Service Manual Kaiyi NPS — Cab and Frame Repair Guide (EN)

CAB AND FRAME

CAB AND FRAME 2-1 FRAME AND CAB SECTION 2 CAB AND FRAME Caution: At assembly and installation, install parts properly with the specified tightening torque values. Contents GENERAL DESCRIPTION ..................................... 2-2 BUMPER................................................................. 2-2 Front Bumper (Except NPS Rigid Axle Model).... 2-2 Front Bumper (NPS Rigid Axle Model)................ 2-3 GLASS .................................................................... 2-5 Front Window Glass ............................................ 2-5 Backlight Glass (Single Cab Model).................. 2-10 Backlight Glass (Crew Cab Model)....................

2-12 FRONT GRILLE.................................................... 2-14 STEP..................................................................... 2-15 Front Step (Except NPS Front Rigid Suspension Model)................................................................ 2-15 Rear Step (Crew Cab Model) ............................ 2-19 INSTRUMENT PANEL.......................................... 2-21 Instrument Panel Assembly............................... 2-21 Instrument Reinforcement Assembly................. 2-25 DOOR ................................................................... 2-27 Front Door Assembly.........................................

2-27 Rear Door Assembly ......................................... 2-30 Front Door Trim Pad.......................................... 2-32 Rear Door Trim Pad .......................................... 2-35 Door Window Glass, Regulator and Glass Run .... 2-37 Rear Window Glass and Regulator ................... 2-40 Door Lock Assembly.......................................... 2-43 Door Outside Handle and Door Lock Cylinder ...... 2-45 Rear Door Lock Mechanism.............................. 2-47 Rear Door Outside Door Release Handle ......... 2-48 Keyless Entry Control Unit................................. 2-49 SEAT.....................................................................

2-50 Driver Side (Except LHD Wide Cab Model)....... 2-50 Driver Side (LHD Wide Cab Model)................... 2-52 Center and Passenger Side .............................. 2-54 Rear Seat (NKR) ............................................... 2-56 INTERIOR TRIM ................................................... 2-59 Front Pillar Trim Cover ...................................... 2-59 Header Shelf...................................................... 2-60 Head Lining (Single Cab Model)........................ 2-61 Head Lining (B Pack Model).............................. 2-62 Head Lining (Crew Cab Model) .........................

2-63 Roof Ventilator................................................... 2-64 SEAT BELT........................................................... 2-65 Tongue Side Seat Belt (Single Cab Model)....... 2-65 Tongue Side Seat Belt (Crew Cab Model) ........ 2-67 Front Center and Driver’s Side Seat Belt Buckle ...... 2-68 Front Center Seat Belt and Assistant’s side Seat Belt Buckle................................................................ 2-70 Rear Seat Belt (Crew Cab Model).....................

2-72 Rear Seat Belt Buckle and Rear Center Seat Belt/ Buckle (Narrow Cab Model)...............................2-74 Rear Seat Belt Buckle and Rear Center Seat Belt/ Buckle (Wide Cab Model) ..................................2-76 CAB MOUNTING...................................................2-78 Front Mounting...................................................2-78 Rear Mounting (Model with Rubber Bushing except Wide Cab Model) ...............................................2-81 Rear Mounting (Wide Cab Model) .....................2-82 Rear Mounting (Model without Rubber Bushing) ...2-83 Cab Stay ............................................................2-84 Cab Lock Assembly ...........................................2-86 Removal and Installation of Cab Assembly .......2-89 BODY PANEL SEALING (SINGLE CAB MODEL) ....2-91 BODY PANEL SEALING (CREW CAB MODEL) ....2-101 MELTING SHEET STICKING POSITIONS.........2-112 SILENCER MAT SETTING POSITIONS.............2-113 BODY PANEL SECTIONAL SHAPES (SINGLE CAB MODEL)...............................................................2-114 BODY PANEL SECTIONAL SHAPES (CREW CAB MODEL)...............................................................2-120 BODY PANEL ASSEMBLY .................................2-124 Specifications...................................................2-124

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Removal

2-2 CAB AND FRAME GENERAL DESCRIPTION General Description This Section describes the installation and removal procedures for the main parts related to the N series body (cab). Each service procedure is applicable to all N series unless otherwise specified. BUMPER Front Bumper (Except NPS Rigid Axle Model) N2A0007E Legend 1. Fog lamp fixing nuts 5. Air guide (Independent suspension) 2. Front bumper reinforcement 6. Air guide fixing bolts 3. Front bumper assembly 7. Air guide (Rigid suspension) 4. Fog lamp assembly Removal 1. Air guide fixing bolts Remove the rear-side bolts/washers fixing the air guide. 2.

Front bumper assembly Remove the two fixing bolts on each side of the left and right front bumper assembly. And disconnect fog lamp harness connection. 3. Front bumper reinforcement Loosen the fixing nuts and bolts, and clips and pull them out. (1) (2) (3) (4) (5) Wide Cab Nut Clip Clip Clip Bolt Others than Wide Bolt Bolt — Clip Bolt

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Front Bumper (NPS Rigid Axle Model)

CAB AND FRAME 2-3 N2A0008E N2A0009E 4. Fog lamp assembly Remove the fixing nuts and pull out the fog lamp (1) to forward from reinforcement (2). Installation For installation, reverse the removal procedure taking the following points into consideration. 1. Tighten the front bumper assembly fixing bolts to the specified tightening torque. Tighten: 40 N m (4.1 kg m/29.5 lb ft) 2. Adjust the installation position referring to “Basic sizes for installation of the front bumper”. Front Bumper (NPS Rigid Axle Model) N2A0010E

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Installation

2-4 CAB AND FRAME Legend 1. Bolt A 5. Front bumper assembly 2. Nut C 6. Front side bumper 3. Front bumper back bar 7. Front center bumper 4. Nut B Removal 1. Front bumper assembly Installation For installation, reverse the removal procedure taking the following points into consideration. Tighten each fixing bolts/nuts to the specified tightening torque. Remove the 2 fixing bolts A on each side of the left and right front bumper assembly. 2. Front side bumper Remove the 3 fixing bolts/nuts B on each side to remove front side bumper from front center bumper. 3. Front bumper back bar Tighten:

Bolt A (M10 Ч 1.25) to 40 N m (4.1 kg m/29.5 lb ft) Nut B (M8 Ч 1.25) to 17 N m (1.7 kg m/12.5 lb ft) Nut C (M10 Ч 1.25) to 34 N m (3.5 kg m/25.1 lb ft) Remove the 4 fixing bolt/nut C on each side. Fixing Torque N2A0011E

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