKIA5626ZZ
: Vehicle front
Replacement part

A
BRM
O
JSKIA5627ZZ
: Vehicle front
P
Replacement part

INFOID:0000000011859054
JSKIA5628GB
Unit: mm (in)
Replacement part
z Lower hoodledge

BRM
N
JSKIA7376GB

Unit: mm (in)
: Vehicle front
Replacement part P

JSKIA7377GB
Urethane foam
Unit: mm (in)
: Vehicle front

BRM
N
JSKIA5632GB

Unit: mm (in)
: Vehicle front
P

JSKIA5646GB
Unit: mm (in)
: Vehicle front
Replacement part

BRM
JSKIA7381GB O
Urethane foam
Unit: mm (in) P
: Vehicle front
Replacement part

JSKIA5651GB
Urethane foam
Unit: mm (in)
: Vehicle front

BRM
N
JSKIA5656GB
Urethane foam O
Unit: mm (in)
: Vehicle front
Replacement part P

JSKIA5657GB
Urethane foam
Unit: mm (in)
: Vehicle front

BRM
JSKIA5660GB O
Body sealing
Unit: mm (in) P
: Vehicle front
Replacement part

JSKIA5665GB
: Vehicle front
Replacement part

BRM
N
JSKIA5666GB
: Vehicle front O
P

JSKIA5668GB
: Vehicle front
Replacement part

A
CAUTION:
Weld the reinforcing sheet on the back of butt welding area, and then perform butt welding. B
BRM
P
JSKIA5669GB

Unit: mm (in)
: Vehicle front

Replacement part
sembly
FOR AUSTRALIA AND NEW ZEALAND : Roof INFOID:0000000011859063
JSKIA5673ZZ
Body sealing
: Vehicle front

Replacement part
z Roof A
EXCEPT FOR THAILAND AND AUSTRALIA (RHD)

B
EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Radiator Core Support
INFOID:0000000011854815
BRM
JSKIA5626ZZ
: Vehicle front

Replacement part
EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Hoodledge INFOID:0000000011854816
JSKIA5627ZZ
: Vehicle front
Replacement part

A
EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Hoodledge (Partial Replace-
ment) INFOID:0000000011854817
B
BRM
P
JSKIA5628GB
Unit: mm (in)
Replacement part
z Lower hoodledge

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Front Pillar INFOID:0000000011859066
JSKIA5639GB

Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5640GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

JSKIA5641GB

Unit: mm (in)
: Vehicle front

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Outer Sill (Partial Replacement)
INFOID:0000000011854819 A
BRM
O
JSKIA5646GB
Unit: mm (in)
P
: Vehicle front
Replacement part

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Outer Sill INFOID:0000000011854820
JSKIA5650GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5651GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P
EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Cab Pillar INFOID:0000000011854821

JSKIA5656GB
Urethane foam
Unit: mm (in)
: Vehicle front
Replacement part

BRM
N
JSKIA5657GB
Urethane foam O
Unit: mm (in)
: Vehicle front
P

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Back Panel INFOID:0000000011854822
JSKIA5660GB
Body sealing
Unit: mm (in)
: Vehicle front
Replacement part

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Body Fender INFOID:0000000011854823
BRM
JSKIA5665GB O
: Vehicle front
Replacement part

JSKIA5666GB
: Vehicle front

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Rear Crossmember INFOID:0000000011854824
BRM
JSKIA5668GB O
: Vehicle front
: N·m (kg-m, ft-lb) P
Replacement part

EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Crush Horn INFOID:0000000011854825
CAUTION:
JSKIA5669GB

Unit: mm (in)
: Vehicle front

Replacement part
z Front side member extension as- A
sembly
View B: Before installing front side member closing bracket B
EXCEPT FOR THAILAND AND AUSTRALIA (RHD) : Roof INFOID:0000000011854826
BRM
JSKIA5673ZZ
Body sealing
: Vehicle front

Replacement part
z Roof

BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS) [SINGLE CAB]
SERVICE DATA AND SPECIFICATIONS (SDS) A

BODY ALIGNMENT
Body Center Marks INFOID:0000000011688610
B
these marks together with body alignment specifications. C
BRM
JSKIA5864ZZ
O
: Vehicle front
P
Unit: mm (in)
B Cowl top Hole 10×12 (0.39×0.47)
C Back panel Indent
D Rear roof Indent

BODY ALIGNMENT

and ″Z″.
JSKIA0073GB
Engine Compartment INFOID:0000000011688612
MEASUREMENT
vehicle.

BODY ALIGNMENT
I
JSKIA5866GB
Unit: mm (in)
J
MEASUREMENT POINTS
BRM

BODY ALIGNMENT
JSKIA5867ZZ
: Vehicle front
Unit: mm (in)

10×12 (0.39×0.47) (0.43)
Underbody INFOID:0000000011688613
MEASUREMENT
vehicle.

BODY ALIGNMENT
BRM
JSKIA5868GB
P
Unit: mm (in)
MEASUREMENT POINTS

BODY ALIGNMENT
JSKIA5869ZZ
: Vehicle front
Unit: mm (in)
Points Remarks Points Remarks
X Y Z X Y Z
±426.0 −528.0 275.0 Hole 14×16 ±570.0 2085.0 100.0
Hole φ8 (0.31)
(±16.772) (−20.787) (10.827) (0.55×0.63) (±22.441) (82.086) (3.937)
±518.0 −483.0 405.0 Hole φ32 ±553.0 4173.0 337.0 Hole 17×18
(±20.394) (−19.016) (15.945) (1.26) (±21.772) (164.291) (13.268) (0.67×0.71)
±437.0 90.0 178.0 Hole φ10 ±484.0 −47.0 513.0 Hole φ52
(±17.205) (3.543) (7.008) (0.39) (±19.055) (−1.850) (20.197) (2.05)
±474.0 804.0 100.0 Hole φ16
– – – – –
(±18.661) (31.653) (3.937) (0.63)
Passenger Compartment (Windshield and Door Opening) INFOID:0000000011688614
MEASUREMENT

BODY ALIGNMENT
vehicle. A
JSKIA5870GB
J
Unit: mm (in)
«The others»
Unit: mm (in) BRM
- 1374 (54.09) - 1457 (57.36) - 1006 (39.61) L

- 1649 (64.92)* - 1490 (58.66) - 794 (31.26)
- 1563 (61.54)* - 997 (39.25) - 900 (35.43)

M
- 1747 (68.78)* - 1077 (42.40) - 1584 (62.36)
- 1453 (57.20) - 862 (33.94) - 1139 (44.84)*

N
- 1673 (65.87)* - 958 (37.72) - 1026 (40.39)*
- 1483 (58.39) - 827 (32.56) - 1057 (41.61)*
- 1916 (75.43)* - 928 (36.54) - 1616 (63.62) O
- 1720 (67.72)* - 1120 (44.09) - 1316 (51.81)*
- 1367 (53.82) - 1191 (46.89) - 1105 (43.50)* P

- 1645 (64.76)* - 915 (36.02) - 978 (38.50)*
MEASUREMENT POINTS

BODY ALIGNMENT
JSKIA5871ZZ
: Vehicle front
Unit: mm (in)

Front pillar indent
10×12 (0.39×0.47)
Passenger Compartment (Rear Window Opening) INFOID:0000000011688615
MEASUREMENT
vehicle.

BODY ALIGNMENT
I
JSKIA5872GB
Unit: mm (in)
J
MEASUREMENT POINTS
BRM

BODY ALIGNMENT
JSKIA5873ZZ
: Vehicle front

Rear Body INFOID:0000000011688616
MEASUREMENT
vehicle.

BODY ALIGNMENT
I
JSKIA5874GB
Unit: mm (in)
J
«The others»
Unit: mm (in)
- 549 (21.61)* - 1496 (58.90)* - 1370 (53.94)*

BODY ALIGNMENT
JSKIA5875ZZ
: Vehicle front
Unit: mm (in)

Header frame panel hole center φ12 (0.47)
(0.55)
End cap bracket hole center φ14 (0.55) – –

A
B
Heat resisting
viation solvents
°C (°F)
C
ABS Acrylonitrile Butadiene Styrene 80 (176) Avoid gasoline and solvents. — D
E
EPDM polymer
F
when burned.
TPO Thermoplastic Olefine 80 (176) ↑ Flammable G
H
tery acid. I
UP Unsaturated Polyester 90 (194) ↑ Flammable J
BRM
PC Polycarbonate
L
Avoid immersing in wa- M
ter.
PAR Polyarylate 180 (356) ↑ — N
O
CAUTION:
P

Location of Plastic Parts INFOID:0000000011688618
JSKIA5876ZZ

Body PP Mudguard PP + EPDM
Door mirror
(Manual Base PA + Glass fiber Lens PMMA
type) Side turn signal lamp
Lower cover ASA Housing PC + ABS
body mod-
Rear combi-
(Electrical
type)
Garnish body mod-
Lens PC Lens PMMA

Front grille
Door outside handle
Rear
Lens Glass Steel
ment
Front fog lamp
PBT + ASA +
Housing Lens PC

H
JSKIA5877ZZ

I
Back pillar garnish PP Cluster lid C PC + ABS
Switch finisher PP Cluster lid C lower PP
Map lamp
Console PP Instrument side finisher PC + ABS J
Lid box PC + ABS Console body PP
Front pillar garnish PP Console box PP
Center con- BRM
Cluster lid A PP Console finisher PC + ABS
sole
Instrument panel PP Outer ABS
Console lid
Glove box PP Inner PP L

Body Repair: Section

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BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

SECTION BRM BODY REPAIR

Revision: August 2015 BRM-1 D23

Revision: August 2015 BRM-2 D23

Revision: August 2015 BRM-3 D23

RHD ..........................................................................284 FOR THAILAND ...................................................... 328

Revision: August 2015 BRM-4 D23

Revision: August 2015 BRM-5 D23

Tail gate handle Material color – – – – – – – –

Revision: August 2015 BRM-6 D23

Tail gate handle Material color – – – – – – – – –

Revision: August 2015 BRM-7 D23

D4D engine : 20 minutes YS23DDT : 4 minutes

Revision: August 2015 BRM-8 D23

Tensile strength Major applicable parts

Revision: August 2015 BRM-9 D23

Tensile strength Major applicable parts

Read the following precautions when repairing HSS:

Revision: August 2015 BRM-10 D23

2. Precautions in spot welding HSS H

• The panel surfaces must fit flush to each other, leaving no

Revision: August 2015 BRM-11 D23

Revision: August 2015 BRM-12 D23

2. Fill procedures before installation of service part. N

Revision: August 2015 BRM-13 D23

Refer to label for information on working times.

Revision: August 2015 BRM-14 D23

Revision: August 2015 BRM-15 D23

: Both sided anti-corrosive precoated steel sections

Inner sill extension assembly (RH & LH) 440 ×

Front floor assembly 590 —

Inner front sill assembly (RH & LH) 590 ×

Cowl top assembly Under 440 ×

Upper dash assembly Under 440 ×

Side dash (RH & LH) under 440 —

Lower dash complete 440 —

Upper rear hoodledge (RH & LH) Under 440 ×

Hoodledge assembly (RH & LH) 440 ×

Lower hoodledge (RH & LH) 440 ×

Side radiator core support (RH & LH) 440 ×

FOR THAILAND : Body Component Parts INFOID:0000000011667144

Refer to parts catalogue for the replacement parts.

Revision: August 2015 BRM-16 D23

Revision: August 2015 BRM-17 D23

Front roof rail 590 —

Roof bow No.1 Under 440 —

Roof bow No.2 Under 440 —

Rear roof rail Under 440 —

Hood Under 440 ×

Front fender (RH & LH) Under 440 ×

Upper inner front pillar (RH & LH) 590 —

Inner lock pillar assembly (RH & LH) 440 —

Outer front pillar reinforcement (RH & LH) 590 —

Outer sill reinforcement (RH & LH) 590 ×

Front fender bracket assembly (RH & LH) Under 440 ×

Outer side roof rail reinforcement (RH & LH) 590 —

Outer lock pillar reinforcement (RH & LH) 590 —

Outer front side body (RH & LH) Under 440 ×

Back panel assembly Under 440 ×

Front door assembly (RH & LH) 590 ×

Outer front door panel (RH & LH) Under 440 ×

Rear door assembly (RH & LH) 590 ×