BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

EXT
A

B
SECTION
EXTERIOR C

E
CONTENTS
PRECAUTION ............................................... 3 COWL TOP ....................................................... 26 F
Exploded View .........................................................26
PRECAUTIONS ................................................... 3 Removal and Installation .........................................26
Precaution for Supplemental Restraint System G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- FENDER COVER .......................................................27
SIONER" ................................................................... 3 FENDER COVER : Removal and Installation ..........27
Precautions Necessary for Steering Wheel Rota-
tion After Battery Disconnection ................................ 3
FENDER PROTECTOR .................................... 29 H
Exploded View .........................................................29
Precaution for Work .................................................. 4
Removal and Installation .........................................29
Precaution for Procedure without Cowl Top Cover...... 4
UNDER COVER ................................................ 30 I
PREPARATION ............................................ 5
FRONT UNDER COVER ............................................30
PREPARATION ................................................... 5 FRONT UNDER COVER : Exploded View ..............30
Special Service Tools .............................................. 5 J
FRONT UNDER COVER : Removal and Installa-
Commercial Service Tools ....................................... 5
tion ...........................................................................30
CLIP LIST ............................................................ 6 ENGINE UNDER COVER ..........................................31 EXT
Descriptions for Clips ................................................ 6 ENGINE UNDER COVER : Exploded View ............31
ENGINE UNDER COVER : Removal and Installa-
SYMPTOM DIAGNOSIS .............................. 10
tion ...........................................................................31 L
SQUEAK AND RATTLE TROUBLE DIAG- REAR UNDER COVER ..............................................32
NOSES ...............................................................10 REAR UNDER COVER : Exploded View ................32
Work Flow ............................................................... 10 REAR UNDER COVER : Removal and Installation M
Generic Squeak and Rattle Troubleshooting .......... 11 ....33
Diagnostic Worksheet ............................................. 14
FLOOR UNDER COVER ...........................................33
REMOVAL AND INSTALLATION ............... 16 N
FLOOR UNDER COVER : Exploded View ..............33
FLOOR UNDER COVER : Removal and Installa-
FRONT BUMPER ...............................................16 tion ...........................................................................33
Exploded View ........................................................ 16 O
Removal and Installation ......................................... 16 MUDGUARD ..................................................... 35
Exploded View .........................................................35
REAR BUMPER .................................................20 Removal and Installation .........................................35
Exploded View ........................................................ 20 P
Removal and Installation ......................................... 21 SIDE STEP ........................................................ 37
Disassembly and Assembly .................................... 22 Exploded View .........................................................37
Removal and Installation .........................................38
FRONT GRILLE .................................................24
Exploded View ........................................................ 24 ROOF RACK ..................................................... 41
Removal and Installation ......................................... 24 Exploded View .........................................................41

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 Removal and Installation ........................................ 41 Exploded View ........................................................ 46
Removal and Installation ......................................... 46
DOOR OUTSIDE MOLDING .............................. 42
Exploded View ........................................................ 42 FRAME GUARD ................................................ 47
Removal and Installation ........................................ 42 Exploded View ........................................................ 47
Removal and Installation ......................................... 47
BED RAILS AND TRIM ..................................... 44
Exploded View ........................................................ 44 CHANNEL ASSEMBLY ..................................... 49
Removal and Installation ........................................ 44 Exploded View ........................................................ 49
Removal and Installation ......................................... 49
ROOF SIDE MOLDING ...................................... 46

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 PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000014513633

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SR and SB section of
this Service Manual.
WARNING: D
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, it is recommended that all mainte-
nance and repair be performed by an authorized NISSAN/INFINITI dealer. E
• Improper repair, including incorrect removal and installation of the SRS, can lead to personal injury
caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module,
see the SR section.
F
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the H
Ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the I
battery or batteries, and wait at least three minutes before performing any service.
Precautions Necessary for Steering Wheel Rotation After Battery Disconnection
INFOID:0000000014260785
J

NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi-
EXT
tion, then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing work. If L
a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
This vehicle is equipped with a push-button ignition switch and a steering lock unit.
If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. M
If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure
below before starting the repair operation.
OPERATION PROCEDURE N
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged. O
2. Carry the Intelligent Key or insert it to the key slot and turn the push-button ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon- P
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.

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 PRECAUTIONS
< PRECAUTION >
Precaution for Work INFOID:0000000014260786

• When removing or disassembling each component, be careful not to damage or deform it. If a component
may be subject to interference, be sure to protect it with a shop cloth.
• When removing (disengaging) components with a screwdriver or similar tool, be sure to wrap the component
with a shop cloth or vinyl tape to protect it.
• Protect the removed parts with a shop cloth and prevent them from being dropped.
• Replace a deformed or damaged clip.
• If a part is specified as a non-reusable part, always replace it with a new one.
• Be sure to tighten bolts and nuts securely to the specified torque.
• After installation is complete, be sure to check that each part works properly.
• Follow the steps below to clean components:
- Water soluble dirt:
• Dip a soft cloth into lukewarm water, wring the water out of the cloth and wipe the dirty area.
• Then rub with a soft, dry cloth.
- Oily dirt:
• Dip a soft cloth into lukewarm water with mild detergent (concentration: within 2 to 3%) and wipe the dirty
area.
• Then dip a cloth into fresh water, wring the water out of the cloth and wipe the detergent off.
• Then rub with a soft, dry cloth.
- Do not use organic solvent such as thinner, benzene, alcohol or gasoline.
- For genuine leather seats, use a genuine leather seat cleaner.
Precaution for Procedure without Cowl Top Cover INFOID:0000000014260787

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.

PIIB3706J

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 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000014260788
B

The actual shape of the tools may differ from those illustrated here.
Tool number Description
(TechMate No.) C
Tool name
— Locating the noise
(J-39570) D
Chassis Ear

SIIA0993E

F
— Repairing the cause of noise
(J-50397)
NISSAN Squeak and Rattle
Kit G

H
ALJIA1232ZZ

— Removing trim components

(J-46534)
Trim Tool Set I

AWJIA0483ZZ

Commercial Service Tools INFOID:0000000014260789 EXT

(TechMate No.) Description L

Tool name
(J-39565) Locating the noise
Engine Ear
M

SIIA0995E

( — ) Loosening nuts, screws and bolts O

Power tool

PIIB1407E

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 CLIP LIST
< PREPARATION >
CLIP LIST
Descriptions for Clips INFOID:0000000014260790

Replace any clips which are damaged during removal or installation.

SIIA0315E

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 CLIP LIST
< PREPARATION >

EXT

SIIA0316E

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 CLIP LIST
< PREPARATION >

SIIA0317E

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 CLIP LIST
< PREPARATION >

ALJIA0564GB I

EXT

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 SQUEAK AND RATTLE TROUBLE DIAGNOSES
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Work Flow INFOID:0000000014260791

SBT842

CUSTOMER INTERVIEW
Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag-
nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any of
the customer's comments; refer to EXT-14, "Diagnostic Worksheet". This information is necessary to duplicate
the conditions that exist when the noise occurs.
• The customer may not be able to provide a detailed description or the location of the noise. Attempt to obtain
all the facts and conditions that exist when the noise occurs (or does not occur).
• If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer is
concerned about. This can be accomplished by a test drive with the customer.
• After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics
are provided so the customer, service adviser and technician are all speaking the same language when
defining the noise.
• Squeak – (Like tennis shoes on a clean floor)
Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard surfaces
= higher pitch noise/softer surfaces = lower pitch noises/edge to surface = chirping
• Creak – (Like walking on an old wooden floor)
Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch depen-
dent on materials/often brought on by activity.
• Rattle – (Like shaking a baby rattle)
Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing
clip or fastener/incorrect clearance.
• Knock – (Like a knock on a door)
Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.
• Tick – (Like a clock second hand)
Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver
action or road conditions.
• Thump – (Heavy, muffled knock noise)
Thump characteristics include softer knock/dead sound often brought on by activity.
• Buzz – (Like a bumble bee)
Buzz characteristics include high frequency rattle/firm contact.
• Often the degree of acceptable noise level will vary depending upon the person. A noise that a technician
may judge as acceptable may be very irritating to the customer.
• Weather conditions, especially humidity and temperature, may have a great effect on noise level.
DUPLICATE THE NOISE AND TEST DRIVE

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 SQUEAK AND RATTLE TROUBLE DIAGNOSES
< SYMPTOM DIAGNOSIS >
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to A
duplicate the same conditions when you confirm the repair.
If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-
cate the noise with the vehicle stopped by doing one or all of the following:
B
1) Close a door.
2) Tap or push/pull around the area where the noise appears to be coming from.
3) Rev the engine.
4) Use a floor jack to recreate vehicle “twist”. C
5) At idle, apply engine load (electrical load, half-clutch on M/T model, drive position on CVT and A/T models).
6) Raise the vehicle on a hoist and hit a tire with a rubber hammer.
• Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs. D
• If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
vehicle body.
CHECK RELATED SERVICE BULLETINS E
After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related
to that concern or symptom.
If a TSB relates to the symptom, follow the procedure to repair the noise.
F
LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE
1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool
(Chassis Ear: J-39570, Engine Ear: J-39565 and mechanic's stethoscope). G
2. Narrow down the noise to a more specific area and identify the cause of the noise by:
• removing the components in the area that you suspect the noise is coming from.
Do not use too much force when removing clips and fasteners, otherwise clips and fasteners can be H
broken or lost during the repair, resulting in the creation of new noise.
• tapping or pushing/pulling the component that you suspect is causing the noise.
Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only
temporarily. I
• feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the
noise.
• placing a piece of paper between components that you suspect are causing the noise. J
• looking for loose components and contact marks.
Refer to EXT-11, "Generic Squeak and Rattle Troubleshooting".
REPAIR THE CAUSE EXT
• If the cause is a loose component, tighten the component securely.
• If the cause is insufficient clearance between components:
- separate components by repositioning or loosening and retightening the component, if possible. L
- insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or urethane
tape. A NISSAN Squeak and Rattle Kit (J-50397) is available through your authorized NISSAN Parts Depart-
ment.
CAUTION: M
Do not use excessive force as many components are constructed of plastic and may be damaged.
NOTE:
• Always check with the Parts Department for the latest parts information. N
• The materials contained in the NISSAN Squeak and Rattle Kit (J-50397) are listed on the inside cover of the
kit; and can each be ordered separately as needed.
• The following materials not found in the kit can also be used to repair squeaks and rattles.
- SILICONE GREASE: Use instead of UHMW tape that will be visible or does not fit. The silicone grease will O
only last a few months.
- SILICONE SPRAY: Use when grease cannot be applied.
- DUCT TAPE: Use to eliminate movement. P
CONFIRM THE REPAIR
Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same
conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.
Generic Squeak and Rattle Troubleshooting INFOID:0000000014260792

Refer to Table of Contents for specific component removal and installation information.

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 SQUEAK AND RATTLE TROUBLE DIAGNOSES
< SYMPTOM DIAGNOSIS >
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1. Cluster lid A and instrument panel
2. Acrylic lens and combination meter housing
3. Instrument panel to front pillar garnish
4. Instrument panel to windshield
5. Instrument panel mounting pins
6. Wiring harnesses behind the combination meter
7. A/C defroster duct and duct joint
These incidents can usually be located by tapping or moving the components to duplicate the noise or by
pressing on the components while driving to stop the noise. Most of these incidents can be repaired by apply-
ing felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring har-
ness.
CAUTION:
Never use silicone spray to isolate a squeak or rattle. If the area is saturated with silicone, the recheck
of repair becomes impossible.
CENTER CONSOLE
Components to pay attention to include:
1. Shifter assembly cover to finisher
2. A/C control unit and cluster lid C
3. Wiring harnesses behind audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console.
DOORS
Pay attention to the following:
1. Finisher and inner panel making a slapping noise
2. Inside handle escutcheon to door finisher
3. Wiring harnesses tapping
4. Door striker out of alignment causing a popping noise on starts and stops
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. The areas can usually be insulated with felt cloth tape or insulator foam blocks to
repair the noise.
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the customer.
In addition look for the following:
1. Trunk lid bumpers out of adjustment
2. Trunk lid striker out of adjustment
3. Trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
OVERHEAD CONSOLE (FRONT AND REAR)
Overhead console noises are often caused by the console panel clips not being engaged correctly. Most of
these incidents are repaired by pushing up on the console at the clip locations until the clips engage.
In addition look for:
1. Loose harness or harness connectors.
2. Front console map/reading lamp lens loose.
3. Loose screws at console attachment points.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sunvisor shaft shaking in the holder
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 SQUEAK AND RATTLE TROUBLE DIAGNOSES
< SYMPTOM DIAGNOSIS >
3. Front or rear windshield touching headlining and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these A
incidents. Repairs usually consist of insulating with felt cloth tape.
SEATS
When isolating seat noise it is important to note the position the seat is in and the load placed on the seat B
when the noise occurs. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include: C
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. Rear seatback lock and bracket D
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area. E
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment. F
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall G
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
H
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best I
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.
J

EXT

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 SQUEAK AND RATTLE TROUBLE DIAGNOSES
< SYMPTOM DIAGNOSIS >
Diagnostic Worksheet INFOID:0000000014260793

LAIA0072E

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 SQUEAK AND RATTLE TROUBLE DIAGNOSES
< SYMPTOM DIAGNOSIS >

EXT

LAIA0071E

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 FRONT BUMPER
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
FRONT BUMPER
Exploded View INFOID:0000000014260794

AWKIA3386ZZ

1. Grommet 2. Front bumper side bracket (RH) 3. Front bumper fascia

4. Front bumper Finisher (RH) 5. Front air spoiler (RH) 6. U nut
7. Front air spoiler (center) 8. Spring nut 9. Front license plate bracket
10. Front air spoiler (LH) 11. Front bumper finisher (LH) 12. Front bumper side bracket
(LH)
13. Retainer assembly (LH) 14. Crossmember 15. Retainer assembly (center)
16. Retainer assembly (RH)
Clip

Removal and Installation INFOID:0000000014260795

REMOVAL
1. Remove front grille. Refer to EXT-24, "Removal and Installation".

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 FRONT BUMPER
< REMOVAL AND INSTALLATION >
2. Remove front air spoiler (center) bolts (A) and clips, and then
remove front air spoiler (center). A

:Clip
B

JSKIA4312ZZ

D
3. Remove front air spoilers (LH/RH) bolts (A).

G
JSKIA4314ZZ

4. Partially remove front fender protectors (LH/RH). Refer to EXT-29, "Removal and Installation".
H
5. Remove front bumper lower bolts (A).

EXT
JSKIA4313ZZ

6. Remove front bumper upper screws (A). L

JSKIA4315ZZ
O

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 FRONT BUMPER
< REMOVAL AND INSTALLATION >
7. Remove front bumper stay screws (A) (LH/RH).

JSKIA4316ZZ

8. Disconnect the fog lamp harness connectors (LH/RH) (if equipped).

9. Remove front bumper fascia.
CAUTION:
When removing bumper fascia, two operators are required so as to prevent it from dropping.
10. Remove the following parts after removing front bumper fascia assembly.
• Front fog lamps assembly. Refer to EXL-128, "Removal and Installation" (LED HEADLAMP). Refer to
EXL-290, "Removal and Installation" (HALOGEN HEADLAMP).
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
After installation, add water up to the upper level of the washer tank inlet and check for water leakage.

NOTE:
After installing, perform fitting adjustment.

ALKIA3978ZZ

Unit: mm (in)

Section Measurement Minimum Target Value Maximum

A-A Clearance 2.8 (0.11) 4.8 (0.19) 6.8 (0.27)
A-A Surface Height -1.5 (-0.06) 0.5 (0.02) 2.5 (0.10)

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 FRONT BUMPER
< REMOVAL AND INSTALLATION >
Section Measurement Minimum Target Value Maximum
A
B-B Clearance 2.1 (0.08) 4.1 (0.16) 6.1 (0.24)
B-B Surface Height -1.5 (-0.06) 0.5 (0.02) 2.5 (0.10)
C-C Clearance 2.1 (0.08) 4.1 (0.16) 6.1 (0.24) B

C-C Surface Height -1.5 (-0.06) 0.5 (0.02) 2.5 (0.10)

D-D Clearance 1.5 (0.06) 3.0 (0.12) 4.5 (0.18) C
E-E Clearance 1.0 (0.04) 3.0 (0.12) 5.0 (0.20)
F-F Clearance 0.0 (0.00) 0.3 (0.01) 1.3 (0.05)
D
F-F Surface Height -0.7 (-0.03) 0.3 (0.01) 1.3 (0.05)
G-G Clearance 1.1 (0.04) 2.6 (0.10) 4.1 (0.16)
E
H-H Clearance 1.5 (0.06) 3.0 (0.12) 4.5 (0.18)
I-I Clearance 1.5 (0.06) 3.0 (0.12) 4.5 (0.18)
J-J Clearance 0.8 (0.03) 2.8 (0.11) 4.8 (0.19) F
J-J Surface Height -1.8 (-0.07) 0.2 (0.01) 2.2 (0.09)
G

EXT

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 REAR BUMPER
< REMOVAL AND INSTALLATION >
REAR BUMPER
Exploded View INFOID:0000000014260796

REMOVAL

AWKIA3503ZZ

1. Rear bumper 2. Rear sonar sensors (if 3. Frame assembly

equipped)

DISASSEMBLY

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 REAR BUMPER
< REMOVAL AND INSTALLATION >

EXT

L
JSKIA4391ZZ

1. Rear bumper stay LH 2. Rear bumper reinforcement 3. Finisher lower M

LH
4. Rear bumper reinforcement RH 5. Crossmember 6. Finisher Upper
7. Rear bumper stay RH N
Clip

Removal and Installation INFOID:0000000014260797 O

REMOVAL
1. Disconnect license plate lamp harness (LH/RH). P
2. Disconnect rear sonar sensor harness connectors (if equipped).

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 REAR BUMPER
< REMOVAL AND INSTALLATION >
3. Remove the rear bumper stay (LH/RH) bolts (A) and then
remove rear bumper from the frame assembly.

JSKIA5220ZZ

4. Remove the following parts after removing rear bumper fascia assembly (if necessary).
• Sonar sensors (if equipped).
• License plate lamp. Refer the following.
- Refer to EXL-138, "Removal and Installation" (LED HEADLAMP).
- Refer to EXL-301, "Removal and Installation" (HALOGEN HEADLAMP).
INSTALLATION
Installation is in the reverse order of removal.
NOTE:
• The following table shows the specified values for checking normal installation status.
• Fitting adjustment cannot be performed.

ALKIA3979ZZ

Unit: mm (in)

Section Measurement Minimum Target Value Maximum

A-A Clearance 19.0 (0.75) 25.0 (0.98) 31.0 (1.22)
B-B Clearance 19.0 (0.75) 25.0 (0.98) 31.0 (1.22)
C-C Clearance 19.0 (0.75) 25.0 (0.98) 31.0 (1.22)

Disassembly and Assembly INFOID:0000000014260798

DISASSEMBLY

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 REAR BUMPER
< REMOVAL AND INSTALLATION >
1. Pull rear bumper upper finisher toward the up side to disengage the pawls from the crossmember.
2. Remove upper finisher. A
3. Remove rear bumper assembly clips (A) and screws (B) from
rear bumper assembly lower side.
B

D
JSKIA4528ZZ

4. Remove lower finisher. E

5. Remove rear bumper reinforcement (LH/RH) mounting bolts (A)
and screw (B), and then remove rear bumper reinforcement (LH/
RH) from crossmember. F

H
JSKIA4529ZZ

6. Remove the rear bumper stay (LH/RH) mounting bolts (A) and I
remove rear bumper reinforcement inner from the crossmember.

EXT

L
JSKIA4530ZZ

7. Disconnect rear sonar sensors (if equipped).

M
8. Disconnect license plate lamp harness (LH/RH).
9. Remove rear bumper stay (LH/RH) from frame.
10. Remove the following parts after removing rear bumper fascia assembly. N
• Rear sonar sensors (if equipped).
• License plate lamp. Refer the following.
- Halogen headlamp. Refer to EXL-138, "Removal and Installation".
- LED headlamp. Refer to EXL-301, "Removal and Installation". O
ASSEMBLY
Assembly is in the reverse order of disassembly.
P

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 FRONT GRILLE
< REMOVAL AND INSTALLATION >
FRONT GRILLE
Exploded View INFOID:0000000014260799

AWKIA3389ZZ

1. Front grille 2. Front emblem 3. Turn fastener

Clip Pawl

Removal and Installation INFOID:0000000014260800

REMOVAL
1. Remove front grille upper clips (A).

JSKIA4526ZZ

Revision: November 2016 EXT-24 2017 D23

 FRONT GRILLE
< REMOVAL AND INSTALLATION >
2. To disengage turn fasteners, insert a suitable tool (A) into service holes on front of grille. Rotate turn fas-
tener (LH) counterclockwise to release fastener. Rotate turn fastener (RH) clockwise to release fastener. A

F
JSKIA4320ZZ

3. Disengage front grille clips from backside while pulling front

grille toward vehicle front. G

: Clip
H

JSKIA4321ZZ
J
4. Remove front grille assembly.
5. Remove the following parts after removing front grille assembly (if necessary).
• Front emblem EXT

INSTALLATION
Installation is in the reverse order of removal.
L
CAUTION:
When installing front grille, install turn fastener to back of front grille, and then install front grille.

Revision: November 2016 EXT-25 2017 D23

 COWL TOP
< REMOVAL AND INSTALLATION >
COWL TOP
Exploded View INFOID:0000000014260801

AWKIA3506ZZ

1. Cowl top cover 2. Front fender cover RH 3. EPT seal lower

4. EPT seal side 5. Cowl top seal 6. Front fender cover LH
7. Cowl top seal
Pawl Clip

Removal and Installation INFOID:0000000014260802

REMOVAL
1. Remove the front wiper arm. Refer to WW-105, "WIPER ARM : Removal and Installation" (WITHOUT
INTELLIGENT KEY). Refer to WW-45, "WIPER ARM : Removal and Installation" (WITH INTELLIGENT
KEY).
2. Disengage fender cover (LH and RH) clips, and then remove fender cover (LH/RH).
3. Remove cowl top cover clips (A).

JSKIA4355ZZ

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 COWL TOP
< REMOVAL AND INSTALLATION >
4. Pull forward to remove cowl top cover from windshield glass.
CAUTION: A
When performing the procedure after removing cowl top
cover, protect the lower of windshield glass with urethane
etc. B

JSKIA4356ZZ
D
5. Disconnect the washer tube at check valve. Refer to WW-114, "Exploded View" (WITHOUT INTELLI-
GENT KEY). Refer to WW-54, "Exploded View" (WITH INTELLIGENT KEY).
6. Remove cowl top cover. E
7. Remove the following parts after removing cowl top cover (if necessary).
• Washer nozzle. Refer to WW-115, "WASHER NOZZLE : Removal and Installation" (WITHOUT INTELLI-
GENT KEY) or Refer to WW-55, "WASHER NOZZLE : Removal and Installation" (WITH INTELLIGENT F
KEY)
INSTALLATION
Installation is in the reverse order of removal. G
CAUTION:
• Clean the joint between the cowl top cover and the windshield, and then install them.
• Replace the cowl top seal on the back surface with new seal when re-using cowl top cover. H
• Replace the EPT seal (Side/Lower) on the back surface with new EPT seal when re-using the cowl
top cover.
• Remove the EPT seal remaining on the cowl top cover using a double-faced adhesive tape remover.
• To maintain adhesion, never wash the vehicle within 24 hours after installation. I
• Perform the stop position adjustment at the installation of the front wiper arms. Refer to WW-106,
"WIPER ARM : Adjustment" (WITHOUT INTELLIGENT KEY). Refer to WW-46, "WIPER ARM : Adjust-
ment" (WITH INTELLIGENT KEY). J
FENDER COVER
FENDER COVER : Removal and Installation INFOID:0000000014260803
EXT
REMOVAL
1. Disengage clip and pawls according to the numerical order 1 → 3 indicated by arrows as shown, and then L
remove front fender cover.

O
AWKIA3507ZZ

: Clip
P
: Pawl
: Front

CAUTION:
When performing the procedure after removing fender cover, protect the lower of windshield glass
with urethane etc.
INSTALLATION

Revision: November 2016 EXT-27 2017 D23

 COWL TOP
< REMOVAL AND INSTALLATION >
Installation is in the reverse order of removal.
CAUTION:
Install so that there is no clearance between windshield glass and cowl top cover.

Revision: November 2016 EXT-28 2017 D23

 FENDER PROTECTOR
< REMOVAL AND INSTALLATION >
FENDER PROTECTOR
A
Exploded View INFOID:0000000014260804

I
JSKIA4510ZZ

1. Fender clip 2. Front fender protector 3. U nut J

4. Grommet

Removal and Installation INFOID:0000000014260805

EXT

REMOVAL
1. Position the wheels as necessary to remove screws and clips. L
2. Remove front mudguard. Refer to EXT-35, "Removal and Installation".
3. Remove front fender protector screws and clips and then remove fender protector.
INSTALLATION M
Installation is in the reverse order of removal.

Revision: November 2016 EXT-29 2017 D23

 UNDER COVER
< REMOVAL AND INSTALLATION >
UNDER COVER
FRONT UNDER COVER
FRONT UNDER COVER : Exploded View INFOID:0000000014260806

ALKIA3941ZZ

1. Front under cover 2. Front under cover lid 3. Engine under cover

FRONT UNDER COVER : Removal and Installation INFOID:0000000014260807

REMOVAL
1. Remove front under cover bolts (A) and clip (B).

JSKIA4532ZZ

Revision: November 2016 EXT-30 2017 D23

 UNDER COVER
< REMOVAL AND INSTALLATION >
2. Remove front under cover.
A
INSTALLATION
Installation is in the reverse order of removal.
ENGINE UNDER COVER
B
ENGINE UNDER COVER : Exploded View INFOID:0000000014260808

EXT

M
ALKIA3941ZZ

1. Front under cover 2. Front under cover lid 3. Engine under cover N

ENGINE UNDER COVER : Removal and Installation INFOID:0000000014260809

O
REMOVAL
P

Revision: November 2016 EXT-31 2017 D23

 UNDER COVER
< REMOVAL AND INSTALLATION >
1. Remove engine under cover bolts (A) from engine under cover
(1).

: Front

AWKIA3504ZZ

2. Remove engine under cover.

INSTALLATION
Installation is in the reverse order of removal.
REAR UNDER COVER
REAR UNDER COVER : Exploded View INFOID:0000000014260810

ALKIA3946ZZ

1. Rear under cover bolts 2. Rear under cover

Front

Revision: November 2016 EXT-32 2017 D23

 UNDER COVER
< REMOVAL AND INSTALLATION >
REAR UNDER COVER : Removal and Installation INFOID:0000000014260811

A
REMOVAL
• Remove rear under cover bolts and remove rear under cover.
CAUTION: B
When removing rear under cover, two operators are required to prevent it from dropping and dam-
age to surrounding parts.
C
INSTALLATION
Installation is in the reverse order of removal.
FLOOR UNDER COVER D

FLOOR UNDER COVER : Exploded View INFOID:0000000014260812

EXT

ALKIA3948ZZ

1. Floor under cover 2. Transmission cross member P

assembly
Front

FLOOR UNDER COVER : Removal and Installation INFOID:0000000014260813

REMOVAL

Revision: November 2016 EXT-33 2017 D23

 UNDER COVER
< REMOVAL AND INSTALLATION >
• Remove floor under cover bolts and remove floor under cover.

INSTALLATION
Installation is in the reverse order of removal.

Revision: November 2016 EXT-34 2017 D23

 MUDGUARD
< REMOVAL AND INSTALLATION >
MUDGUARD
A
Exploded View INFOID:0000000014260814

G
JSKIA4478ZZ

1. Front mudguard 2. Rear mudguard (FR) 3. Rear mudguard (RR)

H
Removal and Installation INFOID:0000000014260815

REMOVAL I
Front Mudguard
1. Remove front mudguard screws (A).
J

EXT

JSKIA4479ZZ
M
2. Remove front mudguard.
Rear Mudguard (FR)
N
1. Remove rear mudguard (FR) screws (A), and then remove rear
mudguard (FR).
O

ALKIA3885ZZ

Rear Mudguard (RR)

Revision: November 2016 EXT-35 2017 D23

 MUDGUARD
< REMOVAL AND INSTALLATION >
1. Remove rear mudguard (RR) screws (A) and clip (B), and then
remove rear mudguard (RR).

AWKIA3391ZZ

INSTALLATION
Installation is in the reverse order of removal.

Revision: November 2016 EXT-36 2017 D23

 SIDE STEP
< REMOVAL AND INSTALLATION >
SIDE STEP
A
Exploded View INFOID:0000000014260816

DOUBLE CAB MODEL B

EXT

AWKIA3392ZZ
M
1. Side step bracket 2. Side step

SINGLE CAB MODEL N

Revision: November 2016 EXT-37 2017 D23

 SIDE STEP
< REMOVAL AND INSTALLATION >

AWKIA4151ZZ

1. Side step 2. Side step cover 3. Side step cap

4. Grommet Pawl Clip
Front

Removal and Installation INFOID:0000000014260817

REMOVAL
Single Cab Model
1. Remove side step cover screws and clips, and then remove side step cover.
2. Apply protective tape (A) on the part to protect it from damage.

JMKIB4741ZZ

Revision: November 2016 EXT-38 2017 D23

 SIDE STEP
< REMOVAL AND INSTALLATION >
3. Disengage side step cap pawls using a suitable tool (A), and
then remove side step cap. A

: Pawl
B

AWKIA4152ZZ

D
4. Remove side step screw (A).

G
JMKIB4743ZZ

5. Disengage side step pawls and clips, and then remove side
step. H

: Clip
: Pawl
I

AWKIA4153ZZ
EXT

REMOVAL
Double cab model L

1. Remove side step mounting bolts (A) and then remove side step
from side step bracket.
M

JSKIA4521ZZ

Revision: November 2016 EXT-39 2017 D23

 SIDE STEP
< REMOVAL AND INSTALLATION >
2. Remove side step bracket mounting nuts (A).

JSKIA4522ZZ

3. Remove side step brackets.

INSTALLATION
Installation is in the reverse order of removal.

Revision: November 2016 EXT-40 2017 D23

 ROOF RACK
< REMOVAL AND INSTALLATION >
ROOF RACK
A
Exploded View INFOID:0000000014260818

I
JSKIA4512ZZ

1. Roof rack RH 2. Roof rack LH J

Front

Removal and Installation INFOID:0000000014260819

EXT

REMOVAL
1. Remove headlining. Refer to INT-67, "Removal and Installation". L
2. Remove RH and LH side roof rack nuts (A) front and back from
roof panel from inside.
M

O
JSKIA5223ZZ

3. Remove roof rack (RH/LH) from the roof panel. P

INSTALLATION
Installation is in the reverse order of removal.

Revision: November 2016 EXT-41 2017 D23

 DOOR OUTSIDE MOLDING
< REMOVAL AND INSTALLATION >
DOOR OUTSIDE MOLDING
Exploded View INFOID:0000000014260820

AWKIA3505ZZ

1. Front door panel 2. Door molding front 3. Rear door panel

4. Door molding rear
Pawl

Removal and Installation INFOID:0000000014260821

FRONT DOOR OUTSIDE MOLDING

Removal
1. Fully open door window.
2. Remove front door mirror. Refer to MIR-22, "DOOR MIRROR : Removal and Installation".
3. Disengage front door outside molding pawl (rear side) with suitable tool (A) and suitable tool (B).
CAUTION:
Apply protective tape (C) on door panel to protect painted
surface from damage.

: Pawl

AWKIA3394ZZ

Revision: November 2016 EXT-42 2017 D23

 DOOR OUTSIDE MOLDING
< REMOVAL AND INSTALLATION >
4. Twist and pull up to upper side, and then remove front door outside molding.
A
Installation
Installation is in the reverse order of removal.
B
REAR DOOR OUTSIDE MOLDING
Removal
1. Fully open door window. C
2. Disengage rear door outside molding pawl (front side) with suitable tool (A) and suitable tool (B).
CAUTION:
Apply protective tape (C) on the door panel to prevent D
painted surface from damage.

: Pawl
E

AWKIA3396ZZ G
3. Twist and pull up to upper side, and then remove rear door outside molding.
Installation H
Installation is in the reverse order of removal.

EXT

Revision: November 2016 EXT-43 2017 D23

 BED RAILS AND TRIM
< REMOVAL AND INSTALLATION >
BED RAILS AND TRIM
Exploded View INFOID:0000000014260822

AWKIA3489ZZ

1. Header panel seal

Clip

Removal and Installation INFOID:0000000014260823

REMOVAL
• Remove header panel seal clips and remove header panel seal.

: Clip

AWKIA3490ZZ

Revision: November 2016 EXT-44 2017 D23

 BED RAILS AND TRIM
< REMOVAL AND INSTALLATION >
INSTALLATION
Installation is in the reverse order of removal. A

EXT

Revision: November 2016 EXT-45 2017 D23

 ROOF SIDE MOLDING
< REMOVAL AND INSTALLATION >
ROOF SIDE MOLDING
Exploded View INFOID:0000000014260824

AWKIA3403ZZ

1. Roof side molding 2. Double-sided tape

Removal and Installation INFOID:0000000014260825

REMOVAL
• Using a suitable tool, release clips for roof side molding and then remove.
CAUTION:
Apply protective tape to painted surfaces to prevent damage.

INSTALLATION
• On vehicles coated with Hard Clear Coat, use double-faced 3M adhesive tape Product No. 4210 or equiva-
lent, after priming with 3M primer Product No. N200 or C-100 or equivalent
• The repair parts are also affixed with double-faced adhesive tape.
• To re-use existing molding, clean all double-faced adhesive tape from molding and apply new double-faced
adhesive tape to the molding.
1. Clean tape removed surface with isopropyl alcohol or equivalent to degrease surface.
2. Align clips and press to engage then put pressure on double sided tape to secure fit.
CAUTION:
• Use double-faced adhesive tape.
• Do not wash vehicle within 24 hours of installation, to secure contact.

Revision: November 2016 EXT-46 2017 D23

 FRAME GUARD
< REMOVAL AND INSTALLATION >
FRAME GUARD
A
Exploded View INFOID:0000000014260826

Double cab models B

ALKIA3954ZZ

H
1. Frame guard
Front

I
Single cab models

EXT

ALKIA4180ZZ
O
1. Frame guard

P
Removal and Installation INFOID:0000000014260827

REMOVAL
Double cab models
• Remove frame guard bolts and remove frame guard.
CAUTION:

Revision: November 2016 EXT-47 2017 D23

 FRAME GUARD
< REMOVAL AND INSTALLATION >
Do not damage rear window when removing frame guard.

Double cab models

1. Remove the pickup bed assembly. Refer to BRM-150, "Rear Body".
2. Remove bolts and remove the frame guard.

INSTALLATION
Installation is in the reverse order of removal.

Revision: November 2016 EXT-48 2017 D23

 CHANNEL ASSEMBLY
< REMOVAL AND INSTALLATION >
CHANNEL ASSEMBLY
A
Exploded View INFOID:0000000014260828

G
ALKIA3955ZZ

1. Header tiedown rail 2. Bed side front tiedown 3. Bed side rear tiedown
4. Tiedown cleat
H
Front

Removal and Installation INFOID:0000000014260829

I

REMOVAL
J
Bed Side Front Tiedown Rail
1. Remove bed side front tiedown rail bolts and remove bed side front tiedown rail.
EXT
2. Remove the following parts after removing bed side front tiedown rail (if necessary).
• Self lock cleat
L
Bed Side Rear Tiedown Rail
1. Remove bed side rear tiedown rail bolts and remove bed side rear tiedown rail.
2. Remove the following parts after removing bed side rear tiedown rail (if necessary). M
• Self lock cleat

Header Tiedown Rail N

• Remove header channel bolts and remove header tiedown rail.

INSTALLATION O
Installation is in the reverse order of removal.
NOTE:
P

Revision: November 2016 EXT-49 2017 D23

 CHANNEL ASSEMBLY
< REMOVAL AND INSTALLATION >
Tighten channel assembly (FR/RR) in the following order.

: Front

ALKIA3956ZZ

Revision: November 2016 EXT-50 2017 D23