ZH7_TI_01.25.18
Service Bulletin Details
Public Details for: ZH7_TI_01.25.18
Technical instructions: technical instructions for warranty enhancement program zh7. Certain 2007-2008 model year tundra. Frame replacement. Update 1.25.18 - added additional frame serial number tracker information.
Models from 2008
2008 TOYOTA TUNDRA |
Models from 2007
2007 TOYOTA TUNDRA |
TECHNICAL INSTRUCTIONS FOR WARRANTY ENHANCEMENT PROGRAM ZH7 ***************************** CERTAIN 2007-2008 MODEL YEAR TUNDRA ***************************** FRAME REPLACEMENT UPDATED 1.25.18 Update 1.25.18 - Added Additional Frame Serial Number Tracker Information Update 12.21.17 - Updated Frame Serial Number Tracker Information The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this recall are required to successfully complete the most current version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians performing this repair are required to currently hold at least one of the following certification levels: • Certified Technician (any specialty) • Expert Technician (any specialty) • Master Technician • Master Diagnostic Technician Final repair must be signed off and validated by a MDT, Shop Foreman or Service Manager using the Frame Replacement Inspection Form. It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this recall repair. Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly trained technicians available to perform this repair at all times. I. OPERATION FLOWCHART Verify Vehicle Eligibility: 1. Check the VIN range 2. Check the TIS vehicle Inquiry system Yes Perform pre-hoist inspection. No No further action required. No Contact your regional representative for assistance. Perform Frame Inspection utilizing the Inspection application. Was perforation 10mm or larger found in the locations identified in green below (during the rust removal and/or cleaning process)? Is the vehicle applicable to LSC H0F? No If No, no further action required; return vehicle to customer. Yes Yes Is your dealership located in a cold climate state? Inspection application submits report for FTS approval. Was approval received from the FTS? If No, H0F cannot be performed at your facility; return vehicle to customer. Yes Yes Order parts and complete frame replacement. Perform LSC H0F Yes WEP Complete 1 II. PREPARATION A. TOOLS & EQUIPMENT • • • • • • • • • • • • • • • • • • • • A/C service equipment Alignment rack Brake bleeder Engine Hanger ° 1GR-FE Engine - 12281-31060 – Engine hanger no. 1 (Qty: 1) - 12282-31040 – Engine hanger no. 2 (Qty: 1) - 90119-08A87 – Bolt (Qty: 4) ° 3UR-FE Engine - 12281-38150 – Engine hanger no. 1 (Qty: 2) - 90119-14120 – Bolt (Qty: 2) (Japan sourced parts) - 90119-A0166 – Bolt (Qty: 2) (Local sourced parts) Engine hoist (Qty: 2) or Hydraulic mini crane (Qty: 2) Engine sling (Qty: 2) Floor jack Protective eyewear Protective gloves Ratcheting tie down strap (2 in X 27 ft, minimum work load capacity: 3,000 lbs) Special Service Tools (SST) ° 09985-20010 – Air conditioner service tool set or Commercially available air conditioning manifold gauge set ° 09325-40010 – Transmission oil plug (Transmission A750E) ° 09325-60010 – Transmission oil plug (Transmission AB60E) ° 09610-20012 – Pitman arm puller ° 09520-32040 – A component of SST 09520-24010, Differential side gear shaft puller ° 09520-01010 – Drive shaft remover attachment ° 09951-04010,09952-04010,09953-04020,09954-04010,09955-04031,09958-04011, – A component of SST 09950-40011, Puller B set ° 09955-04090 – Craw no.9 ° 09922-10010-01 – Variable open wrench Standard hand tools Techstream Torque wrench Torx® T55H tamper resistant socket Socket wrench 39mm Hexagon wrench 8, 10 Deep socket wrench 10, 12, 14, 17, 19, 24mm Union Nut Wrench 10mm Weights B. SUPPLIES • • • • • • • Toyota Genuine ATF WS or DEXRON® lll (DEXRON® ll) – As needed Hypoid gear oil API GL-5 SAE 75W-90 – 2.1 liter R134a refrigerant – As needed Toyota DOT 3 brake fluid – 3 pints Toyota long life coolant – 2 gallons Paint MP Grease 2 C. PARTS To assist dealers in determining the correct part number(s) to order, a website has been set up to look up part numbers by VIN. Please go to http://toyota-frame-parts-lookup.imagespm.info (also linked through TIS), enter the VIN, and the correct part numbers to order will be displayed. The website is for part(s) application reference only and will not order the part, nor will it confirm campaign completion status. • • • The parts will need to be ordered through the Dealer Daily Parts system. ETAs for the parts will be available via the normal system. Frame ETAs will be made available on the Dealer Daily website, in the MAC reference area. Individual Parts: Part Number 04004-1510C 04004-1520C 04004-1530C 04004-1540C 04004-1550C 04004-1560C 04004-1570C 04004-1580C 04004-1590C 04004-1610C 04004-1620C 04004-1630C 04004-1640C 04004-1650C 04004-1660C 04004-1670C 04004-1680C 04004-1690C 04004-1710C 04004-1720C 04004-1730C 04004-1740C 04004-1750C 04004-1760C 04004-1770C 04004-1780C 04004-1790C 04004-1810C 04004-1820C 04004-1830C 04004-1840C Part Description Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Frame, Sub-Assy Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Illustration Name Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame Frame 3 Individual Parts (Continued): Part Number 17176-0P010 47324-0C060 47324-0C080 47324-0C090 47325-0C090 47325-0C100 47325-0C110 48068-09100 48069-09090 48210-0C090 48210-0C100 48210-0C101 48210-0C110 48210-0C120 48210-0C130 48210-0C131 48210-0C140 48210-0C150 48210-0C160 48210-0C170 48210-0C180 48210-0C190 48210-0C210 48210-0C220 48210-0C230 48210-0C240 48210-0C250 48210-0C260 48210-0C280 48210-0C290 48210-0C300 48210-0C310 48210-0C320 48210-0C330 48210-0C340 48210-0C350 48220-0C090 48220-0C100 48220-0C101 48220-0C110 48220-0C120 48220-0C130 48220-0C131 48220-0C140 48220-0C150 48220-0C160 Part Description Gasket, Airsurge Tank To Intake Manifold Tube, Rear Brake, No.4 Tube, Rear Brake, No.4 Tube, Rear Brake, No.4 Tube, Rear Brake, No.5 Tube, Rear Brake, No.5 Tube, Rear Brake, No.5 Arm, Sub-Assy, Front Suspension, Lower No.1 RH Arm, Sub-Assy, Front Suspension, Lower No.1 LH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear RH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Illustration Name Exhaust System Brake Tubes Brake Tubes Brake Tubes Brake Tubes Brake Tubes Brake Tubes Front Suspension Front Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension 4 Individual Parts (Continued): Part Number 48220-0C170 48220-0C180 48220-0C190 48220-0C210 48220-0C220 48220-0C230 48220-0C240 48220-0C250 48220-0C260 48220-0C280 48220-0C290 48220-0C300 48220-0C310 48220-0C320 48220-0C330 48220-0C340 48220-0C350 51900-34050 77412-34010 77412-34010 77412-34010 82164-0C870 82164-0CA00 82164-0C890 90080-11373 90080-11717 90080-17229 90080-46263 90105-A0179 90105-A0179 90105-A0179 90105-A0179 90117-A0003 90117-A0004 90119-A0169 90119-A0169 90119-A0170 90119-A0219 90119-A0219 90119-A0271 90119-A0271 90126-A0011 90126-A0011 90126-A0011 90189-06236 Part Description Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Spring Assy, Rear LH Carrier Assy, Spare Wheel Clamp, Fuel Tube, No.4 Clamp, Fuel Tube, No.4 Clamp, Fuel Tube, No.4 Wire, Frame Wire, Frame Wire, Frame Bolt Bolt Nut Clamp Bolt Bolt Bolt Bolt Bolt, U (For Rear Spring) Bolt, U (For Rear Spring) Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt, Stud (For Exhaust Manifold, RH) Bolt, Stud (For Exhaust Manifold, LH) Bolt, Stud (For Manifold To Exhaust Pipe) Clip Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 1 1 1 2 16 1 1 1 3 4 5 4 4 5 2 1 4 10 4 2 3 3 6 4 Illustration Name Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Rear Suspension Spare Tire Carrier Fuel Tubes Fuel Tubes Fuel Tubes Wire Harness Clamps Wire Harness Clamps Wire Harness Clamps Fuel Tank Front Bumper AT Shift Cable Exhaust System Engine Mounting Fuel Tubes Fuel Tubes Fuel Tubes Rear Suspension Rear Suspension Under Cover Under Cover Engine Mounting Rear Bumper Rear Bumper Rear Bumper Rear Bumper Exhaust System Exhaust System Exhaust System Front Fender 5 Individual Parts (Continued): Part Number 90461-15017 90469-A0004 90469-A0004 90469-A0004 90917-06085 90917-06093 47312-0C080 47313-0C090 47322-0C110 47323-0C090 Part Description Clamp Clamp, Brake Tube, No.7 Clamp, Brake Tube, No.7 Clamp, Brake Tube, No.7 Gasket, Exhaust Pipe, Center Gasket, Exhaust Pipe, Center TUBE, FR BRAKE, NO.2 TUBE, FR BRAKE, NO.3 TUBE, RR BRAKE, NO.2 TUBE, RR BRAKE, NO.3 Quantity 1 7 8 9 1 1 1 1 1 1 Illustration Name Exhaust System Brake Tubes Brake Tubes Brake Tubes Exhaust System Exhaust System Brake Tubes Brake Tubes Brake Tubes Brake Tubes Parts Kits: Part Number 04004-19134 Part Description Parts Kit No.1 – Common Replacement Kit A Quantity 1 The kit listed above includes the following parts: Part Number 48190-34010 48198-34010 48409-34041 48452-34011 77285-34370 77289-26010 77413-34010 90099-14120 90178-18003 90179-06178 90201-19011 90252-04003 90412-10266 90412-10267 90412-10268 94622-51400 Part Description Cam Assy, Camber Adjust Cam, Camber Adjust, No.2 Cam Sub-Assy, Front Suspension Toe Adjust Plate, Front Suspension Toe Adjust, No.2 Clamp, Fuel Tube, No.2 Clamp, Fuel Tube, No.1 Clamp, Fuel Tube, No.5 O-Ring Nut Nut Washer Cotter Pin Way, No.1 (For Front Brake Tube) Way, No.2 (For Front Brake Tube) Way (For Rear Brake Tube) Washer Part Number 04007-18134 Quantity 2 2 2 2 3 1 1 1 2 6 2 2 1 1 1 10 Illustration Name Front Suspension Front Suspension Front Suspension Front Suspension Fuel Tubes Fuel Tubes Fuel Tubes Air Conditioning Front Suspension Front Bumper Front Suspension Power Steering Brake Tubes Brake Tubes Brake Tubes Rear Suspension Page 11 11 11 11 17 17 17 26 11 26 11 19 13-15 13-15 13-15 12 Part Description Plug, Hole Kit Quantity 1 The kit listed above includes the following parts: Part Number 90950-01993 90950-01994 90950-01A09 90950-01987 90950-01988 9095001A06 90950-01990 90950-01A11 90950-01A24 Part Number 90950-01A31 Part Description PLUG HOLE PLUG HOLE PLUG HOLE PLUG HOLE PLUG HOLE PLUG HOLE PLUG HOLE PLUG HOLE PLUG HOLE Part Description PLUG,HOLE Quantity 6 6 6 6 2 2 2 2 2 Quantity 2 6 Parts Kits: Part Number 04004-1920C Part Description Parts Kit No.2 – Common Replacement Kit B Quantity 1 The kit listed above includes the following parts: Part Number 04483-0C040 04483-0C040 16492-21050 47314-0C020 47315-0C030 or 47315-0C031 48304-0C030 48304-0C030 52238-0C010 77272-0C030 77285-34380 77296-0C010 or 77296-0C020 77414-0C010 90069-08009 90080-10138 or 90105-A0381 90080-11555 90080-17187 90080-46327 90105-A0064 90119-A0380 90119-A0077 90119-A0080 90119-A0169 90119-A0169 90119-A0184 90119-A0192 90119-A0204 90119-A0210 90119-A0222 90119-A0224 90178-A0044 90178-A0049 90178-A0050 90178-A0052 90178-A0067 90178-A0071 90468-A0007 90917-A6002 Part Description Shackle Kit, Rear Spring RH Shackle Kit, Rear Spring LH Packing (For Radiator Drain Cock) Tube, Front Brake No.4 Quantity 1 1 1 1 Tube, Front Brake No.5 1 Bumper, Front Spring, No.1 RH Bumper, Front Spring, No.1 LH Holder, Body Mounting, Rear Support, Breather Tube, No.1 Clamp, Fuel Tube, No.1 2 2 2 1 3 Clamp, Fuel Tube, No.3 1 Clamp, Fuel Tube, No.6 O-Ring 1 1 Bolt 2 Bolt Nut Clip (For Front Fender Apron Seal) Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Nut Nut Nut (For Front Suspension) Nut Nut Clip Gasket, Exhaust Pipe 1 6 22 3 1 2 8 2 4 1 4 2 4 2 4 8 2 10 8 6 2 4 2 7 Part Number 04004-19334 Part Description Parts Kit No.3 – JPN Source Parts Kit 4WD Quantity 1 The kit listed above includes the following parts: Part Number Part Description Quantity 12157-10010 43514-34020 43514-34020 90311-47012 or 90311-47027 90311-47013 90430-24003 95381-04050 Gasket, Front Differential Filler Plug Cap, Front Axle Hub Grease, RH Cap, Front Axle Hub Grease, RH 1 1 1 Seal, Oil (For Differential Side Gear Shaft 1 Seal, Oil (For Differential Side Gear Shaft Gasket, (For Front Differential Drain Plug Cotter Pin 1 1 2 Part Number Part Description Quantity 04004-1940C Parts Kit No.4 – USA Source Parts Kit 4WD 1 The kit listed above includes the following parts: Part Number 43425-0C010 90105-A0193 90119-A0151 90464-00897 Part Description Ring, Shaft Snap (For Front Drive Inner Shaft Outer) Bolt Bolt Clamp Quantity 2 1 2 1 Illustration Name Front Suspension Front Differential Propeller Shaft Front Differential Page 11 19 20 19 8 D. PARTS ILLUSTRATION Frame 9 Frame & Cab Mounting 10 Under Cover Spare Tire Carrier 11 Front Suspension 12 Rear Suspension 13 Brake Tubes 14 Brake Tubes Continued… 15 Brake Tubes Continued… 16 Fuel Tank 17 Fuel Tubes 18 Wire Harness Clamps ABS & VSC 19 Power Steering Front Differential Engine Mounting 20 Propeller Shaft 21 Exhaust System 22 Exhaust System Continued… 23 Exhaust System Continued… 24 Exhaust System Continued… 25 AT Shift Cable Radiator 26 Air Conditioning Front Bumper 27 Rear Bumper Front Fender 28 Front Fender Apron 29 III. FRAME INSPECTION 1. PERFORM INITIAL PRE-HOIST INSPECTION 1. INSPECT THE FRAME FOR EXCESSIVE FRAME CORROSION THAT COULD AFFECT THE STRUCTURAL INTEGRITY OF THE FRAME 2. FRAME INSPECTION All frame inspection must be performed using the NEW frame inspection application on TIS. Ensure you inspect the frame and properly document the inspection. Failure to perform this will result in denial of the claim. 1. ACCESS INSPECTION APPLICATION a. Run the VIN in TIS and click on the Warranty Tab b. Click on the “Frame Inspection” link on TIS 2. LOG INTO THE INSPECTION APPLICATION a. Reenter your TIS password 30 3. ENTER VEHICLE INFORMATION a. Enter the vehicle mileage. b. Select the state from the drop-down menu that the vehicle is registered. Note: Do NOT select the state the dealership is located. c. Inspect the frame for CRC compound that could have been previously applied: CRC was Previously Applied: Select the CRC Bottle Button NO CRC Previously Applied: Select Frame Button Note: CRC could only be previously applied to 2005 to 2008 Tacoma vehicles. 4. INSPECT THE FRAME SECTIONS a. Inspect the frame in the colored areas below and use the application to document the results of the inspection. Note: Crossmember mounting locations should be inspected 6” into the crossmember. Tundra 07 to 08 b. Select Section A Note: The frame inspection application must be completed in alphabetical order. 31 c. Inspect the frame section and inspect all surfaces of the frame rail and crossmember. Select the photo that best represents the frame condition. If perforation of 10mm or larger is identified select “Peroration of the Frame”. Note: You must click the bubble next to the image to select the condition. d. If you selected Perforation of the Frame, the application will request more information about the size of perforation(s) and location. e. The section with perforation will split into 2 sub-sections to further identify the perforation location. f. Select the size of the perforation in each sub-section. g. Upload a photo for each area containing perforation and describe the location in the comments section. Note: • If both sub-sections have perforation, it will require two pictures to be uploaded. • If perforation was accidentally selected use the back button to reselect the correct frame condition. h. Select Next to move onto the next section. 32 i. Once all sections have been completed, select the Submit button. NO Perforation Found j. If no perforation was not found, follow the directions as provided. Perforation Found k. If perforation was found, this application will be submitted to your Regional Office for review. The region office will review the inspection and provide feedback if the frame replacement is approved for future repair. DO NOT proceed with frame replacement or parts ordering until you are provided with approval from the Regional Office. Approval will be sent to the TIS inbox for the inspection, Service Manager and Parts Manager. 33 34 IV. FRAME REPLACEMENT WORK PROCEDURE A. PERFORM PRELIMINARY VEHICLE INSPECTION 1. Perform health check and record any preexisting DTCs 2. Test drive the vehicle and inspect the following vehicle functions/current operating conditions prior to vehicle repair. • • • • • 4WD System (4WD Only) Interior Lights Exterior Lights HVAC System Audio System • • • • • Power Windows Power Door Locks All Gauges, Indicators and Warning Lights Cooling Fans Etc. 3. Documents the current vehicle operating condition on the Frame Replacement Inspection Sheet. B. SAFETY CHECKLIST & PRECAUTIONS WHEN DRAINING THE FUEL SYSTEM • • • • Always remember “SAFETY FIRST”. Be extremely careful when handling fuel to prevent fires from occurring. Before beginning work on the fuel system, perform the following safety check list. Before removing any fuel system part, drain all fuel to prevent spilling. 1. AIR VENTILATION Perform work in a well-ventilated area. DO NOT work underground or in an area where fuel vapors may fill the room due to poor ventilation. Quickly clean up any spilled fuel with a dry cloth and dissipate the fuel vapors. Dry all cloths that have come in contact with fuel in a well-ventilated area and dispose of them properly (according to applicable local regulations). 2. FIRES AND IGNITION SOURCES ARE STRICTLY PROHIBITED Fires and ignition sources are prohibited while working on the fuel system. Clearly display the sign found on the next page stating “WORKING WITH GASOLINE, NO FIRES OR IGNITION SOURCES”. Smoking is prohibited near the work area. DO NOT work in areas where there are welders, grinders, drills, electric motors, heaters, etc. DO NOT use work lamps or any other electrical appliance due to the risk of sparks flying from the power switch or a rise in temperature. DO NOT use metal hammers while working, due to the risk of flying sparks. DO NOT start any engines or perform any of the above in neighboring work bays. 3. FIRE EXTINGUISHER Have a fire extinguisher ready and available before beginning work. 4. PREVENT STATIC ELECTRICITY To help prevent static electricity, lightly wet the floor with water, but not to the point where it creates a hazardous working condition. Place appropriate warning cones or stand signs around the area as a caution. 5. PRECAUTIONS WHEN USING A LIFT For bays equipped with auto lifts, cover all access cover joints with duct tape. In the event that fuel has leaked inside the auto lift, remove the access cover and clean up any spilled fuel. Dissipate fuel vapors until the smell is gone. 6. PREVENT THE FUEL FROM SPRAYING When disconnecting any fuel tubes, pipes, hoses or connectors there may still be some pressure remaining, even after discharging the system. To prevent the fuel from spraying, cover the tubes, pipes or connectors with a shop rag before disconnecting. Remember to always wear protective goggles especially when disconnecting fuel tubes, pipes, hoses or connectors. 7. PREVENT THE FUEL FROM CONTACTING OTHER PARTS Do not allow the fuel to come in contact with any parts made of rubber or leather. 8. ASSIGN A SAFETY SUPERVISOR Assign a safety supervisor to be in charge of all safety precautions and fire hazards around the work area. 35 36 37 C. REMOVE THE REAR BED ASSY • • • • • If the frame is perforated, ONLY raise the vehicle high enough to remove the tires. For added safety and support place jack stands under the front and rear portions of the frame. DO NOT work directly underneath the vehicle when performing bed assy removal. The actual vehicle specs, equipment and parts required may differ than what is shown. Please use the correct specifications and parts for the model you are working on. For additional repair information, please reference to the appropriate repair manual found on TIS for the vehicle you are working on. 1. CENTER THE VEHICLE BETWEEN THE LIFT ARMS a) Verify the vehicle is aligned with the center point of the lift to prevent interference and damage to the frame and/or lift. 2. REMOVE THE FOLLOWING PARTS • • • • • License Plate Light Assy LH/RH No.3 Frame Wire Rear Quarter Panel Mudguard LH/RH (If Equipped) Rear Bumper Assy Side Step Assy LH/RH (If Equipped) 3. DISCONNECT THE FRAME WIRE HARNESS a) Disconnect the clamps, connectors and the frame wire harness from the bed assy. NOTE: • The number of connectors may differ depending on the vehicle specification. • Be careful not to damage the wire harness clamps when removing them. 4. DISCONNECT THE FUEL TANK INLET PIPE SUB-ASSY a) Remove the 2 nuts and disconnect the fuel tank inlet pipe sub assy. 38 5. REMOVE THE REAR BED ASSY a) Using a Torx® T55H Tamper Resistant Socket, remove the Torx ® bolts from the rear bed assy. • Long Bed: 8 Torx® bolts • Standard Bed and Crewmax (Short Bed): 6 Torx® bolts NOTE: • Use 4 or more people to remove the rear bed assy from the frame. • Evenly support the rear bed assy when removing it. • If you find excessive corrision around the bed mounting bolts and believe the bed cannot be securly reattached after removal, contact your FTS 39 D. DISCHARGE THE FUEL SYSTEM PRESSURE • • • DO NOT disconnect any part of the fuel system until you have discharged the fuel system pressure. Even after discharging the fuel system pressure, place a piece of cloth around the tubes, pipe, hoses and connectors as you separate them to reduce the risk of fuel spraying on yourself, in the engine compartment and onto other parts. For additional repair information, please reference to the appropriate repair manual in TIS for the vehicle you are working on. 1. CHECK FOR DTCs 2. RECORD THE RADIO STATION PRESETS 3. DISCONNECT THE NEGATIVE (-) BATTERY TERMINAL NOTE: Wait 90 seconds after the negative (-) terminal cable is disconnected from the battery before proceeding. Doing so will prevent the SRS from being deployed (i.e. airbag, seat belt pretensioner, etc.). 4. DISCHARGE THE FUEL SYSTEM PRESSURE a) b) c) d) Disconnect the 2 fuel pump ECU connectors. Reconnect the cable to the negative (-) battery terminal. Start the engine. After the engine has stopped, turn the ignition switch OFF. e) Crank the engine again to check that it does not start. f) Disconnect the negative (-) battery terminal. NOTE: Please make sure to follow the procedure listed above. This will prevent a large amount of gasoline from spilling out when high pressure fuel tube is disconnected. 40 E. REMOVE THE CAB BODY ASSY • • • • • If the frame is perforated, ONLY raise the vehicle high enough to remove the tires. For added safety and support place jack stands under the front and rear portions of the frame. DO NOT work directly underneath the vehicle when performing cab body assy removal, unless noted. The actual vehicle specs, equipment and parts required may differ than what is shown. Please use the correct specs and parts for the model you are working on. For additional repair information, please reference to the appropriate repair manual in TIS for the vehicle you are working on. 1. REMOVE THE ENGINE UNDER COVER No.1 NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle. 2. EVACUATE THE REFRIGERANT FROM THE AIR CONDITIONING SYSTEM 3. DRAIN THE FOLLOWING FLUIDS • • • Coolant Brake Fluid Front Differential Fluid NOTE: DO NOT remove the radiator cap while the radiator and engine are hot, doing so may cause the coolant to spray out causing potential injuries. 4. REMOVE THE FOLLOWING PARTS • • • • • • • • • • • • Front Door Scuff Plate LH/RH Cowl Side Trim Board LH/RH No.2 Dash Panel Insulator Pad No.3 Dash Panel Insulator Pad Jack and Tool (Standard Tool) No.1 w/ Box Speaker Assy (If Equipped) Luggage Compartment Box LH (Regular Cab Only) Upper Back Panel Garnish (Regular Cab Only) Front Seat Outer Belt Assy LH (Regular Cab Only) Lower LH Quarter Trim Panel Assy (Regular Cab Only) Lift up the second seat and pull up the rear edge of the Floor Carpet (Double Cab Only) Back Panel Trim LH/RH (Crewmax Only) 5. REMOVE THE FOLLOWING PARTS • • • • • • • • • • Front Wheels Front End Panel LH/RH Front Fender Splash Shield Sub-Assy LH/RH Front Bumper Assy Front Bumper Reinforcement Sub-Assy No.2 Front Bumper Extension Sub-Assy LH/RH Front Fender Mudguard LH/RH (If Equipped) Throttle Body Cover Sub- Assy (2UZ-FE Only) V-Bank Cover Sub- Assy (1GR-FE, 3UR-FE Only) Air Cleaner Hose and Air Cleaner Assy 41 6. DISCONNECT THE ENGINE WIRE HARNESS (LH SIDE) a) Remove the nut and disconnect the 2 (+) positive battery cables. b) Remove the bolt and disconnect the ground wire. c) Disconnect the clamp. d) Remove the No.1 relay block cover. e) Disconnect the 2 connectors and clamps. f) Remove the nut and disconnect the (+) positive battery cable. g) Disconnect the 6 connectors and 2 clamps. h) Remove the bolt and disconnect the ground wire. 7. DISCONNECT THE No.1 COOLER REFRIGERANT SUCTION HOSE ASSY a) Remove the nut and disconnect the suction hose. 8. DISCONNECT THE VACUUM HOSE ASSY a) Disconnect the vacuum hose. 42 9. DISCONNECT THE ENGINE WIRE HARNESS (RH SIDE) a) Disconnect the 3 connectors and 2 clamps. b) Disconnect the 5 connectors and 2 clamps. c) Remove the connector holder block cover upper. d) Disconnect the skid control sensor connector and clamp. NOTE: Disconnect the clamp of the sensor completely from the Body. e) Remove the bolt and disconnect the ground wire. NOTE: Disconnect on the engine side otherwise the bolt may be broken. 10. DISCONNECT THE INLET HEATER HOSE AND OUTLET HEATER HOSE, ENGINE SIDE 43 1GR-FE 11. DISCONNECT THE AIR INJECTION SYSTEM HOSES a) Disconnect the No.5 hose and No.4 hose. (1GR-FE) b) Disconnect the No.2 hose and clamp. (2UZ-FE) c) Disconnect the clamp, No.2 hose and No.3 hose. (3UR-FE) 2UZ-FE 3UR-FE 44 1GR-FE 12. DISCONNECT THE AIR PUMP HARNESS a) Disconnect the 2 connectors and 4 clamps. (1GR-FE) b) Disconnect the connector and 2 clamps. (2UZ-FE) c) Disconnect the 2 connectors and 3 clamps. (3UR-FE) 2UZ-FE 3UR-FE 13. REMOVE THE FOLLOWING PARTS • • • • Upper Center Front Bumper Retainer (Air Oil Cooler Equipped Vehicles Only) Oil Cooler Assy (Air Oil Cooler Equipped Vehicles Only) Radiator Side Deflector LH Radiator Side Deflector RH (If Equipped) 45 14. DISCONNECT THE No.1 COOLER REFRIGERANT DISCHARGE HOSE a) Remove the bolt and disconnect the discharge hose. 15. REMOVE THE FOLLOWING PARTS • • • • • Radiator Inlet Hose Radiator Outlet Hose Radiator Fan Fan Shroud Radiator Assy 16. DISCONNECT THE VANE PUMP OIL RESERVOIR ASSY a) Remove the 3 bolts of the windshield washer jar assy to make space for removal of the bolt. b) Remove the 3 bolts and disconnect the vane pump oil reservoir assy. 46 LH Side 17. REMOVE THE FRONT FENDER APRON SEALS a) Remove the left side 11 clips and front fender apron seal LH/RH. b) Remove the right side 11 clips and front fender apron seal LH/RH. RH Side LH Side 18. DISCONNECT THE FRONT BRAKE TUBES a) Disconnect the front brake tube and remove the bolt. b) Repeat the procedure on the opposite side. RH Side 47 19. DISCONNECT THE FRONT DIFFERENTIAL VACUUM HOSES (4WD ONLY) a) Disconnect the clamp and vacuum hoses. 20. DISCONNECT THE No.2 STEERING INTERMEDIATE SHAFT a) Make sure the front wheels are in a straight-ahead position and the steering wheel is centered. b) Reconnect the front seat outer belt assy LH. (Regular Cab Only) c) Using the seat belt, hold the steering wheel in position as shown in the illustration, in order to prevent damage to the spiral cable. d) Place matchmarks on the intermediate shaft and No.2 intermediate shaft. e) Remove the bolt. f) Disconnect the intermediate shaft from the No.2 intermediate shaft. NOTE: If the intermediate shaft cannot be pulled out completely, spread the gap of the sliding yoke with a flathead screwdriver or a wrench and pull out the intermediate shaft. 48 21. DISCONNECT THE No.1 PARKING BRAKE CABLE a) Remove the nut and No.1 wire adjusting nut. NOTE: If No.1 wire adjusting nut is too rusty to remove, then separate parking brake mechanism from frame. b) Remove the bolt and cable retainer. c) Disconnect the No.1 parking brake cable. NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle. 22. DISCONNECT THE TRANSMISSION CONTROL CABLE a) Remove the bolt and disconnect the ground wire. b) Disconnect the 3 clamps. NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle. c) Remove the nut. d) Remove the 2 bolt and disconnect the transmission control cable. 23. DISCONNECT THE REAR BRAKE TUBES a) Disconnect the 2 rear brake tubes. b) Remove the bolt and disconnect brake tube. NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle. 49 24. REINSTALL THE FRONT WHEELS 25. REMOVE THE CAB BODY ASSY USING AN ABOVE GROUND LIFT a) b) c) d) e) f) g) Remove the 6 bolts, 6 nuts, 4 washers and 2 No.1 lower cab mounting cushion sub-assy. Set the lift arms under the cab body assy so they DO NOT interfere with the frame or cab mounts. Check that all wire harnesses, hoses, cables and the steering shaft are disconnected. Lift the cab assy up slowly, making sure it does not interfere with anything while being raised. Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab assy. Pull the frame assy out from under the vehicle. Lower the cab assy all the way down and leave it on the lift. NOTE: • Center the cab assy weight on the lift arms so that it does not slant/tilt to one side. • Raise the cab assy slightly off the frame and verify that it is held securely by the lift arms. • The center of gravity position of the cab body may become inappropriate depending on the shape of the lift arm used and under such situation the cab body may fall when lifted. To prevent falling off of the cab body, use some weights to establish right balance and secure the cab body to the lift arm using ratchet tie down belts. • DO NOT work directly underneath the vehicle when pulling the frame assy out from under. • DO NOT remove the cab mount bolts, as they will be used as guides during cab assy reinstallation process. 50 F. DISASSEMBLE THE FRAME 1. PLACE THE FRAME ON A LIFT a) Place the frame on the lift, and secure it with a ratcheting tie down strap. This will prevent the frame from tilting or falling off as parts are removed. • Ratcheting Tie Downs: Qty 1 ° Length: 2 in X 27 ft ° Minimum Work Load Capacity: 3,000 lbs 2. REMOVE THE FOLLOWING PARTS • • Spare Tire Wheels 3. DISCONNECT THE OXYGEN SENSOR CONNECTORS a) Disconnect the 4 oxygen sensor connectors. 4. REMOVE THE FOLLOWING PARTS • • • Propeller Shaft Heat Insulator (4WD Only) Front Propeller Shaft Assy (4WD Only) Rear Propeller Shaft Assy ° Insert SST 09325-40010 (A750E) or SST 09325-60010 (AB60E) into the transmission after the rear propeller shaft is removed to prevent oil leakage (2WD Only) NOTE: Make sure to place matchmarks on the front (if equipped) and rear propeller shafts prior to removal. 5. REMOVE THE FOLLOWING PARTS • • • • No.1 Fuel Tank Protector Sub-Assy (If Equipped) Fuel Tank Strap Fuel Tank Assy Charcoal Canister Assy 51 6. DISCONNECT THE PARKING BRAKE SYSTEM a) Remove the tension spring. b) Remove the bolt and cable retainer. c) Disconnect the 2 parking brake cables. d) Remove the 3 bolts and cable support bracket (A). e) Remove the 2 bolts and parking brake intermediate lever (B). f) Remove the 2 bolts and No.2 cable support bracket (C). 7. DISCONNECT THE FUEL PIPES a) Remove the No.1 fuel pipe clamp. b) Disconnect the 2 fuel pipes. NOTE: Put a shop towel under the fuel pipe to catch any spilled fuel. 8. DISCONNECT THE FUEL VAPOR FEED HOSE ASSY 52 4WD Only 2UZ-FE, 3UR-FE 9. DISCONNECT THE ENGINE WIRE (2UZ-FE, 3UR-FE ONLY) 10. DISCONNECT THE DIFFERENTIAL WIRE (4WD ONLY) 11. REMOVE AND SET ASIDE THE POWER STEERING PUMP ASSY a) b) c) d) Remove the drive belt. Disconnect the connectors. Disconnect the harness clamp. (3UR-FE Only) Remove the 2 bolts and nut (2UZ-FE Only) or the 2 bolts (1GR-FE, 3UR-FE Only) and the power steering vane pump. NOTE: • DO NOT disconnect the power steering pump hoses or tubes. • Make sure to keep the power steering pump reservoir in an upright position to prevent the fluid from leaking out. 12. REMOVE THE INTAKE AIR SURGE TANK (1GR-FE ONLY) 1GR-FE 13. REMOVE THE ENGINE AND TRANSMISSION ASSY a) Disconnect and remove the necessary items/parts to prepare the engine and transmission assy for removal. b) Install the engine hanger. (1GR-FE, 3UR-FE) For 1GR-FE 12281-31060 = Engine Hanger No.1, Qty: 1 12282-31040 = Engine Hanger No.2, Qty: 1 90119-08A87 = Bolt, Qty: 4 3UR-FE For 3UR-FE 12281-38150 = Engine Hanger No.1, Qty: 2 90119-14120 or 90119-A0166 = Bolt, Qty: 2 53 c) Remove the engine and transmission assy. NOTE: • When removing the engine and transmission assy, ALWAYS use 2 engine hoists or mini cranes to lift it. • DO NOT use 1 engine hoist or mini crane to lift the engine and transmission assy, as the unbalanced weight may lead to an accident or injury. • ONLY use engine hoists or mini cranes that can properly support the weight of the engine and transmission assy. • Carefully adjust the 2 engine hoists or mini cranes used so that the engine and transmission assy is properly balanced. 14. REMOVE THE FUEL TUBES a) Remove the bolts, clamps and fuel tubes. NOTE: • The number of clamps will differ depending on the vehicle specification. • Take care not to damage or break the clamps during removal. 15. DISCONNECT THE SKID CONTROL SENSOR WIRES a) Remove the 2 bolts and disconnect the skid control sensor wire. (LH Side) b) Remove the bolt and disconnect the skid control sensor wire. (RH Side) 16. DISCONNECT THE FRONT BRAKE HOSES a) b) c) d) Disconnect the brake tube from the brake hose Remove the clip. Remove the bolt and disconnect the front brake hose. Repeat the procedure on the opposite side. 54 17. REMOVE THE FOLLOWING PARTS • • • • Front Stabilizer Bar Front Axle Shaft Nut (4WD Only) Tie Rod End Sub-Assy ° Remove the cotter pin and nut. ° Using the SST 09610-20012, disconnect the tie rod end. Lower Ball Joint ° Remove the 2 bolts and disconnect the lower ball joint from the steering knuckle. 18. REMOVE THE FRONT SUSPENSION UPPER ARM AND STEERING KNUCKLE ASSY a) Remove the bolt, nut, 2 washers and front suspension upper arm w/ steering knuckle. b) Repeat the procedure on the opposite side. NOTE: If the drive shaft is difficult to disconnect, tap the drive shaft loose with a plastic hammer. (4WD Only) 19. REMOVE THE FOLLOWING PARTS • • Front Shock Absorber Assy Front Drive Shaft Assy (4WD Only) ° Using the SST 09520-24010 (09520-32040), 09520-01010, remove the front drive shaft NOTE: Be careful not to damage the dust cover and oil seal. • Power Steering Link Assy w/ Power Steering Vane Pump NOTE: • When removing the power steering link with the vane pump attached, have one person support the power steering link and the other support the vane pump. • Make sure to keep the power steering pump reservoir in an upright position to prevent the fluid from leaking out. • Front Differential Carrier Assy (4WD Only) • Front Suspension Lower Arm Sub-Assy NOTE: If the bolt is seized and the front suspension lower arm cannot be removed, remove the lower ball joint with the front suspension lower arm left on the frame. • Lower Ball Joint NOTE: When the front suspension arm can be removed, this work is not required. ° Remove the cotter pin and nut. ° Using the SST 09950-40011 (09951-04010,09953-04020,09954-04010,09955-04031, 09958-04011,09952-04010),09955-04090, remove the lower ball joint. • No.1 Front Spring Bumper (Qty: 4) ° Using the SST 09922-10010-01, remove the front spring bumper. 55 20. DISCONNECT THE PARKING BRAKE CABLE a) Remove the 11 bolts, clamp and disconnect the parking brake cable. 21. DISCONNECT THE REAR BRAKE TUBES a) Disconnect the No.4 rear brake tube. b) Disconnect the No.5 rear brake tube. c) Remove the 2 clip and disconnect the flexible hose. 22. REMOVE THE FOLLOWING PARTS • • • Rear Shock Absorber Assy Rear Differential Assy Fuel Pump Control Computer Assy 56 23. REMOVE THE FRAME WIRE HARNESS a) Remove the bolt and disconnect the ground wire. (If Equipped) b) Disconnect the clamps and remove the frame wire harness. NOTE: • The number of wire harness clamps will differ depending on the vehicle specification. • Take care not to damage or break the wire harness clamps during removal. 24. REMOVE THE No.6 FUEL TUBE CLAMP a) Remove the bolt and No.6 fuel tube clamp. 25. REMOVE THE CLIPS 26. REMOVE THE FRONT DIFFERENTIAL SUPPORT ASSY (4WD ONLY) a) Remove the bolt, nut and differential support assy. 57 27. REMOVE THE ENGINE WIRE CLAMP (2UZ-FE, 3UR-FE ONLY) 28. REMOVE THE FRAME WIRE CLAMP 29. REMOVE THE No.2 FRONT ENGINE MOUNTING BRACKET LH 30. REMOVE THE EXHAUST SYSTEM a) b) c) d) Remove the 6 nuts. Remove the exhaust pipe and 4 exhaust pipe supports. Remove the 2 exhaust pipe gaskets. Remove the exhaust tail pipe and exhaust tail pipe support. 31. REMOVE THE FRAME FROM THE LIFT a) Remove the ratcheting tie down strap and the frame from the lift. 58 G. ASSEMBLE THE NEW FRAME 1. PLACE THE NEW FRAME ON THE LIFT a) Place the NEW frame on the lift, and secure it with a ratcheting tie down strap. This will prevent the frame from tilting or falling off as parts are installed. • H. Ratcheting Tie Downs: Qty 1 ° Length: 2 in X 27 ft ° Minimum Work Load Capacity: 3,000 lbs INSTALLATION OF BODY PLUGS 1. REMOVE THE PLASTIC SHEET 2. INSTALL THE PLUGS AS SHOWN BELOW 1/2 PLUG INSTALLATION FRONT 59 2/2 PLUG INSTALLATION FRONT 60 NEW Replacement Parts Part Number 04483-0C040 04483-0C040 90080-10138 or 90105-A0381 90178-A0050 94622-51400 Varies ** Varies ** 2. INSTALL THE REAR LEAF SPRINGS Part Description Shackle Kit, Rear Spring RH Shackle Kit, Rear Spring LH Kit # Quantity 2 1 2 1 a) Install the NEW rear leaf spring with all NEW parts (shackle, bushings, bolts, washers & nuts) and torque to spec. Bolt 2 2 Torque Spec: 77 ft∙lbs (105 N∙m, 1071 kgf∙cm) Nut Washer Rear Leaf Spring (LH) Rear Leaf Spring (RH) 2 1 Na* Na* 2 2 1 1 b) Repeat the procedure on the opposite side. * Individual Part(s) ** Only 1 part is used. The part number depending on the list 61 3. REINSTALL THE CAB MOUNTS NEW Replacement Parts Part Number 90119-A0080 Part Name Bolt Kit # 2 Qty 8 a) Reinstall cab mounts No.1. b) Reinstall cab mounts No.2 & No.3 with 8 NEW bolts and torque to spec. Torque Spec: 45 ft∙lbs (61 N∙m, 622 kgf∙cm) 4. INSTALL THE FRONT SUSPENSION LOWER ARMS NEW Replacement Parts Part Number Part Name Kit # Arm, Sub-Assy, Front Suspension, 48068-09100 NA* Lower No.1 RH Arm, Sub-Assy, Front Suspension, 48069-09090 NA* Lower No.1 LH 48190-34010 Cam Assy, Camber Adjust 1 48198-34010 Cam, Camber Adjust, No.2 1 Cam Sub-Assy, Front Suspension 48409-34041 1 Toe Adjust Plate, Front Suspension Toe 48452-34011 1 Adjust, No.2 90119-A0204 Bolt 2 90178-18003 Nut 1 90201-19011 Washer 1 * Individual Part(s) 1 a) Install the NEW front suspension lower arm with NEW bolt, NEW toe adjusting cam, NEW toe adjusting plate, NEW nut, NEW washer, NEW No.2 camber adjusting cam, NEW camber adjusting cam, then torque to spec. 2 2 Torque Spec: 207 ft∙lbs (280 N∙m, 2855 kgf∙cm) 2 b) Repeat the procedure on the opposite side. Qty 1 2 2 2 2 62 5. REINSTALL THE LOWER BALL JOINTS NOTE: • If the front suspension lower arm is to be replaced with a new one, install the lower ball joint on the new front suspension lower arm. • If the holes for the cotter pin are not aligned, tighten the axle nut further, up to 60 degree. a) Reinstall the lower ball joint with the nut and torque to spec. Torque Spec: 123 ft∙lbs (167 N∙m, 1703 kgf∙cm) b) Install the NEW cotter pin. c) Repeat the procedure on the opposite side. 6. INSTALL THE No.1 SPRING BUMPERS NEW Replacement Parts Part Number 48304-0C030 48304-0C030 Part Name Bumper, Front Spring, No.1 RH Bumper, Front Spring, No.1 LH Kit # 2 2 Qty 2 2 a) Install the 2 NEW front spring bumpers to the frame and torque to spec. Torque Spec: 23 ft∙lbs (31 N∙m, 316 kgf∙cm) b) Repeat the procedure on the opposite side. NEW Replacement Parts Part Number 90105-A0179 90119-A0170 Part Name Bolt** Kit # NA* NA* Qty 1 1 * Individual Part(s) ** Only 1 part used. The part number depending on the list. 7. REINSTALL THE ENGINE WIRE CLAMP (2UZ-FE, 3UR-FE ONLY) Torque Spec: 13 ft∙lbs (17.2 N∙m, 175 kgf∙cm) 8. REINSTALL THE FRAME WIRE CLAMP Torque Spec: 23 ft∙lbs (31 N∙m, 316 kgf∙cm) 9. REINSTALL THE No.2 FRONT ENGINE MOUNTING BRACKET LH Torque Spec: 24 ft∙lbs (32 N∙m, 326 kgf∙cm) 63 10. REINSTALL THE FRONT DIFFERENTIAL SUPPORT ASSY (4WD ONLY) a) Reinstall the front differential support with the nut and bolt, then torque to spec. Torque Spec: 83 ft∙lbs (113 N∙m, 1152 kgf∙cm) 11. INSTALL THE CLIPS NEW Replacement Parts Part Number 52238-0C010 Part Name Holder, Body Mounting, Rear Kit # 2 Qty 2 12. INSTALL THE No.6 FUEL TUBE CLAMP NEW Replacement Parts Part Number 77414-0C010 90105-A0179 Part Name Clamp, Fuel Tube, No.6 Bolt * Individual Part(s) Kit # 2 NA* Qty 1 1 a) Install the NEW No.6 fuel tube clamp with the NEW bolt, and torque to spec. Torque Spec: 23 ft∙lbs (31 N∙m, 316 kgf∙cm) 64 13. INSTALL THE REAR BRAKE TUBES NEW Replacement Parts Part Number 47324-0C060 47324-0C080 47324-0C090 47325-0C090 47325-0C100 47325-0C110 90469-A0004 90469-A0004 90469-A0004 Part Name Tube, Rear Brake, No.4** Tube, Rear Brake, No.5** Clamp, Brake Tube, No.7** Kit # NA* NA* NA* NA* NA* NA* NA* NA* NA* Qty 1 1 1 1 1 1 7 8 9 a) Install the NEW rear brake tubes with the NEW clamp(s). NOTE: The number of clamps will differ depending on the vehicle spec. * Individual Part(s) ** Only 1 part used. The part number depending on the list. NEW Replacement Parts Part Number Varies** Part Name Kit # Qty Wire, Frame NA* 1 * Individual Part(s) ** Only 1 part used. The part number depending on the list. 14. INSTALL THE FRAME WIRE HARNESS a) Connect the clamps to install the NEW frame wire harness. b) Connect the ground wire with the bolt and torque to spec. (If Equipped) Torque Spec: 22 ft∙lbs (29.3 N∙m, 299 kgf∙cm) NOTE: The number of wire harness clamps will differ depending on the vehicle spec. 65 NEW Replacement Parts Part Number 90119-A0169 51900-34050 Part Name Bolt Carrier Assy, Spare Wheel * Individual Part(s) 15. INSTALL THE SPARE WHEEL CARRIER ASSY Kit # 2 NA* Qty 4 1 a) Install the NEW spare wheel carrier assy with the 4 NEW bolts and torque to spec. Torque Spec: 15 ft∙lbs (20 N∙m, 204 kgf∙cm) 16. REINSTALL THE FUEL PUMP CONTROL COMPUTER ASSY a) Reinstall the fuel pump control computer with the 2 nuts and torque to spec. Torque Spec: 14 ft∙lbs (19.5 N∙m, 199 kgf∙cm) b) Reconnect the 2 connectors. 17. REINSTALL THE FOLLOWING PARTS • Rear Differential Assy ° Reinstall the rear differential assy with the 4 NEW U - bolts, 2 spring seats, 2 spring bumpers, 8 NEW mounting nuts and 8 NEW washers, then torque to spec. ° Torque Spec: 74 ft∙lbs (100 N∙m, 1020 kgf∙cm) • Rear Shock Absorber Assy ° Reinstall the rear shock absorber assy with the NEW nut, retainer and 2 cushions, then torque to spec. ° Torque Spec: Nut (Upper Side) - 21 ft∙lbs (28 N∙m, 286 kgf∙cm) ° Reinstall with the bolt, 2 nuts and torque to spec. ° Torque Spec: Nut (Lower Side) - 66 ft∙lbs (90 N∙m, 918 kgf∙cm) ° Repeat the procedure on the opposite side. NEW Replacement Parts Part Number 90117-A0003 90117-A0004 90178-A0050 94622-51400 90178-A0071 Part Name Bolt, U (For Rear Spring) ** Kit # NA* NA* 2 1 2 Qty 4 4 8 8 2 Nut Washer Nut * Individual Part(s) ** Only 1 part used. The part number depending on the list. 66 18. RECONNECT THE REAR BRAKE TUBES NEW Replacement Parts Part Number 90468-A0007 Part Name Clip Kit # 2 Qty 2 a) Reconnect the 2 flexible hose with a 2 NEW clips. b) Reconnect the 2 rear brake tube and torque to spec. Torque Spec: 11 ft∙lbs (15 N∙m, 153 kgf∙cm) 19. REINSTALL THE PARKING BRAKE CABLE a) Reinstall the parking brake cables with the clamp and 11 bolts, then torque to spec. Torque Spec: Bolt A - 14 ft∙lbs (19 N∙m, 194 kgf∙cm) Bolt B - 10 ft∙lbs (13.5 N∙m, 138 kgf∙cm) 20. REINSTALL THE FRONT DIFFERENTIAL CARRIER ASSY (4WD ONLY) a) Reinstall the front differential carrier assy with the 3 bolts, 2 stoppers and 2 nuts, then torque to spec. Torque Spec: 83 ft∙lbs (113 N∙m, 1152 kgf∙cm) 67 b) Reinstall the breather tubes with the NEW bolt and torque to spec. NEW Replacement Parts Part Number 90105-A0193 Part Name Bolt Kit # 4 Qty 1 Torque Spec: 12 ft∙lbs (16.6 N∙m, 169 kgf∙cm) c) Reinstall the differential wire connector with the bolt and clamp, then torque to spec. Torque Spec: 13 ft∙lbs (17.2 N∙m, 175 kgf∙cm) 68 21. REINSTALL THE POWER STEERING LINK ASSY W/ POWER STEERING VANE PUMP a) Place the power steering link assy w/ power steering vane pump on the frame as shown in the figure. NOTE: • When reinstalling the power steering link with the vane pump attached, have one person support the power steering link and the other support the vane pump. • Make sure to keep the power steering pump reservoir in an upright position to prevent the fluid from leaking out. • Take care not to deform the power steering tube etc. during placement. b) Install the 2 bolts (A) and 2 nuts, then torque to spec. Torque Spec: Nut - 89 ft∙lbs (120 N∙m, 1224 kgf∙cm) c) Install the bolts (b) (2UZ-FE: 5 bolts, 1GR-FE, 3UR-FE: 6 bolts) and torque to spec. Torque Spec: Bolt - B 21 ft∙lbs (28 N∙m, 286 kgf∙cm) 22. REINSTALL THE FRONT DRIVE SHAFT ASSY (4WD ONLY) NEW Replacement Parts Part Number 90311-47012 or 90311-47027 90311-47013 43425-0C010 Part Description Kit # Quantity Seal, Oil (For Differential Side Gear Shaft 3 1 3 1 4 2 Seal, Oil (For Differential Side Gear Shaft Ring, Shaft Snap (For Front Drive Inner Shaft Outer) a) Install a NEW snap ring. b) Reinstall the front drive shaft assy. c) Repeat the procedure on the opposite side. NOTE: • Be careful not to damage the dust cover and oil seal. • If the oil seal is damaged, replace the NEW parts. 69 23. REINSTALL THE FRONT SHOCK ABSORBERS NEW Replacement Parts Part Number 90178-A0052 Part Name Nut (For Front Suspension Support) Kit # 2 Qty 8 a) Reinstall the front shock absorber assy with the 4 NEW nuts (A) and torque to spec. Torque Spec: Nut A - 33 ft∙lbs (45 N∙m, 459 kgf∙cm) b) Reinstall the bolt and nut (B), then torque to spec. Torque Spec: Nut B - 144 ft∙lbs (195 N∙m, 1988 kgf∙cm) c) Repeat the procedure on the opposite side. 24. REINSTALL THE FRONT SUSPENSION UPPER ARM AND STEERING KNUCKLES a) Reinstall the front suspension upper arm w/ steering knuckle assy with the bolt, nut and 2 washers, then torque to spec. Torque Spec: 173 ft∙lbs (235 N∙m, 2396 kgf∙cm) b) Repeat the procedure on the opposite side. 25. REINSTALL THE FOLLOWING PARTS • • NEW Replacement Parts Part Number 90252-04003 90119-A0192 Part Name Cotter Pin Bolt Kit # 1 2 Qty 2 4 • • Lower Ball Joint ° Reinstall the lower ball joint with the 2 bolts and torque to spec. ° Torque Spec: 221 ft∙lbs (300 N∙m, 3059 kgf∙cm) ° Repeat the procedure on the opposite side. Tie Rod End Sub-Assy ° Reinstall the tie rod end with the nut and torque to spec. ° Torque Spec: 51 ft∙lbs (69 N∙m, 704 kgf∙cm) ° Install the NEW cotter pin. ° Repeat the procedure on the opposite side. Front Axle Shaft Nut (4WD Only) ° Temporarily reinstall the front axle nut. ° This nut will be tightened when the vehicle is completed. ° Repeat the procedure on the opposite side. Front Stabilizer Bar ° Reinstall the stabilizer bar with the 2 brackets and 4 NEW bolts, then torque to spec. ° Torque Spec: 51 ft∙lbs (69 N∙m, 704 kgf∙cm) ° Reconnect the stabilizer links with the 2bolts and torque to spec. ° Torque Spec: 89 ft∙lbs (120 N∙m, 1224 kgf∙cm) 70 26. RECONNECT THE FRONT BRAKE HOSES NEW Replacement Parts Part Number 90119-A0222 90468-A0007 Part Name Bolt Clip a) Reinstall a bracket with a NEW bolt and torque to spec. Kit # 2 2 Qty 2 2 Torque Spec: 21 ft∙lbs (29 N∙m, 296 kgf∙cm) b) Reinstall the front brake hose with the NEW clip. c) Repeat the procedure on the opposite side. 27. RECONNECT THE SKID CONTROL SENSOR WIRES NEW Replacement Parts Part Number 90105-A0064 Part Name Bolt Kit # 2 Qty 3 a) Reinstall the skid control sensor wire with the 2 NEW bolts and torque to spec. (LH Side Connects to the Frame) b) Reinstall the skid control sensor wire with the NEW bolt and torque to spec. (RH Side Connects to the Body) Torque Spec: 9 ft∙lbs (12.5 N∙m 127 kgf∙cm) 71 NEW Replacement Parts Part Number 77285-34380 77289-26010 77285-34370 77296-0C010 or 77296-0C020 77412-34010 77412-34010 77412-34010 77413-34010 90105-A0179 90105-A0179 90105-A0179 28. REINSTALL THE FUEL TUBES Part Description Clamp, Fuel Tube, No.1 Clamp, Fuel Tube, No.1 Clamp, Fuel Tube, No.2 Kit # 2 1 1 Quantity 3 1 3 Clamp, Fuel Tube, No.3 2 1 NA* NA* NA* 1 NA* NA* NA* 1 2 3 1 2 3 4 Clamp, Fuel Tube, No.4** Clamp, Fuel Tube, No.5 Bolt** a) Reinstall the fuel tubes with the NEW clamps and NEW bolts, then torque to spec. Torque Spec: 21 ft∙lbs (29 N∙m, 296 kgf∙cm) NOTE: The number of clamps will differ depending on the vehicle spec. * Individual Part(s) ** Only 1 part is used. The part number depending on the list 29. REINSTALL THE ENGINE AND TRANSMISSION ASSY a) Reinstall engine and transmission assy. NOTE: • When reinstalling the engine and transmission assy, ALWAYS use 2 engine hoists or mini cranes to lift it. • DO NOT use 1 engine hoist or mini crane to lift the engine and transmission assy, as the unbalanced weight may lead to an accident or injury. • ONLY use engine hoists or mini cranes that can properly support the weight of the engine and transmission assy. • Carefully adjust the 2 engine hoists or mini cranes used so that the engine and transmission assy is properly balanced. 72 b) Attach the engine mounts with the 4 NEW bolts and torque to spec. NEW Replacement Parts Part Number 90119-A0224 Part Name Bolt Kit # 2 Qty 4 LH Side Torque Spec: 58 ft∙lbs (79 N∙m, 806 kgf∙cm) RH Side c) Attach the transmission mount with 4 NEW bolts and torque to spec. NEW Replacement Parts Part Number 90119-A0210 Part Name Bolt Kit # 2 Qty 4 Torque Spec: 12 ft∙lbs (16 N∙m, 163 kgf∙cm) d) Remove the bolt(s) and the engine hangers. (1GR-FE, 3UR-FE Only) e) Reinstall the items/parts that were removed during the engine and transmission assy removal. 73 30. REINSTALL THE INTAKE AIR SURGE TANK (1GR-FE ONLY) a) Install the NEW air surge tank to intake manifold gasket. b) Reinstall the intake air surge tank with the 4 bolts and the 2 nuts, then torque to spec. Torque Spec: 21 ft∙lbs (28 N∙m, 286 kgf∙cm) NEW Replacement Parts Part Number 17176-0P010 Part Name Gasket, Airsurge Tank To Intake Manifold * Individual Part(s) Kit # Qty NA* 1 c) Reinstall the 3 surge tank stays with the 6 bolts and torque to spec. Torque Spec: 15 ft∙lbs (21 N∙m, 214 kgf∙cm) d) Reinstall the oil baffle plate with the bolt and torque to spec. Torque Spec: 80 in∙lbs (9.0 N∙m, 92 kgf∙cm) e) Reinstall the 2 water by-pass hoses. f) Reinstall the No.1 ventilation hose. g) Reinstall the 3 connectors and 4clamps. 31. REINSTALL THE POWER STEERING PUMP ASSY a) Reinstall the power steering vane pump with the 2 bolts and the nut (2UZ-FE Only) or the 2 bolts (1GR-FE, 3UR-FE Only), then torque to spec. Torque Spec: 21 ft∙lbs (28 N∙m, 286 kgf∙cm) b) Reconnect the clamp. (3UR-FE Only) c) Reconnect the connectors. d) Reinstall the drive belt. 4WD Only 2UZ-FE, 3UR-FE 32. RECONNECT THE DIFFERENTIAL WIRE (4WD ONLY) 33. RECONNECT THE ENGINE WIRE (2UZ-FE, 3UR-FE ONLY) 74 34. RECONNECT THE FUEL PIPES a) Reconnect the 2 fuel pipes. b) Reinstall the No.1 fuel pipe clamp. 35. RECONNECT THE FUEL VAPOR FEED HOSE ASSY 36. RECONNECT THE PARKING BRAKE SYSTEM a) Reconnect the cable support bracket with the 3 bolts and torque to spec (A). b) Reconnect the parking brake intermediate lever with the 2 bolts and torque to spec (B). c) Reconnect the No.2 cable support bracket with the 2 bolts and torque to spec (C). Torque Spec: 14 ft∙lbs (19 N∙m, 194 kgf∙cm) d) Reconnect the 2 parking brake cables. e) Reinstall the tension spring. f) Reinstall the cable retainer with the bolt and torque to spec. Torque Spec: 9 ft∙lbs (12.5 N∙m, 127 kgf∙cm) 37. REINSTALL THE CHARCOAL CANISTER ASSY a) Reinstall the charcoal canister assy with the 4 bolts and 2 nuts, then torque to spec. Torque Spec: Bolt - 21 ft∙lbs (29 N∙m, 296 kgf∙cm) Nut – 9 ft∙lbs (12.5 N∙m, 127 kgf∙cm) b) Reconnect the fuel hose, connector and clamp. 75 38. REINSTALL THE FUEL TANK STRAPS a) Reinstall the fuel tank straps with the 2 pins and 2 clips. NEW Replacement Parts Part Number 90119-A0077 77272-0C030 Part Name Bolt Support, Breather Tube, No.1 39. REINSTALL THE FUEL TANK ASSY Kit # 2 2 Qty 2 1 a) Reinstall the fuel tank assy with the 2 NEW bolts and torque to spec. Torque Spec: 30 ft∙lbs (40 N∙m, 408 kgf∙cm) b) Reconnect the 2 fuel tubes. c) Reconnect the connector and clamps. d) Reconnect the NEW No.1 breather tube support and hose. 40. REINSTALL THE No.1 FUEL TANK PROTECTOR ASSY (IF EQUIPPED) NEW Replacement Parts Part Number 90080-11373 Part Name Bolt * Individual Part(s) Kit # NA* Qty 2 a) Reinstall the No.1 fuel tank protector with the 2 NEW bolts and the 2 nuts, then torque to spec. Torque Spec: Bolt - 21 ft∙lbs (29 N∙m, 296 kgf∙cm) Nut - 15 ft∙lbs (20 N∙m, 204 kgf∙cm) 76 41. REINSTALL THE REAR PROPELLER SHAFT ASSY a) Remove the SST. (2WD Only) b) Referencing the matchmarks, reinstall the propeller shaft assy to the transmission / transfer case. c) Reinstall the 4 nuts and torque to spec. (4WD Only) Torque Spec: 52 ft∙lbs (70 N∙m, 714 kgf∙cm) d) Reinstall the center support bearing to the frame as shown in the illustration with 2 washer and 2 bolts, then torque to spec. (3-Joint Type Only) Torque Spec: 30 ft∙lbs (40.2 N∙m, 410 kgf∙cm) e) Referencing the matchmarks, reinstall the propeller shaft assy to the rear differential with 4 bolts, and 4 nuts, then torque to spec. Torque Spec: 52 ft∙lbs (70 N∙m, 714 kgf∙cm) 42. REINSTALL THE FRONT PROPELLER SHAFT ASSY a) Referencing the matchmarks, install the front propeller shaft assy to the transfer case and the front differential with 8 nuts and 8 washers, then torque to spec. Torque Spec: 59 ft∙lbs (80.3 N∙m, 819 kgf∙cm) 43. REINSTALL THE PROPELLER SHAFT HEAT INSULATOR (4WD ONLY) NEW Replacement Parts Part Number 90119-A0151 Part Name Bolt Kit # 4 Qty 2 a) Reinstall the propeller shaft heat insulator with the 2 NEW bolts and torque to spec. Torque Spec: 12 ft∙lbs (15.7 N∙m, 160 kgf∙cm) 77 44. REINSTALL THE EXHAUST SYSTEM NEW Replacement Parts Part Number 90917-A6002 90126-A0011 90126-A0011 90126-A0011 90080-17187 Part Name Kit # Gasket, Exhaust Pipe 2 Bolt, Stud (For Exhaust Manifold, NA* RH) 3UR# Bolt, Stud (For Exhaust Manifold, NA* LH) 3UR# Bolt, Stud (For Manifold To NA* Exhaust Pipe) Nut 2 * Individual Part(s) Qty 2 3 a) Install the 2 NEW exhaust pipe gaskets. b) Reinstall the exhaust pipe and 4 exhaust pipe supports. c) Install the 6 NEW nuts and torque to spec. Torque Spec: 40 ft∙lbs (54.3 N∙m, 554 kgf∙cm) 3 6 6 45. RECONNECT THE OXYGEN SENSOR CONNECTORS a) Reconnect the 4 oxygen sensor connectors. 78 46. REINSTALL THE EXHAUST TAIL PIPE ASSY NEW Replacement Parts Part Number 90917-06085 90917-06093 90119-A0380 90080-46263 90461-15017 Part Name Gasket, Exhaust Pipe, Center** Bolt Clamp** Kit # NA* NA* 2 NA* NA* Qty 1 1 1 1 1 * Individual Part(s) ** Only 1 part used. The part number depending on the list. a) Install the NEW exhaust pipe gasket. b) Reinstall the exhaust tail pipe and exhaust pipe support. c) Install the NEW bolt and NEW clamp, then torque to spec. Torque Spec: 24 ft∙lbs (32 N∙m, 326 kgf∙cm) 47. REINSTALL THE FOLLOWING PARTS • • Spare Tire Wheels 48. REMOVE THE FRAME FROM THE LIFT a) Remove the ratcheting tie down strap from the frame. b) Lower the frame to the ground. 79 I. REINSTALL THE CAB BODY ASSY 1. REINSTALL THE CAB BODY ASSY a) b) c) d) e) Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab. Push the frame under the cab assy. Lower the cab assy slowly, making sure it does not interfere with anything. Adjust the vehicle’s frame as needed to align the cab mounts with the cab assy bolts. Once the cab assy is set on the mounts, secure it to the frame with 6 bolts, 6 nuts, 4 washers and 2 No.1 lower cab mounting cushion sub-assy, then torque to spec. Torque Spec: 40 ft∙lbs (54 N∙m, 551 kgf∙cm) NOTE: • DO NOT work directly underneath the vehicle when pushing the frame under the cab assy. • Slowly lower the cab body assy while making sure that the wire harness, steering shaft and hoses do not interfere. • With 2 to 3 people checking for interference, slowly lower the cab body assy to the frame. 80 2. RECONNECT THE REAR BRAKE TUBES NEW Replacement Parts Part Number 90412-10268 90119-A0184 Part Name Way (For Rear Brake Tube) Bolt Kit # 1 2 Qty 1 1 a) Reconnect the rear brake tubes with the NEW bolt and torque to spec. Torque Spec: 23 ft∙lbs (31 N∙m, 316 kgf∙cm) b) Reconnect the 2 rear brake tubes and torque to spec. Torque Spec: 11 ft∙lbs (15.2 N∙m, 155 kgf∙cm) 3. RECONNECT THE TRANSMISSION CONTROL CABLE NEW Replacement Parts Part Number 90080-17229 Part Name Nut * Individual Part(s) Kit # NA* Qty 1 a) Reconnect the shift cable with the 2 bolts and NEW nut, then torque to spec. Torque Spec: Bolt - 9 ft∙lbs (12 N∙m, 122 kgf∙cm) Nut - 10 ft∙lbf (14 N∙m, 143 kgf∙cm) b) Reconnect the ground wire with the bolt and torque to spec. Torque Spec: 73 in∙lbs (8.3 N∙m, 85 kgf∙cm) c) Reconnect the 3 clamps. 81 4. RECONNECT THE No.1 PARKING BRAKE CABLE a) Reconnect the No.1 parking brake cable. b) Reinstall the cable retainer with the bolt and torque to spec. Torque Spec: Bolt - 9 ft∙lbs (12.5 N∙m, 127 kgf∙cm) c) Reinstall the No.1 wire adjusting nut and nut, then torque to spec. Torque Spec: Nut - 11 ft∙lbs (15 N∙m, 153 kgf∙cm) 5. REMOVE THE FRONT WHEELS 6. RECONNECT THE No.2 STEERING INTERMEDIATE SHAFT NEW Replacement Parts Part Number 90080-11555 Part Name Bolt Kit # 2 Qty 1 a) Make sure the front wheels are in a straight-ahead position and the steering wheel is centered. b) Referencing the matchmarks, connect the No.2 intermediate shaft to the intermediate shaft with the NEW bolt. c) Torque bolt to spec. Torque Spec: 26 ft∙lbs (35 N∙m, 357 kgf∙cm) d) Disconnect the seat belt that is holding the steering wheel. 7. RECONNECT THE FRONT DIFFERENTIAL VACUUM HOSE (4WD ONLY) NEW Replacement Parts Part Number 90464-00897 Part Name Clamp Kit # 4 Qty 1 a) Reconnect the NEW clamp and vacuum hose. 82 8. RECONNECT THE FRONT BRAKE TUBES NEW Replacement Parts Part Number 90412-10266 90412-10267 47314-0C020 47315-0C030 or 47315-0C031 90119-A0169 Part Description Way, No.1 (For Front Brake Tube) Way, No.2 (For Front Brake Tube) Tube, Front Brake, No.4 Kit # Quantity 1 1 1 1 2 1 Tube, Front Brake, No.5 2 1 Bolt 2 2 a) Reconnect the front brake tube with the NEW bolt and torque to spec. Torque Spec: 23 ft∙lbs (31 N∙m, 316 kgf∙cm) b) Temporarily install the NEW front brake tube. c) Torque the front NEW brake tube to spec. LH Side Torque Spec: 11 ft∙lbs (15.2 N∙m, 155 kgf∙cm) d) Repeat the procedure on the opposite side. RH Side 83 9. REINSTALL THE FRONT FENDER APRON SEALS NEW Replacement Parts Part Number 90080-46327 Part Name Clip (For Front Fender Apron Seal) LH Side Kit # 2 Qty 22 a) Reinstall the left side 2 front fender apron seals LH / RH with the 11 NEW clips. b) Reinstall the right side 2 front fender apron seals LH / RH with the 11 NEW clips. RH Side 10. RECONNECT THE VANE PUMP OIL RESERVOIR ASSY a) Reconnect the vane pump oil reservoir assy with the 3 bolts and torque to spec. Torque Spec: 71 in∙lbs (8.0 N∙m, 82 kgf∙cm) b) Reconnect the windshield washer jar assy with the 3 bolts and torque to spec. Torque Spec: 31 in∙lbs (3.5 N∙m, 36 kgf∙cm) 84 11. REINSTALL THE FOLLOWING PARTS • NEW Replacement Parts Part Number 16492-21050 Part Name Packing (For Radiator Drain Cock) Kit # 2 Qty 1 • • • 12. RECONNECT THE No.1 COOLER REFRIGERANT DISCHARGE HOSE NEW Replacement Parts Part Number 90099-14120 Part Name O-Ring Radiator Assy ° Install the NEW radiator drain cock packing. ° Reinstall the radiator assy with the 4 bolts and torque to spec. ° Torque Spec: 13 ft∙lbs (18 N∙m, 184 kgf∙cm) Fan Shroud ° Reinstall the fan shroud with the 2 bolts and torque to spec. ° Torque Spec: 58 in∙lbs (6.5 N∙m, 66 kgf∙cm) Radiator Outlet Hose Radiator Inlet Hose Kit # 1 Qty 1 a) Install a NEW o-ring to the A/C discharge hose. b) Reconnect the A/C discharge hose with the bolt and torque to spec. Torque Spec: 87 in∙lbs (9.8 N∙m, 100 kgf∙cm) 13. REINSTALL THE FOLLOWING PARTS • • Radiator Side Deflector RH (If Equipped) Radiator Side Deflector LH 14. REINSTALL THE OIL COOLER (AIR OIL COOLER EQUIPPED VEHICLES ONLY) a) Reinstall the oil cooler with the 3 bolts and torque to spec. Torque Spec: 10 ft∙lbs (14 N∙m, 143 kgf∙cm) b) Reconnect the No.1 oil cooler inlet hose and No.1 oil cooler outlet hose. c) Reconnect the clamp. 85 15. REINSTALL THE UPPER CENTER FRONT BUMPER RETAINER (AIR OIL COOLER EQUIPPED VEHICLES ONLY) NEW Replacement Parts Part Number 90179-06178 Part Name Nut 1GR-FE Kit # 1 Qty 6 a) Reinstall the front bumper retainer upper center with the 6 NEW nuts and torque to spec. Torque Spec: 48 in∙lbs (5.4 N∙m, 55 kgf∙cm) 16. RECONNECT THE AIR PUMP HARNES a) Reconnect the 2 connectors and 4 clamps. (1GR-FE) b) Reconnect the connector and 2 clamps. (2UZ-FE) c) Reconnect the 2 connectors and 3 clamps. (3UR-FE) 2UZ-FE 3UR-FE 86 1GR-FE 17. RECONNECT THE AIR INJECTION SYSTEM HOSES a) Reconnect the No.5 hose and No.4 hose. (1GR-FE) b) Reconnect the No.2 Hose and clamp. (2UZ-FE) c) Reconnect the No.2 hose and No.3 hose. (3UR-FE) 2UZ-FE 3UR-FE 18. RECONNECT THE INLET HEATER HOSE AND OUTLET HEATER HOSE, ENGINE SIDE 19. RECONNECT THE ENGINE WIRE HARNESS (RH SIDE) a) Reconnect the ground wire with the bolt and torque to spec. Torque Spec: 73 in∙lbs (8.3 N∙m, 85 kgf∙cm) b) Reconnect the skid control sensor connector and clamp. 87 c) Reconnect the 2 clamps and 3 connectors. d) Reconnect the 2 clamps and 5 connectors. e) Reinstall the connector holder block cover upper. 20. RECONNECT THE VACUUM HOSE ASSY NEW Replacement Parts Part Number 90069-08009 Part Name O-Ring Kit # 2 Qty 1 a) Reconnect the vacuum hose assy. 21. RECONNECT THE No.1 COOLER REFRIGERANT SUCTION HOSE a) Install a NEW o-ring to the A/C suction hose. b) Reconnect the A/C suction hose and torque to spec. Torque Spec: 87 in∙lbs (9.8 N∙m, 100 kgf∙cm) 22. RECONNECT THE ENGINE WIRE HARNESS (LH SIDE) a) Reconnect the ground wire with the bolt and torque to spec. Torque Spec: 73 in∙lbs (8.3 N∙m, 85 kgf∙cm) b) Reconnect the 2 clamps and 6 connectors. 88 c) Reconnect the (+) positive battery cable with the nut and torque to spec. Torque Spec: 7 ft∙lbs (10 N∙m, 102 kgf∙cm) d) Reconnect the clamp and 2 connectors. e) Reinstall the No.1 relay block cover. f) Reconnect the clamp. g) Reconnect the ground wire with the bolt and torque to spec. Torque Spec: 73 in∙lbs (8.3 N∙m, 85 kgf∙cm) h) Reconnect the 2 positive (+) battery cables with the nut and torque to spec. Torque Spec: 9 ft∙lbs (12.7 N∙m, 130 kgf∙cm) 89 NEW Replacement Parts Part Number 90178-A0044 90178-A0067 90189-06236 90080-11717 Part Name Nut Nut Clip Bolt * Individual Part(s) Kit # 2 2 NA* NA* Qty 8 6 4 16 23. REINSTALL THE FOLLOWING PARTS • Air Cleaner Hose and Air Cleaner Assy (1GR-FE Only) ° Torque Spec: Air Cleaner Assy - 71 in∙lbs (8.0 N∙m, 82 kgf∙cm) Air Cleaner Hose - 66 in∙lbs (7.5 N∙m, 76 kgf∙cm) • Air Cleaner Hose and Air Cleaner Assy (2UZ-FE, 3UR-FE Only) ° Torque Spec: 44 in∙lbs (5.0 N∙m, 51 kgf∙cm) • Throttle Body Cover Sub- Assy (2UZ-FE Only) ° Torque Spec: 66 in∙lbs (7.5 N∙m, 76 kgf∙cm) • V-Bank Cover Sub- Assy (1GR-FE, 3UR-FE Only) ° Torque Spec: 66 in∙lbs (7.5 N∙m, 76 kgf∙cm) (1GR-FE Only) • Front Fender Mudguard LH/RH (If Equipped) • No.2 Front Bumper Extension Sub-Assy LH/RH ° Reinstall the No.2 front bumper extension Sub-Assy with 8 NEW nuts and torque to spec. ° Torque Spec: 43 ft∙lbs (58 N∙m, 591 kgf∙cm) • Front Bumper Reinforcement Sub-Assy ° Reinstall the front bumper reinforcement Sub-Assy with 6 NEW nuts and torque to spec. ° Torque Spec: 52 ft∙lbs (71 N∙m, 724 kgf∙cm) • Front Bumper Assy (Steel Bumper Equipped Vehicles Only) ° Reinstall the front bumper bar with the 8 bolts and 4 NEW clips, then torque to spec. ° Torque Spec: Bolt 24 ft∙lbs (32 N∙m, 326 kgf∙cm) ° Reinstall the front bumper cover with the 16 NEW bolts, 10 clips and 2 screws. • Front Bumper Cover Assy (Resin Bumper Equipped Vehicles Only) ° Reinstall with the 6 screws and 16 clips. • Front Fender Splash Shield Sub-Assy LH/RH • Front End Panel LH/RH • Front Wheels 24. REINSTALL THE FOLLOWING PARTS • • • • • • • • • • • • Lower LH Quarter Trim Panel Assy (Regular Cab Only) Front Seat Outer Belt Assy LH (Regular Cab Only) ° Reconnect the front seat outer belt assy LH. ° Torque Spec: 31 ft∙lbs (42 N∙m, 428 kgf∙cm) Upper Back Panel Garnish (Regular Cab Only) Luggage Compartment Box LH (Regular Cab Only) Floor Carpet is returned (Double Cab Only) Back Panel Trim LH/RH (Crewmax Only) No.1 w/ Box Speaker Assy (If Equipped) Jack and Tool (Standard Tool) No.2 Dash Panel Insulator Pad No.3 Dash Panel Insulator Pad Cowl Side Trim Board LH/RH Front Door Scuff Plate LH/RH 90 J. REINSTALL THE REAR BED ASSY 1. REINSTALL THE REAR BED ASSY a) Using a Torx® T55H Tamper Resistant Socket, reinstall the rear bed assy Torx ® bolts and torque to spec. • Long Bed: 8 Torx® bolts • Standard Bed and Crewmax (Short Bed): 6 Torx® bolts Torque Spec: 44 ft∙lbs (66 N∙m, 673 kgf∙cm) NOTE: • Use 4 or more people to install the rear bed assy from the frame. • Evenly support the rear bed assy when reinstalling it. • Be careful not to damage or hit the fuel inlet pipe when reinstalling the rear bed assy. • If you find excessive corrision around the bed mounting bolts and believe the bed cannot be securly reattached after removal, contact your FTS 2. REINSTALL THE FUEL TANK INLET PIPE SUB-ASSY NEW Replacement Parts Part Number 90178-A0049 Part Name Nut Kit # 2 Qty 2 a) Reinstall the fuel inlet pipe sub-assy with the 2 NEW nuts and torque to spec. Torque Spec: 15 ft∙lbs (20 N∙m, 204 kgf∙cm) 91 3. RECONNECT THE FRAME WIRE HARNESS a) Reconnect the clamps, connectors and the frame wire harness to the rear bed assy. NOTE: The number of connectors will differ depending on the vehicle spec. • Use new clamps if the original ones are damaged. • 4. REINSTALL THE FOLLOWING PARTS NEW Replacement Parts Part Number 90119-A0219 90119-A0219 90119-A0271 90119-A0271 Part Name Bolt (w/o Towing Hitch) Bolt (w/ Towing Hitch) Bolt (w/o Towing Hitch) Bolt (w/ Towing Hitch) * Individual Part(s) Kit # NA* NA* NA* NA* Qty 4 10 4 2 • • • • • • • No.1 Rear Wheel House Liner LH Fuel Filler Opening Lid Sub- Assy Side Step Assy LH/RH (If Equipped) Rear Bumper Assy ° Reinstall the rear bumper assy with the 12 NEW bolts and torque to spec. (Trailer Hitch Equipped Vehicles Only) ° Reinstall the rear bumper assy with the 8 NEW bolts and torque to spec. ° Torque Spec: 113 ft∙lbs (153 N∙m, 1560 kgf∙cm) Rear Quarter panel Mudguard LH/RH (If Equipped) No.3 Frame Wire License Plate Light Assy LH/RH 92 K. FINAL ASSEMBLY 1. REINSTALL THE NEGATIVE (-) BATTERY TERMINAL 2. REFILL THE FOLLOWING FLUIDS • NEW Replacement Parts Part Number 12157-10010 90430-24003 Part Name Gasket, Front Differential Filler Plug Gasket (For Front Differential Drain Plug) Kit # 3 Qty 1 3 1 • • Brake Fluid ° Remove the brake tubes from the master cylinder. ° Refill with Toyota Dot 3 Brake Fluid. ° Bleed the master cylinder. ° Reinstall the brake tubes to the master cylinder and torque to spec. ° Torque Spec: 11 ft∙lbs (15.2 N∙m, 155 kgf∙cm) ° Refill with Toyota Dot 3 Brake Fluid. ° Bleed the brake system at each wheel and torque the bleeder screws to spec. ° Torque Spec: 8 ft∙lbs (11 N∙m, 112 kgf∙cm) Coolant ° Refill with Toyota Long Life Coolant. ° Bleed the cooling system. Front Differential ° Install a NEW drain plug washer and torque to spec. ° Torque Spec: 29 ft·lbs (39.2 N·m, 400 kgf·cm) ° Refill with Hypoid Gear Oil API GL-5 75W-90. ° Install a NEW filler plug washer and torque to spec. ° Torque Spec: 29 ft·lbs (39.2 N·m, 400 kgf·cm) 3. START THE VEHICLE AND INSPECT THE FOLLOWING FOR LEAKS • • • • Fuel System ° Start the engine and let it run for 5 seconds, then stop the engine and inspect for leaks. ° If there are no leaks, restart the engine and re-inspect. Cooling System Brake System Front Differential System 4. RECHARGE THE A/C SYSTEM AND CHECK FOR PROPER OPERATION AND REFRIGERANT LEAKS 5. CHECK THE OPERATION OF THE FOLLOWING SYSTEMS AND ADJUST AS NEEDED Make sure to follow the procedure outlined in the appropriate repair manual for the vehicle you are working on when checking, and if needed, adjusting the operation of the systems listed below. This is an important step, and must be performed thoroughly to ensure proper operation of these systems. • • Parking Brake Travel Shift Control Lever 6. CHECK ALL FLUID LEVELS AND ADJUST AS NEEDED 93 7. TORQUE THE FRONT AXLE NUT (4WD ONLY) NEW Replacement Parts Part Number 95381-04050 43514-34020 43514-34020 Part Name Kit # Cotter Pin 3 Cap, Front Axle Hub Grease, RH 3 Cap, Front Axle Hub Grease, LH 3 Qty 2 1 1 a) Remove the front wheels. b) Torque the front axle nut to spec. Torque Spec: 249 ft∙lbs (338 N∙m, 3447 kgf∙cm) c) d) e) f) Reinstall the lock cap with the NEW cotter pin. Reinstall the NEW grease cap. Repeat the procedure on the opposite side. Reinstall the front wheels and torque to spec. Torque Spec: Aluminum Wheel - 97 ft∙lbs (131 N∙m, 1336 kgf∙cm) Steel Wheel - 154 ft∙lbs (209 N∙m, 2131 kgf∙cm) NOTE: If the holes for the cotter pin are not aligned, tighten the axle nut further, up to 60 degree. 8. PERFORM A WHEEL ALIGNMENT 9. CHECK THE HEADLIGHT AIM AND ADJUST AS NEEDED 10. REINSTALL THE ENGINE UNDER COVER No.1 NEW Replacement Parts Part Number 90119-A0169 90119-A0169 Part Name Bolt (Large TYPE) Bolt (Small TYPE) * Individual Part(s) Kit # NA* NA* Qty 5 2 a) Reinstall the engine under cover No.1 with 5 NEW bolts and 3 screws, then torque to spec. (Front Bumper Chrome Plated Type) b) Reinstall the engine under cover No.1 with 2 NEW bolts and 3 screws, then torque to spec. (Front Bumper Resin Type) Torque Spec: 21 ft∙lbs (29 N∙m, 296 kgf∙cm) 11. CHECK FOR DTC’S AND REPAIR AS NEEDED 12. PERFORM INITIALIZATION 1. FINAL INSPECTION a) Check the operation of the following systems: • 4WD System (4WD Only) • Power Windows • Interior Lights • Power Door Locks • Exterior Lights • All Gauges, Indicators and Warning Lights • HVAC System • Cooling Fans • Audio System • Etc. 2. TEST DRIVE THE VEHICLE AND DOCUMENT FINAL REPAIR STATUS a) Test drive the vehicle and perform final repair sign off with the Frame Replacement Inspection Sheet. This must be performed and signed off by an MDT, Shop Foreman or Service Manager and retained with Final R.O. 94 3. RECORD THE FRAME SERIAL NUMBER a) Log into the frame tracker website using your dealer code and password. URL: https://zh-frame-tracker.imagespm.info/ Default password: xxxxx b) Select 2007 to 2008 Tundra ZH7 from the pick list. c) Enter the VIN of the vehicle. 95 d) Enter the frame serial off of the case label along with the R.O. number and Approved Frame Inspection Case Number. The Frame Serial Number may be located in one of 2 locations. Please see the images below for location reference. OR e) Press submit and print a copy of the serial number and file with the R.O. 96 1. APPENDIX As required by Federal Regulations, please make sure all recalled parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused. Adequate time has been provided in the repair time to cut up and dispose of the perforated frame. 97