a) Reinstall the bolt and reconnect the ground wire and torque to spec. (1GR-FE Only)
Torque Spec: 8.0 N∙m (82kgf∙cm, 71 in∙lbf)
b) Reinstall the power steering vane pump with the 2 bolts, then torque to spec.
Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf)
c) Reconnect the connector.
d) Reconnect the clamp. (1GR-FE Only)
46. REINSTALL THE FAN AND GENERATOR V-BELT
47. REINSTALL THE FUEL TANK STRAPS
a) Reinstall the fuel tank straps with the 2 pins and 2 clips.

48. REINSTALL THE FUEL TANK

NEW Replacement Parts
Part #
90080-11376

Part Name
Bolt, W/ Washer

Kit #
2

Qty
2

a) Reinstall the fuel tank with the 2 NEW bolts and torque to
spec.
Torque Spec: 62 N∙m (632 kgf∙cm, 46 ft∙lbf)
b) Reinstall the 2 fuel tubes.
c) Reconnect the connector.

49. REINSTALL THE NO.2 FUEL TANK PROTECTOR (IF EQUIPPED)
50. REINSTALL THE NO.1 FUEL TANK PROTECTOR ASSY
(IF EQUIPPED)

NEW Replacement Parts
Part #
90179-08241

Part Name
Nut
*Individual Part(s)

Kit #
NA*

Qty
4

a) Reinstall the No.1 fuel tank protector assy with the 4
NEW nuts and torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)

66

51. REINSTALL THE CHARCOAL CANISTER ASSY
a) Reinstall the charcoal canister assy with the bolt and 3
nuts, then torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
b) Reconnect the fuel tank vent hose.
c) Reconnect the fuel hose.
d) Reconnect the main tube support and reconnect the filter
hose.
e) Reconnect the connector.
f) Reinstall the bolt and reconnect the skid control sensor
wire and torque to spec.
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
52. REINSTALL THE EXHAUST SYSTEM (1GR-FE ONLY)

NEW Replacement Parts
Part #
90080-17187
90080-43036
90126-A0011

Part Name
Nut, Lock
Gasket, Exhaust Pipe
Stud, Hex lobular

Kit #
6
6
6

Qty
4
2
4

a) Install the 2 NEW exhaust pipe gaskets.
b) Reinstall the front exhaust pipe assy and 2 exhaust pipe
supports.
c) Install the 4 NEW nuts and torque to spec.
d) Reconnect the 2 oxygen sensor connectors.
Torque Spec: 54.3 N∙m (554 kgf∙cm, 40 ft∙lbf)
NOTE: If the stud bolt is damaged, replace the NEW
parts.

Part #
17451-0A010
90080-10291

NEW Replacement Parts
Part Name
Gasket, Exhaust Pipe
Bolt

Kit #
2
6

Qty
1
2

e) Install the NEW exhaust pipe gasket.
f) Reinstall the center exhaust tail pipe and 4 exhaust pipe
supports.
g) Install the 2 NEW bolts and 2 springs, then torque to
spec.
Torque Spec: 43 N∙m (438 kgf∙cm, 32 ft∙lbf)

67

53. REINSTALL THE EXHAUST SYSTEM (2TR-FE ONLY)

NEW Replacement Parts
Part #
17451-0A010
90080-10064
90080-10291
90080-43033
90177-A0004

Part Name
Gasket, Exhaust Pipe
Bolt. Flange
Bolt. Flange
Gasket, Exhaust Pipe
Nut, Lock

Kit #
2
7
7
7
7

Qty
1
2
2
1
2

a) Install the NEW exhaust pipe gasket.
b) Reinstall the front exhaust pipe assy and exhaust pipe
support.
c) Install the 2 NEW bolts and 2 springs, then torque to
spec.
Torque Spec: 43 N∙m (438 kgf∙cm, 32 ft∙lbf)
d) Reconnect the 2 oxygen sensor connectors and 2 wire
harness clamps.
e) Install the NEW exhaust pipe gasket.
f) Reinstall the center exhaust tail pipe and 4 exhaust pipe
supports.
g) Install the 2 NEW bolts and torque to spec.
Torque Spec: 48 N∙m (489 kgf∙cm, 35 ft∙lbf)

54. REINSTALL THE EXHAUST PIPE STOPPER BRACKET
(IF EQUIPPED)

NEW Replacement Parts
Part #
90080-11180

Part Name
Bolt, w/ Washer

Kit #
6

Qty
2

a) Reinstall the exhaust pipe stopper bracket with the 2
bolts and torque to spec.
Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf)
55. REINSTALL THE REAR PROPELLER SHAFT ASSY
a) Remove the SST. (2WD Only)
b) Referencing the matchmarks, reinstall the propeller shaft
assy to the the transmission / transfer case.
c) Reinstall the 4 washers and 4 nuts, then torque to spec.
(4WD Only)
Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf)
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: 36.2 N∙m (369 kgf∙cm, 27 ft∙lbf)
e) Referencing the matchmarks, reinstall the propeller shaft
assy to the rear differential with 4 bolts, 4 washers and 4
nuts, then torque to spec.
Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf)

68

56. 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 4 bolts, 8 washers and 8 nuts, then torque to spec.
Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf)
57. REINSTALL THE FOLLOWING PARTS
•
•

Spare Tire
Wheels

58. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap from the frame.
b) Lower the frame to the ground.
I.

REINSTALL THE CAB BODY ASSY
Before lowering the cab assembly ensure that you install the NEW brakelines onto the
bulk head.

Part #
47313-04190
47313-04200
47315-04160
47315-04170
47323-04160
47323-04170
47324-04120
47324-04130

NEW Replacement Parts
Part Name
Tube, FR Brake No. 3**
Tube, FR Brake No. 5**

Kit #
10
11
10
11
NA*
11
NA*
11

Qty
1
1
1
1
1
1
1
1

Tube, RR Brake No. 3
Tube, RR Brake No. 3
Tube, RR Brake No. 4
Tube, RR Brake No. 4
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.

1. INSTALL THE NEW ENGINE COMPARTMENT BRAKE
TUBES
a) Install the NEW No.3 and NEW No.5 front brake tubes.
b) Install the NEW No.3 and NEW No.4 rear brake tubes.
c) Torque all brake tubes to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)

69

2. REINSTALL THE CAB BODY ASSEMBLY
a) Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab.
b) Push the frame under the cab assy and line the tires up with the alignment marks.
c) Lower the cab assy slowly, making sure it does not interfere with anything.
d) Adjust the vehicle’s frame as needed to align the cab mounts with the cab assy bolts.
e) Once the cab assy is set on the mounts, secure it to the frame with 6 bolts, 6 nuts, 6 washers and torque to spec.
Torque Spec:
No.1 - 37.5 N∙m (382 kgf∙cm, 28 ft∙lbf)
No.2, No.3 - 45 N∙m (459 kgf∙cm, 33 ft∙lbf)
NOTE:
• DO NOT work directly underneath the vehicle when pushing the frame under the cab assy.
• Slowly lower the cab assy making sure the wire harness, steering shaft & hoses don’t interfere.
• With 2 to 3 people checking for interference, slowly lower the cab body assembly to the frame.

3. RECONNECT THE PARKING BRAKE CABLE

Part #
90412-10248
90119-A0169

NEW Replacement Parts
Part Name
Kit #
Qty
Way, 2
2
1
Bolt, w/ Washer
13 or NA* 1
*Individual Part(s)

4. RECONNECT THE REAR BRAKE TUBES
a) Temporarily install the 4 rear brake tubes and NEW 2 way.
b) Install the NEW bolt to the 2 way and torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
c) Reconnect the 4 rear brake tubes and torque to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)

70

5. RECONNECT THE FUEL TANK TUBES
a) Reconnect the 2 fuel tank tubes.
b) Reinstall the fuel pipe clamp.
NOTE:
• Align the connector with the pipe, and push into
the connector until the connector makes a "click"
sound. If the connection is tight, apply a little
amount of fresh engine oil on the tip of the pipe.
• Ensure the pipe and the connector are securely
connected by pulling them.
6. RECONNECT THE NO.2 FUEL HOSE
a) Reconnect the No.2 fuel hose with the clip

Cable Type

7. RECONNECT THE SHIFT CABLE (AUTO TRANS ONLY)
Cable Type:
a) Reconnect the shift cable with the nut and torque to
spec.
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
b) Reinstall the clip.

NEW Replacement Parts (Rod Type)
Part #
Part Name
Kit #
90240-08054
Pin, W/ Hole
NA*
90468-14033
Clip
NA*
*Individual Part(s)

Qty
1
1

Rod Type:
c) Reconnect the shift cable with the NEW pin and NEW
clip.
8. CONNECT THE CLUTCH RELEASE CYLINDER ASSY
(2TR-FE MANUAL TRANS ONLY)
a) Reconnect the clutch release cylinder with the 2 bolts
and torque to spec.
Torque Spec: 11.8 N∙m (120 kgf∙cm, 9 ft∙lbf)
b) Reconnect the clutch hose with the bolt and torque to
spec.
Torque Spec: 37 N∙m (377 kgf∙cm, 27 ft∙lbf)
9. RECONNECT THE NO.1 CLUTCH HOSE
(1GR-FE MANUAL TRANS ONLY)
a) Reconnect the clutch hose with the clip.
b) Reconnect the clutch release cylinder tube to the clutch
hose.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)

71

NEW Replacement Parts
Part #
90080-11555

Part Name
Bolt, w/ Washer

Kit #
2

Qty
2

10. RECONNECT THE STEERING SLIDING YOKE
a) Make sure the front wheels are in a straight-ahead
position and the steering wheel is centered.
b) Referencing the match marks, connect the steering
sliding yoke 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)
e) Disconnect the seat belt that is holding the steering
wheel.

LH Side

11. RECONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS
a) Reconnect the harness clamp and front skid control
sensor connector.
b) Repeat the procedure on the opposite side.

RH Side

LH Side

12. RECONNECT THE FRONT BRAKE TUBES
a) Reconnect the front brake tube and torque to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
b) Repeat the procedure on the opposite side.

RH Side

72

13. RECONNECT THE AIR CONDITIONING DISCHARGE
AND SUCTION HOSES TO THE COMPRESSOR

NEW Replacement Parts
Part #
90210-A0002
90210-A0004

Part Name
Washer, Seal

Kit #
2
2

Qty
1
1

a) Install a NEW o-ring to the A/C discharge and suction
hoses.
b) Reconnect the A/C discharge and suction hoses to the
compressor, then torque to spec.
Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf)
c) Reconnect the cooler bracket with the bolt and torque
to spec.
Torque Spec: 7.5 N∙m (76 kgf∙cm, 66 in∙lbf)

LH Side

14. REINSTALL THE FRONT FENDER APRON SEAL
4WD, Pre-Runner Only (Shown):
a) Reinstall the 4 front fender apron seals with the 20
clips.
2WD Only:
b) Reinstall the 4 front fender apron seals with the 22
clips.

RH Side

15. RECONNECT THE WATER / HEATER HOSES, ENGINE SIDE
16. RECONNECT THE ENGINE WIRE HARNES
a) Reinstall the engine wire harness container to the cowl
panel.
b) Reconnect the clamp.

17. RECONNECT THE NO.1 HOSE (2TR-FE ONLY)
a) Reconnect the No.1 hose.
18. RECONNECT THE GROUND WIRE (2TR-FE ONLY)
a) Reconnect the ground wire with the bolt.
Torque Spec: 8.3 N∙m (85 kgf∙cm, 73 in∙lbf)

73

19. RECONNECT THE POWER STEERING PUMP
RESERVOIR ASSY (1GR-FE ONLY)
a) Reconnect the power steering pump reservoir assy.
20. RECONNECT THE GROUND WIRE (1GR-FE ONLY)
a) Reconnect the ground wire with the bolt.
b) Reconnect the clamp.
Torque Spec: 8.3 N∙m (85 kgf∙cm, 73 in∙lbf)
21. REINSTALL THE FAN SHROUD
22. REINSTALL THE RADIATOR
a) Install the NEW o-ring to the drain plug.
b) Tighten the radiator drain plug.
c) Reinstall the radiator with 4 bolts and torque to spec.

NEW Replacement Parts
Part #
90069-08019

Part Name
Ring, O

Kit #
2

Qty
1

Torque Spec: 18 N∙m (184 kgf∙cm, 13 ft∙lbf)
d) Reinstall the automatic transmission cooler lines (Auto
Trans Only).
e) Reinstall the fan shroud with the 2 bolts.
Torque Spec: 5.0 N∙m (51 kgf∙cm, 44 in∙lbf)
23. REINSTALL THE SUPPORT TO FRAME SEAL
24. RECONNECT THE VACUUM HOSE
a) Reconnect the vacuum hose.

25. RECONNECT THE FUEL PIPES
a) Reconnect the No.1 and No.2 fuel pipe.
b) Reinstall the 2 fuel pipe clamps.
26. RECONNECT THE FUEL VAPOR FEED HOSE

27. RECONNECT THE FRONT DIFFERENTIAL BREATHER
TUBES (4WD ONLY)
a) Reconnect the front differential breather tubes.
NOTE: There may be 2 different breather tubes
depending on the vehicle spec.

74

28. RECONNECT THE NO.2 ENGINE WIRE HARNESS
a) Reinstall fuse box wire harness with the nut and torque
to spec.
Torque Spec: 12.7 N∙m (130 kgf∙cm, 9 ft∙lbf)
b) Reconnect the 3 connectors.
c) Reinstall the No.1 upper relay block cover.
d) Reconnect the No.2 engine wire harness to the clip.
e) Reinstall the (+) positive battery cable with the nut and
torque to spec.
Torque Spec: 12.7 N∙m (130 kgf∙cm, 9 ft∙lbf)
f)

Reinstall the ground wire with the bolt and torque to
spec.

Torque Spec: 8.3 N∙m (85 kgf∙cm, 73 in∙lbf)
29. REINSTALL THE FOLLOWING PARTS

•

•
•

Air Cleaner Hose and Air Cleaner Assy (1GR-FE Only)
° Torque Spec:
Air Cleaner Assy - 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
Air Cleaner Hose - 12 N∙m (122 kgf∙cm, 9 ft∙lbf)
Air Cleaner Hose and Air Cleaner Assy (2TR-FE Only)
° Torque Spec: 12 N∙m (122 kgf∙cm, 9 ft∙lbf)
V-Bank Cover (1GR-FE Only)
° Torque Spec: 7.5 N∙m (76 kgf∙cm, 66 in∙lbf)

30. REINSTALL THE FOLLOWING PARTS
• Rear Floor Side Service Hole Cover LH/RH (Access Cab) • No.1 w/ Box Speaker Assy (If Equipped)
• Seat Floor Box (Access Cab)
• Luggage compartment Side Tray (Double Cab)