8. RECONNECT THE VANE PUMP OIL RESERVOIR
a) Reinstall the vane pump oil reservoir with the 2 nuts
and torque to spec.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)

9. RECONNECT THE HEATER WATER HOSE
10. RECONNECT THE REAR HEATER WATER HOSES
(IF EQUIPPED)
a) Reconnect the 2 rear heater water hoses to the water
pipe.

61

11. RECONNECT THE A/C DISCHARGE HOSE AND
SUCTION HOSE

NEW Replacement Parts
A/C Line O-Rings
Part Number
90069-08007
90099-14121

Part Name
Ring, O

Kit #
4

Qty
1

2

1

a) Install the NEW O-rings to the discharge hose and
suction hose.
b) Reinstall the discharge hose and suction hose with the
nuts and torque to spec.
Torque Spec: 10 N∙m (102 kgf∙cm, 7 ft∙lbf)
12. RECONNECT THE NO.2 ENGINE WIRE HARNESS
a) Reinstall the No.2 engine wire harness with the nut and
torque to spec.
b) Reconnect the No.2 engine wire harness to the 2
clamps of the junction block.
c) Reinstall the nut and reconnect the positive (+) battery
cable and torque to spec.
d) Reinstall the bolt and reconnect the ground wire to the
LH side inner fender and torque to spec.
e) Reconnect the connector and clamp.
f) Reinstall the fuel pump relay.
g) Reinstall the relay block cover.
Torque Specs: Nut A - 10 N∙m (102 kgf∙cm, 7 ft∙lbf)
Torque Specs: Nut B - 13 N∙m (133 kgf∙cm, 10 ft∙lbf)
Torque Specs: Bolt - 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
13. RECONNECT THE FOLLOWING ENGINE
COMPARTMENT HOSES
a) Reconnect the No.2 fuel vapor feed hose
b) Reconnect the brake booster hose.

14. REINSTALL THE RADIATOR
a) Install the NEW radiator drain cock plug O-ring.
b) Tighten the radiator drain cock plug.
c) Reinstall the radiator with the 4 bolts and torque to
spec.

NEW Replacement Parts
Drain Cock O-Ring
Part Number
16492-21050

Part Name
Ring, O Radiator

Kit #
2

Qty
1

Torque Spec: 12 N∙m (122 kgf∙cm, 9 ft·lbf)
d) Reconnect the upper and lower radiator hoses,
automatic transmission cooler hoses.
e) Reinstall the fan shroud.
f) If equipped re-install external transmission cooler

15. REINSTALL THE FOLLOWING PARTS
•
•

Air Cleaner
Throttle Body Cover
° Torque Spec: Nut - : 9.0 N∙m (92 kgf∙cm, 80 in∙lbf)
16. RECONNECT THE ENGINE WIRE HARNESS
a) Reinstall the engine wire harness connector with the 2
nuts and torque to spec.
b) Reinstall the bolt and torque to spec.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
c) Reconnect the ground wire to the cowl panel with the
bolt and torque to spec.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
NEW Replacement Parts
Rear Bumper Extension

Part Number
90178-08011
90119-A0064

Part Name
Nut, Flange
Bolt, w/ Washer

Kit #
2
4

Qty
4
4

17. REINSTALL THE REAR BUMPER EXTENSION
MOUNTING BRACKET W/ BACK STEP
REINFORCEMENT
a) Reinstall the rear bumper extension mounting bracket
w/ back step reinforcement with the 4 NEW nuts and
torque to spec.
b) Install the 4 NEW bolts and torque to spec.
Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf)

18. REINSTALL THE FOLLOWING REAR BODY COMPONENTS
•
•

Rear Bumper Cover
° Torque Spec: 7.0 N∙m (71 kgf∙cm, 62 in∙lbf)
Rear Quarter Panel Mudguard LH/RH
19. RECONNECT THE FRONT FENDER LINER
a) Reconnect the front fender liners with the 2 screws.

20. RECONNECT THE AUTOMATIC TRANSMISSION NO.2
OIL COOLER OUTLET TUBE
a) Reinstall the No.2 oil cooler outlet tube with the bolt and
torque to spec.
b) Reconnect the hose.
Torque Spec: 12 N∙m (122 kgf∙cm, 9 ft∙lbf)

63

21. REINSTALL THE FOLLOWING FRONT BODY PARTS
•
•

NEW Replacement Parts
Side Step Assy LH/RH
Part Number
90179-08068

Part Name
Nut

Kit #
2

Qty
6

90119-08516

Bolt, w/ Washer

2

10

NEW Replacement Parts

22. RECONNECT THE FUEL TANK TO FILLER PIPE HOSE
AND FUEL TANK BREATHER HOSE

Fuel Tank Filler and Breather Hose
Clamps
Purt Number
90460-37003
90460-40007

Purt Name
Clamp, Hose

Kit #
2
2

•
•

Front Bumper Energy Absorber
Front Bumper Cover
° Torque Spec: 7.0 N∙m (71 kgf∙cm, 62 in∙lbf)
Front Fender Mudguard LH/RH
Side Step Assy LH/RH with the 10 new bolts and 6 new
nuts.
° Torque Spec: 20 N·m (204 kgf∙cm, 15 ft·lbf)

Qty
1
1

a) Reconnect the fuel tank to filler pipe hose with the 2
NEW clamps.
b) Reconnect the fuel tank breather hose with the 2 NEW
clamps.
NOTE:
• Tighten the clamp of the fuel tank to filler pipe hose
until it comes into contact with the stopper.

23. RECONNECT THE FUEL TANK VENT HOSE
NOTE:
After finishing the connection, check whether the
pipe and the connector are securely connected by
pulling them.

24. RECONNECT THE NO.1 PARKING BRAKE CABLE
a) Reconnect the No.1 parking brake cable with the bolt
and torque to spec.
b) Reinstall the cable support bracket with the bolt and
torque to spec.
Torque Spec: 26 N∙m (265 kgf·cm, 19 ft∙lbf)

c) Reconnect the No.2 parking brake cable with the clip
and pin.
d) Reconnect the No.1 parking brake cable to the No.3
parking brake cable and torque to spec.
Torque Spec: 13 N∙m (133 kgf∙cm, 10 ft∙lbf)

25. RECONNECT THE REAR BRAKE TUBES
a) Using a flare nut wrench, connect the 2 rear brake
tubes and torque to spec.
Torque Spec: 15 N·m (153 kgf∙cm, 11 ft·lbf)

NEW Replacement Parts
Intermediate Shaft
Part Number
90080-11555

Part Name
Bolt, w/ Washer

Kit #
4

26. RECONNECT THE NO.2 STEERING INTERMEDIATE
SHAFT
Qty
2

a) Make sure the front wheels are in a straight-ahead
position and the steering wheel is centered.
b) Aligning the matchmarks, connect the No.2 steering
intermediate shaft to the control valve shaft with the
NEW bolt (B).
c) Remove bolt (A) and install the NEW bolt (A).
d) Torque all bolts to spec.
Torque Spec: 35 N∙m (357 kgf∙cm, 26 ft∙lbf)

NEW Replacement Parts
Auto Transmission Control Cable
Part Number
90179-08054

Part Name
Nut

Kit #
2

Qty
1

27. RECONNECT THE TRANSMISSION CONTROL CABLE
a) Reinstall the bolt and connect the transmission control
cable and torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
b) Reinstall the pin or NEW nut and NEW washer, then
torque to spec.
Torque Spec: Nut- 13 N∙m (133 kgf∙cm, 10 ft∙lbf) (Only
For Vehicles Produced On Or Before June 2003)
Torque Spec: Nut- 15 N·m (153 kgf∙cm, 11 ft∙lbf) (Only
For Vehicles Produced After June 2003)
NOTE: Vehicles produced after August 2003 is not
equipped with washer.

65

28. REINSTALL FRONT WHEELS
29. LOWER THE VEHICLE
30. RECONNECT THE ENGINE WIRE HARNESS
a) Reconnect the connectors and clamp.
NOTE:
• The number of connectors will differ depending on
the vehicle specs.
• Incorrectly connected connectors may cause the
engine to start improperly. Be certain that the
connectors are correctly connected.

31. RECONNECT THE FRAME WIRE CONNECTOR
a) Reinstall the frame wire harness grommet.
b) Reconnect the 2 connectors.

32. REINSTALL THE FOLLOWING INTERIOR COMPONENTS
a) Glove Compartment
• No.4 Heater To Register Duct
• Lower No.2 Instrument Finish Panel
• Glove Compartment Door
b) Center Console (4WD Only)
• Transfer High and Low Shift Lever
• No.1 Shift and Select Lever Boot
° Torque Spec: 7.0 N∙m (71 kgf∙cm, 62 in∙lbf)
• Upper Console Panel
• Shifting Hole Cover
• Transfer Shift Lever Knob
c) Front Seat and Trim
• Front Seat RH
° Torque Spec: 37 N∙m (377 kgf∙cm, 27 ft∙lbf)
• Cowl Side Trim Board LH/RH
• Front Door Scuff Plate LH/RH
d) Rear Passenger and Cargo Area
• Rear Door Scuff Plate LH/RH
• Rear Quarter Trim Panel LH/RH
• Rear Floor Mat Support Plate
• Rear No.2 Seat Outer Belt Floor Anchor (If Equipped)
° Torque Spec: 42 N∙m (428 kgf∙cm, 31 ft∙lbf)
• Rear No.1 Seat Outer Belt Floor Anchor
° Torque Spec: 42 N∙m (428 kgf∙cm, 31 ft∙lbf)
• Rear 3rd Row Seat (If Equipped)
• Put 2nd Row Seat back into place
33. PUT THE REAR NO.1 SEATS BACK INTO PLACE

I.

FINAL ASSEMBLY

1. RECONNECT THE NEGATIVE BATTERY TERMINAL CABLE
2. REFILL THE FOLLOWING

NEW Replacement Parts
Front Differential Gaskets (4WD Only)
Part Number
12157-10010

Part Name
Gasket, Drain Plug

Kit #
NA*

Qty
1

90430-24003

Gasket

NA*

1

a) Brake Fluid
• Fill with Toyota DOT 3 Brake Fluid.
• Remove the brake lines from the master cylinder.
• Bleed the master cylinder.
• Reinstall the brake lines to the master cylinder and
torque to spec.
• Torque Spec: 15 N·m (153 kgf∙cm, 11 ft·lbf)
Bleed the brake system at each wheel and torque
the bleeder screws to spec.
° Torque Spec: 11 N∙m (112 kgf∙cm, 8 ft∙lbf)
• Top off brake fluid
b) Coolant
• Refill with Toyota Long Life Coolant.
c) Front Differential (4WD Only)
• Install the NEW drain plug gasket and torque to
spec.
• Torque Spec: 65 N·m (663 kgf·cm, 48 ft·lbf)
• Refill with Hypoid Gear Oil API GL-5 75W-90.
• Install the NEW filler plug gasket and torque to
spec.
° Torque Spec: 39 N·m (398 kgf·cm, 29 ft·lbf)
d) Recharge A/C System

3. START THE VEHICLE AND PERFORM AND INSPECT THE FOLLOWING
•
•
•
•
•

Fuel System
° Start the engine and let it run for 5 seconds, and then stop the engine and inspect for leaks.
° If there are no leaks, restart the engine and re-inspect.
Bleed Cooling System and Check for Leaks
Brake System Leaks
Front Differential System
Operation of A/C System

4. INSPECT FOR A/C REFRIGERANT LEAKS
5. CHECK THE OPERATION OF THE FOLLOWING ITEMS 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 items
listed below. This is an important step, and must be performed thoroughly to ensure
proper operation of these items.
•
•

Parking Brake Lever Travel
Shift Control Lever

6. CHECK ALL FLUID LEVELS AND ADJUST AS NEEDED

67

7. REINSTALL AND TORQUE THE REAR LATERAL
CONTROL ROD
NEW Replacement Parts
Rear Lateral Control Rod
Part Number
90179-14062

Part Name
Nut

Kit #
2

Qty
1

Torque Specs:
Nut: 140 N∙m (1428 kgf∙cm, 103 ft∙lbf)
Bolt: 130 N∙m (1326 kgf∙cm, 96 ft∙lbf)
NOTE:
• After stabilizing the suspension, torque the nut.
• Perform tightening with the vehicle grounded.

8. TORQUE THE BOLTS AND NUTS OF THE REAR SUSPENSION ARMS TO SPEC
Torque Specs: No.1 Rear Suspension Arm (Nut) - 140 N∙m (1428 kgf∙cm, 103 ft∙lbf)
Torque Specs: Bolt Of Lower Control Arm (Bolt) - 130 N∙m (1326 kgf∙cm, 96 ft·lbf)
NOTE:
• After stabilizing the suspension, torque the bolt and nut.
• Perform tightening with the vehicle grounded.
9. REINSTALL THE SPARE WHEEL
NEW Replacement Parts

10. TORQUE THE FRONT AXLE NUTS (4WD ONLY)

Front Axle
Part Number
95381-04045

Part Name
Pin, Cotter
*Individual Part(s)

Kit #
NA*

Qty
2

a) Remove the front wheels.
b) Torque the front axle nuts to spec.
Torque Spec: 235 N∙m (2396 kgf∙cm, 173 ft∙lb)
c)
d)
e)
f)

Reinstall the lock cap with the NEW cotter pin.
Reinstall the grease cap.
Repeat the procedure on the opposite side.
Reinstall the front wheels and torque to spec.

Torque Spec: 112 N∙m (1142 kgf∙cm, 83 ft∙lbf)
NOTE:
If the holes for the cotter pin are not aligned, tighten the
axle nut further, up to 60°.
11. PERFORM A WHEEL ALIGNMENT
12. CHECK THE HEADLIGHT AIM AND ADJUST AS NEEDED
13. REINSTALL THE NO.1 ENGINE UNDER COVER
NEW Replacement Parts
a) Install the No.1 engine under cover with the NEW bolts
and torque to spec.

Engine Under Cover
Part Number
90080-11373

Part Name
Bolt, w/ Washer

Kit #
4

Qty
5

Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)

14. CHECK FOR DTCS AND REPAIR AS NEEDED
15. PERFORM INITIALIZATION

16. FINAL INSPECTION
a) Check the operation of the following systems:
•
•
•
•
•

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.

17. 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.
18. 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 2005 to 2007 Sequoia ZH8 from the pick list.

69

c) Enter the VIN of the vehicle.

d) Enter the frame serial off of the case label along with the R.O. number and Approved Frame Inspection Case
Number.

Sample Case Label

e) Press submit and print a copy of the serial number and file with the R.O.
f)

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.