•

•

NEW Replacement Parts
Part Number
90252-04003
90119-A0192

Part Name
Cotter Pin
Bolt

Kit #
1
2

Qty
2
4

•

•

36. RECONNECT THE FRONT BRAKE HOSES

NEW Replacement Parts
Part Number
90119-A0222
90468-A0007

Part Name
Bolt
Clip

Lower Ball Joint
° Reinstall the lower ball joint with the 2 bolts and
torque to spec.
° Torque Spec: 221 ft∙lbf (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∙lbf (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 2 brackets and 4
NEW bolts, then torque to spec.
° Torque Spec: 51 ft∙lbf (69 N∙m, 704 kgf∙cm)
° Reconnect the stabilizer bar links with the 2bolts
and torque to spec.
° Torque Spec: 89 ft∙lbf (120 N∙m, 1224 kgf∙cm)

Kit #
2
2

Qty
2
2

a) Reinstall a bracket with a NEW bolt and torque to
spec.
Torque Spec: 21 ft∙lbf (29 N∙m, 296 kgf∙cm)
b) Reinstall the front brake hose with the NEW clip.
c) Repeat the procedure on the opposite side.

74

37. RECONNECT THE SKID CONTROL SENSOR WIRES

NEW Replacement Parts
Part Number
90119-A0050

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)
b) Reinstall the skid control sensor wire with the NEW
bolt and torque to spec. (RH Side)
Torque Spec: 9 ft∙lbf (12.5 N∙m, 127 kgf∙cm)

38. RECONNECT THE ABSORBER CONTROL
ACTUATORS (W/ AIR SUSPENSION)

NEW Replacement Parts
Part Number
89269-34010
89269-34020
94130-01202

Part Name
Bracket, Suspension Control RH
Bracket, Suspension Control LH
Nut

Kit #
6
6
1

Qty
1
1
2

a) Install the NEW suspension control bracket with a
NEW nut and torque to spec.
Torque Spec: 11 ft∙lbf (15 N∙m, 153 kgf∙cm)

75

b) Using a hexagon wrench, reinstall the absorber control
actuator with the 2 NEW bolts and torque to spec.

NEW Replacement Parts
Part Number
90110-05004

Part Name
Bolt

Kit #
6

Qty
4

Torque Spec: 69 in∙lbf (7.8 N∙m, 80 kgf∙cm)
c) Reconnect the clamp.
d) Repeat the procedure on the opposite side.

39. REINSTALL THE FUEL TUBES
NEW Replacement Parts
Part Number
77289-26010
77285-34370
77296-0C010

Part Name
Clamp, Fuel Tube, No.1
Clamp, Fuel Tube, No.2
Support, Fuel Tube Protector, No.1

a) Reinstall the fuel tubes with the NEW clamps.
Kit #
1
1
2

Qty
1
4
1

40. 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.

76

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

Torque Spec: 58 ft∙lbf (79 N∙m, 806 kgf∙cm)

LH Side

RH Side

NEW Replacement Parts
Part Number
90119-A0210

Part Name
Bolt

Kit #
2

Qty
4

c) Attach the transmission mount with 4 NEW bolts and
torque to spec.
Torque Spec: 12 ft∙lbf (16 N∙m, 163 kgf∙cm)
d) Remove the bolt(s) and the engine hangers
(3UR-FE Only).
e) Reinstall the items/parts that were removed during the
engine and transmission assy removal.

41. 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
(3UR-FE Only), then toque to spec.
Torque Spec: 21 ft∙lbf (28 N∙m, 286 kgf∙cm)
b) Reconnect the clamp. (3UR-FE Only)
c) Reconnect the connectors.
d) Reinstall the drive belt.

77

4WD Only

LH Side

42. RECONNECT THE DIFFERENTIAL WIRE (4WD ONLY)
43. RECONNECT THE ENGINE WIRE

44. RECONNECT THE FUEL PIPES
a) Reconnect the 2 fuel pipes.
b) Reinstall the No.1 fuel pipe clamp.
45. RECONNECT THE FUEL VAPOR FEED HOSE ASSY

46. 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∙lbf (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∙lbf (12.5 N∙m, 127 kgf∙cm)

78

47. REINSTALL THE FUEL TANK STRAPS
a) Reinstall the fuel tank straps with the 2 pins and 2
clips.

48. REINSTALL THE FUEL TANK ASSY

NEW Replacement Parts
Part Number
90119-A0077

Part Name
Bolt

Kit #
2

Qty
2

a) Reinstall the fuel tank assy with the 2 NEW bolts and
torque to spec.
Torque Spec: 30 ft∙lbf (40 N∙m, 408 kgf∙cm)
b) Reconnect the 2 fuel tubes.
c) Reconnect the connector and clamp.

49. REINSTALL THE FRONT PROPELLER SHAFT ASSY (4WD ONLY)
a) Referencing the matchmarks, install the front propeller shaft assy to the transfer case and the front
differential with 8 washers and 8 nuts, then torque to spec.
Torque Spec: 59 ft∙lbf (80.3 N∙m, 819 kgf∙cm)
50. 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∙lbf (15.7 N∙m, 160 kgf∙cm)

79

51. REINSTALL THE EXHAUST SYSTEM

NEW Replacement Parts
Part Number
90917-A6002
90080-17187

Part Name
Gasket, Exhaust Pipe
Nut

Kit #
2
2

Qty
2
6

90126-A0011

Bolt, Stud (For Exhaust Manifold,
RH) 3UR# USK6#

NA*

3

NA*

3

NA*

6

90126-A0011
90126-A0011

Bolt, Stud (For Exhaust Manifold, LH)

3UR# USK6#
Bolt, Stud (For Manifold To
Exhaust Pipe) 2UZ-FE UCK6#
*Individual Part(s)

a) Install the 2 NEW exhaust pipe gaskets.
b) Reinstall the exhaust pipe and 4exhaust pipe supports.
c) Install the 6 NEW nuts and torque to spec.
Torque Spec: 40 ft∙lbf (54.3 N∙m, 554 kgf∙cm)

52. RECONNECT THE OXYGEN SENSOR CONNECTORS
a) Reconnect the 4 oxygen sensor connectors.

80

53. REINSTALL THE EXHAUST TAIL PIPE ASSY

NEW Replacement Parts
Part Number
90917-06085
90917-06093

Part Name
Gasket, Exhaust Pipe, Center**

Kit #
NA*
NA*

Qty
1
1

Clamp No.1, Exhaust TAIL Pipe
NA*
1
(For Rear)**
90461-15017
Clamp**
NA*
1
90119-A0380
Bolt
2
1
*Individual Part(s)
** Only 1 part used. The part number depending on the list.
90080-46263

a) Install the NEW exhaust pipe gasket.
b) Reinstall the exhaust tail pipe and exhaust pipe
supports.
c) Install the NEW bolt and NEW clamp, then torque to
spec.
Torque Spec: 24 ft∙lbf (32 N∙m, 326 kgf∙cm)

54. REINSTALL THE REAR STABILIZER
a) Reinstall the stabilizer bar with the 2 brackets and 4
NEW bolts, then torque to spec.
NEW Replacement Parts
Part Number
90119-08782

Part Name
Bolt

Kit #
1

Qty
4

Torque Spec: 20 ft∙lbf (27 N∙m, 275 kgf∙cm)
b) Reconnect the 2 stabilizer links with the 2 nuts, then
torque to spec.
Torque Spec: 72 ft∙lbf (98 N∙m, 999 kgf∙cm)

55. 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∙lbf (70 N∙m, 714 kgf∙cm)
d) Referencing the matchmarks, reinstall the propeller shaft assy to the rear differential with 4 nuts and
torque to spec.
Torque Spec: 52 ft∙lbf (70 N∙m, 714 kgf∙cm)
56. REINSTALL THE WHEELS
57. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap from the frame.
b) Lower the frame to the ground.
G. REINSTALL THE CAB BODY ASSY

81

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 8 bolts, 8 nuts, 6 washers and 2 No.1
lower cab mounting cushion sub-assy, then torque to spec.

Torque Spec: 40 ft∙lbf (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.
2. REMOVE THE WHEELS

82

3. RECONNECT THE FUEL TANK PIPES AND TANK VENT
HOSE
a) Reconnect the 2 fuel tank pipes and fuel tank vent
hose.

4. RECONNECT THE FRAME WIRE AND No.3 FRAME
WIRE
a) Reconnect each connector and clamp.
NOTE:
The number of connectors and clamps will differ
depending on the vehicle spec.

b) Reinstall the connector cover and reconnect the 2
craws.

5. RECONNECT THE FUEL PUMP ECU CONNECTORS
a) Reconnect the 2 connectors.

83

6. 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∙lbf (31 N∙m, 316 kgf∙cm)
b) Reconnect the 2 rear brake tubes and torque to spec.
Torque Spec: 11 ft∙lbf (15.2 N∙m, 155 kgf∙cm)

7. RECONNECT THE HEIGHT CONTROL HOSE
(W/ AIR SUSPENSION)

8. RECONNECT THE TRANSMISSION CONTROL CABLE

NEW Replacement Parts
Part Number
90080-17229

Part Name
Nut

Kit #
2

Qty
1

a) Reconnect the shift cable with the 2 bolts and NEW
nut, then torque to spec.
Torque Spec:
Bolt - 9 ft∙lbf (12 N∙m, 122 kgf∙cm)
Nut - 10 ft∙lbf (14 N∙m, 143 kgf∙cm)

84

b) Reconnect the ground wire with the bolt and torque to
spec.
Torque Spec: 73 in∙lbf (8.3 N∙m, 85 kgf∙cm)
c) Reconnect the 3 clamps.

9. RECONNECT THE FUEL HOSE
a) Reconnect the fuel hose.

10. 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: 9 ft∙lbf (12.5 N∙m, 127 kgf∙cm)
c) Reinstall the No.1 wire adjusting nut and nut, then
torque to spec.
Torque Spec: 9 ft∙lbf (12.5 N∙m, 127 kgf∙cm)
11. RECONNECT THE FOLLOWING PARTS
• Receiver Hitch Cap (If Equipped)
• Spare Wheel
• Rear Bumper Energy Absorber
• Rear Bumper Arm Brackets
° Reinstall the 2 rear bumper arm brackets with 4 bolts and torque to spec.
° Torque Spec: 71 in∙lbf (8.0 N∙m, 82 kgf∙cm)
• Rear bumper Cover Assy
° Reinstall the front bumper with 6 bolts for upper side and torque to spec.
° Torque Spec: 71 in∙lbf (8.0 N∙m, 82 kgf∙cm)
° Reinstall the 2 bolts for lower side and torque to spec.
° Torque Spec: 80 in∙lbf (9.0 N∙m, 92 kgf∙cm)
° Reinstall the 4 bolts for rear floor stay brackets and torque to spec.
° Torque Spec: 71 in∙lbf (8.0 N∙m, 82 kgf∙cm)
° Reinstall the 2 screws.
° Disconnect the ultrasonic connectors (If Equipped).
• Rear Quarter Panel Mudguard LH/RH

85

12. RECONNECT THE No. 2 STEERING INTERMEDIATE