SUPPLEMENTAL TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN F0U
ANCILLARY PART REPLACEMENT
- OUTER DASH PANEL INSULATOR
- ENGINE ROOM MAIN WIRE HARNESS
- ENGINE WIRE HARNESS
CERTAIN 2010- 2014 MODEL YEAR TACOMA 2TR-FE VEHICLES

The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians
performing this procedure 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 are required to currently hold at least one of the following certification
levels to perform this operation:

•
•
•
•

*Toyota Certified
*Toyota Expert
Master
Master Diagnostic Technicians

• *Note: Certified technicians can perform the inspection and catalytic converter replacement, however if
the inspection determines that the vehicle requires additional electrical repairs it must be performed by
a technician that is Toyota Expert or above.
It is the dealership’s responsibility to select technicians with the above certification level or greater to perform
this 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 FLOW CHART

II. IDENTIFICATION OF AFFECTED VEHICLES
A. COVERED VIN RANGE
•

•

Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall, and that the
campaign has not already been completed prior to dealer shipment or by another dealer.
TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were
completed by another dealer.

III. PREPARATION
A. PARTS
ANCILLARY PARTS ARE ONLY REPLACED AS NEED BASED ON THE VEHICLE INSPECTION. PRIOR TO
REPLACING ANY ANCILLARY COMPONENTS, IT IS REQUIRED THAT A TAS CASE IS CREATED AND THAT
FTS APPROVAL IS PROVIDED BEFORE PROCEEDING.
B. TOOLS & EQUIPMENT

・ Techstream
・ Standard Hand Tools
・ Vernier Calipers

・ Protective Glasses
・ Wooden Pieces
・ Inspection Mirror

・ Protective Gloves
・ Torque Wrench

SST- These are essential special service tools that the dealership should have.
Part Number
Description
09224-00010
O2 Sensor Wrench

Quantity
1

2

IV. BACKGROUND
In the subject vehicles the front catalytic converter internal components may become deteriorated and begin to
rattle. If continually operated in this condition, the deteriorated components could become dislodged and restrict the
exhaust flow. If this occurs, the vehicle may illuminate a check engine light, and, depending on the level of exhaust
restriction, the vehicle may experience a reduction in power.

V. TABLE OF CONTENT
•
•
•
•
•

Section VI-Brake Tube Clamp Replacement
Section VII- Outer Dash Panel Insulator Replacement
Section VII- Engine Room Main Wire Harness Replacement
Section IX- Engine Wire Harness Replacement
Section X- Final Vehicle Check (required for all repairs)

Note: The supplemental TI is only intended to cover components that do not have direct repair manual
instructions, if other components are in need of replacement that are not covered by this TI please refer
to the repair manual.

3

VI. BRAKE TUBE CLAMP REPLACEMENT
COMPONENTS TO BE REPLACED/REMOVED OVERVIEW

A. VEHICLE DISASSEMBLY
1.

TEMPORARILY RELOCATE THE AIR INJECTION DRIVER
a) Remove the 2 bolts securing the air injection driver to the inner
passenger fender.
b) Temporarily relocate the driver to give you additional room to
move the actuator assembly.

2. REMOVE BRAKE ACTUATOR NUTS
a)

Remove the 3 brake actuator bracket nuts that secure it to the
wheel well.
Note: By loosening the brake actuator it gives you more flex
in the brake lines so that the brake tube clamps can be
replaced.

Always gently move the brake tubes when
replacing the brake tube clamps.

4

3. REMOVE THE HEAT DAMAGED BRAKE TUBE CLAMPS
a) Carefully disengage the brake tube bracket from the brake tube.
b) Turn the brake tube clamps in the direction shown to remove
them from the studs.

Always gently move the brake tubes when
replacing the brake tube clamps.

B. VEHICLE REASSEMBLY
1. INSTALL THE NEW BRAKE TUBE CLAMPS
a) Set the 5 brake tubes into the 2 NEW clamps.
b) Install the 2 new clamps onto the studs.

2. REINSTALL THE BRAKE ACTUATOR
a) Reinstall the 3 nuts and torque to specification.
Torque Spec: 19 Nm (194 kgf·cm, 14ft·lbf)

3. REINSTALL THE AIR INJECTION DRIVER
a) Insert the bracket tabs into the fender guide holes and reinstall
the 2 nuts.
Torque Spec: 10 Nm (102 kgf·cm, 7 ft·lbf)

4. PROCEED TO SECTION X: FINAL VEHICLE CHECK

5

5.

VII. OUTER DASH PANEL INSULATOR REPLACEMENT

COMPONENTS TO BE REPLACED/REMOVED OVERVIEW

6

COMPONENTS TO BE REPLACED/REMOVED OVERVIEW CONTINUED…

7

• Always use caution when working in the engine bay because many sharp edges are exposed.
• The following procedure is intended to help guide you, always use the repair manual links to help
with the detailed procedure for certain component removal.
A. OUTER DASH PANEL INSULATOR REPLACEMENT
1. EVACUATE A/C REFRIGERANT
2. DRAIN ENGINE COOLANT
ENGINE COOLANT DRAIN RM LINK
3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
a) Disconnect the mass air flow meter connector.
b) Disconnect the wire harness clamp.
c) Loosen the hose clamp bolt, then disconnect the air cleaner
hose No. 1.
d) Disconnect the 2 air cleaner clamps.
e) Remove the air cleaner cap together with the air cleaner hose
No. 1.
4. REMOVE BRAKE TUBES FROM ACTUATOR
a) Remove the 2 bolts securing the air injection driver to the inner
passenger fender.
b) Temporarily relocate the driver to give you additional room to
access the actuator.

c) Label the brake tubes so they return to the correct location.

d) Using a union nut wrench, separate the brake tubes from the
actuator.

e) Separate the brake tubes from the brake tube brackets from the
4 locations.
f) Remove the brake tube brackets as shown.

8

g) Bind the brake tubes together with vinyl tape.

h) Disconnect the No. 5 front brake tube.
i) Remove the brake tube clamp bolt.

5. REMOVE WIRE HARNESS BRACKET
a) Disengage the 2 clamps.
b) Remove the bolt and wire harness bracket.

6. SEPARATE WATER HOSE
a) Remove the hose clamps and remove the coolant hoses.

b) Cover water hoses with plastic bags to ensure foreign objects
do not enter the system.

7. REMOVE BRAKE BOOSTER ASSEMBLY
BRAKE BOOSTER REMOVAL RM LINK

9

8. REMOVE STEERING INTERMEDIATE SHAFT
STEERING INTERMEDIATE SHAFT (2wd) RM LINK
STEERING INTERMEDIATE SHAFT (4wd) RM LINK
9. DISCONNECT THE A/C SUCTION HOSE
a) Remove the 2 bolts.

b) Insert 2 screwdrivers into the 2 piping clamp slots, and while
holding them down, disengage the piping clamp claws and the
piping clamp.
c) Disconnect the suction hose.

Never use a screwdriver to pry apart the
suction hose from the A/C Unit.
d) Remove the O-rings from the suction hoses as they will be
replaced.
e) Cover the hose and A/C unit line to prevent debris from entering
the system.

10. DISCONNECT A/C DISCHARGE HOSE
a) Remove the bolt.
b) Disengage the 2 clamps and separate the A/C discharge hose.
c) Insert 2 screwdrivers into the 2 piping clamp slots, and while
holding them down, disengage the piping clamp claws and the
piping clamp.
d) Disconnect the A/C discharge hose.

Never use a screwdriver to pry apart the air
conditioning tube from the A/C Unit.
e) Remove the O-ring from the air conditioning tube.
f) Cover the hose and A/C unit line to prevent debris from entering
the system.
11. TEMPORARILY RELOCATE THE A/C HOSES
a) Move the A/C hoses so that they do not interfere with removing
the insulator.

10

12. REMOVE THE OUTER DASH PANEL INSULATOR
a) Remove the 4 clips securing the insulator.
b) Move the brake tubes toward the front of the vehicle to obtain sufficient workspace.
c) Remove the insulator.

11

B. NEW OUTER DASH PANEL INSULATOR INSTALLATION
1. TAPE THE 5 STUDS WITH PROTECTIVE TAPE

2. INSTALL THE NEW OUTER DASH PANEL INSULATOR
a)
b)
c)
d)

Move the tubes toward the front of the vehicle to obtain sufficient workspace.
Carefully install the NEW insulator as shown.
Remove the protective tape form the studs and engine.
Fasten the insulator with the 4 clips.

12

3. REINSTALL THE A/C DISCHARGE HOSE
a) Apply compressor oil to the 2 NEW O-rings and install them.
b) Install the hose and clamp as shown.

c)

Install the bracket with the bolt and 2 clamps.
Torque Spec: 7.5 Nm (76 kgf·cm, 66in·lbf)

4. REINSTALL THE A/C SUCTION HOSE
a) Apply compressor oil to the 2 NEW O-rings and install them.
b) Install the hose and clamp as shown.

c) Install the bracket with the 2 bolts.
Torque Spec: 7.5 N·m (76 kgf·cm, 66in·lbf)

13. REINSTALL STEERING INTERMEDIATE SHAFT
STEERING INTERMEDIATE SHAFT (2wd) RM LINK
STEERING INTERMEDIATE SHAFT (4wd) RM LINK
14. REINSTALL BRAKE BOOSTER ASSEMBLY
BRAKE BOOSTER REINSTALLATION RM LINK

13

15. REINSTALL WATER HOSE
a) Remove the plastic bags from the water hoses.
b) Reinstall the hoses and secure with the hoses clamps.

16. REINSTALL BRAKE TUBES TO ACTUATOR
a) Remove the vinyl tape form the brake tubes.

b) Install the 4 brake tube clamps

c) Reinstall the front No. 5 brake line.
Torque Spec: 15 Nm (87 kgf-cm, 11ft-lbs)
d) Reinstall the brake bracket bolt.
Torque Spec: 8.5 Nm (56 kgf-cm, 75in-lbs)

14

e) Temporarily install the brake tubes in the correct locations.
f) Remove the labels form the brake tubes

g) Using a union nut wrench torque the brake tubes.
Torque for 10mm line nut:
without union nut wrench
with union nut wrench
15 Nm (155 kgf·cm, 11ft·lbf) 14 Nm (145 kgf·cm, 10ft·lbf)
Torque for 12mm line nut:
without union nut wrench
with union nut wrench
20 Nm (199 kgf·cm, 14ft·lbf) 18 Nm (187 kgf·cm, 13ft·lbf)

17. REINSTALL WIRE HARNESS BRACKET

18. REINSTALL AIR CLEANER CAP SUB-ASSEMBLY
f)

Reinstall the air cleaner cap together with the air cleaner hose
No. 1.
g) Connect the 2 air cleaner clamps.
h) Tighten the hose clamp bolt.
i) Connect the mass air flow meter connector.
j) Connect the 2 air cleaner clamps.
19. BLEED BRAKE LINES
BRAKE BLEEDING RM LINK
20. ADD ENGINE COOLANT
ENGINE COOLANT RM LINK
21. CHARGE A/C SYSTEM
A/C CHARGE RM LINK
22. PROCEED TO SECTION X: FINAL VEHICLE CHECK

15

VIII. ENGINE ROOM MAIN WIRE HARNESS REPLACEMENT

16

COMPONENTS TO BE REPLACED/REMOVED OVERVIEW

17

COMPONENTS TO BE REPLACED/REMOVED OVERVIEW CONTINUED…

18

•
•
•

Always use caution when working in the engine bay because many sharp edges are exposed.
The following procedure is intended to help guide you, main harness configuartions may vary
based on vehicle options.
Use the repair manual links to help with the detailed procedure for certain component removal.

A. ENGINE ROOM MAIN WIRE HARNESS REPLACEMENT
1. REMOVE BATTERY
a) Disconnect both the negative and positive battery cables.
b) Remove the nut and battery securing bracket.
c) Remove battery assembly.

2. REMOVE THE WINDSHIELD WIPER ARMS
a) Confirm that the wiper arms are at the auto stop location.
b) Remove the 2 windshield wiper arm caps with a screwdriver
wrapped in protective tape.

c) Remove the nuts and wiper arms.

3. REMOVE COWL TOP VENTILATOR LOUVER
a) Remove the RH and LH side front fender to cowl seal by
disengaging the 2 claws as shown.

19

Disengage the 15 claws, then remove the

b) Disengage the 2 clips on the cowl top ventilation louver.
c) Remove the cowl top ventilator louver.

4. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH
a) Disengage the 9 clips and remove.

5. REMOVE AIR CLEANER
a) Disconnect the mass air flow meter connector.
b) Disconnect the wire harness clamp.
c) Loosen the hose clamp bolt, then disconnect the air cleaner
hose No. 1.
d) Disconnect the 2 air cleaner clamps.
e) Remove the air cleaner cap together with the air cleaner hose
No. 1.
f) Remove filter element.
g) Remove the 3 bolts and air cleaner base.
6. SEPARATE WINDSHIELD WASHER JAR
c) Remove the 2 bolts and remove the windshield washer jar.

20

7. DISCONNECT ENGINE ROOM MAIN WIRE HARNESS
a) Disconnect the connectors and disengage the clamps as shown in the following illustrations.

•
•
•

Exact wire harness configuration can vary based upon vehicle options, use the following
pages as a guide when disconnecting the harness.
The vehicle engine bay is broken up into 4 quadrants for your reference.
Use the following pages as a check sheet to ensure you remove all connectors and clamps.

21

b) Disconnect the connectors and disengage the clamps as shown in the following illustrations.

•
•
•

Exact wire harness configuration can vary based on vehicle options, use the following pages
as a guide when disconnecting the harness.
The vehicle engine bay is broken up into 4 quadrants for your reference.
Use the following pages as a check sheet to ensure you remove all connectors and clamps.

22

c) Disconnect the connectors and disengage the clamps as shown in the following illustrations.
d) Remove the body ground bolt.

•
•
•

Exact wire harness configuration can vary based on vehicle options, use the following pages
as a guide when disconnecting the harness.
The vehicle engine bay is broken up into 4 quadrants for your reference.
Use the following pages as a check sheet to ensure you remove all connectors and clamps.

23

e) Remove the upper relay block cover No.1.
f) Disconnect the connectors and disengage the clamps as shown in the following illustrations.
g) Remove the 2 bolts and the 2 nuts.

•
•
•

Exact wire harness configuration can vary based on vehicle options, use the following pages
as a guide when disconnecting the harness.
The vehicle engine bay is broken up into 4 quadrants for your reference.