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∙lbf (35 N∙m, 356 kgf∙cm)
d) Disconnect the seat belt that is holding the steering
wheel.

13. RECONNECT THE FRONT DIFFERENTIAL VACUUM
HOSES (4WD ONLY)

NEW Replacement Parts
Part Number
90464-00897

Part Name
Clamp

Kit #
4

Qty
1

a) Reconnect the NEW clamp and vacuum hoses.

86

14. RECONNECT THE FRONT BRAKE TUBES

NEW Replacement Parts
Part Number
90412-10266
90412-10267
90119-A0222
47314-0C020
47315-0C030

Part Name
Kit #
Way,No.1 (For Front Brake Tube)
1
Way,No.2 (For Front Brake Tube)
1
Bolt
2
Tube, Front Brake, No.4
2
Tube, Front Brake, No.5
2

LH Side

Qty
1
1
2
1
1

a) Reconnect the front brake tube with the NEW bolt and
torque to spec.
Torque Spec: 23 ft∙lbf (31 N∙m, 316 kgf∙cm)
b) Temporarily install the NEW front brake tube.
c) Torque the front brake tube to spec.
Torque Spec: 11 ft∙lbf (15.2 N∙m, 155 kgf∙cm)
d) Repeat the procedure on the opposite side.

RH Side

87

15. REINSTALL THE FRONT FENDER APRON SEALS

NEW Replacement Parts
Part Number
90080-46327

Part Name

Kit #

Clip (For Front Fender Apron Seal)

2

LH Side

Qty
22

a) Reinstall the front fender apron seals rear LH / RH with
the 11 NEW clips.
b) Reinstall the front fender apron seal LH / RH with the
11 NEW clips.

RH Side

16. RECONNECT THE ABSORBER CONTROL ACTUATOR
CONNECTOR (W/ AIR SUSPENSION)
a) Reconnect the connector and clamp.
b) Repeat the procedure on the opposite side.

17. 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∙lbf (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∙lbf (3.5 N∙m, 36 kgf∙cm)

88

18. REINSTALL THE FOLLOWING PARTS
•

NEW Replacement Parts
Part Number
16492-21050

Part Name

Kit #

Packing (For Radiator Drain Cock)

2

Qty
1

•

•
•

19. 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∙lbf (18 N∙m, 184 kgf∙cm)
° Reconnect the 2 radiator seals with 2 clips.
Fan Shroud
° Reinstall the fan shroud with the 2 bolts and torque
to spec.
° Torque Spec: 58 in∙lbf (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∙lbf (9.8 N∙m, 100 kgf∙cm)

89

20. REINSTALL THE FOLLOWING PARTS

•
•

Radiator Side Deflector RH (If Equipped)
Radiator Side Deflector LH
21. REINSTALL THE OIL COOLER ASSY
(AIR OIL COOLER EQUIPPED VEHICLES ONLY)
a) Reinstall the oil cooler with the 3 bolts and torque to
spec.
Torque Spec: 10 ft∙lbf (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.

22. REINSTALL THE FRONT BUMPER RETAINER UPPER
CENTER
(AIR OIL COOLER EQUIPPED VEHICLES ONLY)

NEW Replacement Parts
Part Number
90179-06178

Part Name
Nut

Kit #
1

Qty
6

a) Reinstall the front upper center bumper retainer with
the 6 NEW nuts and torque to spec.
Torque Spec: 48 in∙lbf (5.4 N∙m, 55 kgf∙cm)

90

2UZ-FE

23. RECONNECT THE AIR PUMP HARNESS
a) Reconnect the connector and 2 clamps. (2UZ-FE)
b) Reconnect the 2 connectors and 3 clamps. (3UR-FE)

3UR-FE

2UZ-FE

24. RECONNECT THE AIR INJECTION SYSTEM HOSES
a) Reconnect the No.2 hose. (2UZ-FE)
b) Reconnect the No.2 hose and No.3 hose. (3UR-FE)

3UR-FE

91

25. RECONNECT THE INLET HEATER HOSE AND OUTLET HEATER HOSE, ENGINE SIDE
26. RECONNECT THE ENGINE WIRE HARNESS (RH SIDE)
a) Reconnect the ground wire with the bolt and torque to
spec.
Torque Spec: 73 in∙lbf (8.3 N∙m, 85 kgf∙cm)
b) Reconnect the skid control sensor connector and
clamp.

c) Reconnect the 6 connectors and 2 clamps.

27. 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.
28. RECONNECT THE COOLER REFRIGERANT SUCTION
HOSE ASSY
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∙lbf (9.8 N∙m, 100 kgf∙cm)

92

29. RECONNECT THE ENGINE WIRE HARNESS (LH SIDE)
a) Reconnect the ground wire with the bolt and torque to
spec.
Torque Spec: 73 in∙lbf (8.3 N∙m, 85 kgf∙cm)
b) Reconnect the 2 clamps and 7 connectors.

c) Reconnect the (+) positive battery cable with the nut
and torque to spec.
Torque Spec: 7 ft∙lbf (10 N∙m, 102 kgf∙cm)
d) Reconnect the clamp and 2 connectors.
e) Reinstall the relay block cover.

f)

Reconnect the clamp.

g) Reconnect the ground wire with the bolt and torque to
spec.
Torque Spec: 73 in∙lbf (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∙lbf (12.7 N∙m, 130 kgf∙cm)

93

30. REINSTALL THE FOLLOWING PARTS

•
•
•
•
•

NEW Replacement Parts
Part Number
90178-A0044
90178-A0067

Part Name
Nut
Nut

Kit #
2
2

Qty
8
6

•

•

•
•
•

Air Cleaner Hose and Air Cleaner Assy
° Torque Spec: 44 in∙lbf (5.0 N∙m, 51 kgf∙cm)
Throttle Body Cover Sub- Assy (2UZ-FE Only)
° Torque Spec: 66 in∙lbf (7.5 N∙m, 76gf∙cm)
V-Bank Cover Sub- Assy (3UR-FE Only)
Front Fender Mudguard LH/RH (If Equipped)
No.2 Front Bumper Extension Sub- Assy LH/RH
° Reinstall with 8 NEW nuts.
° Torque Spec: 43 ft∙lbf (58 N∙m, 591 kgf∙cm)
Front Bumper Reinforcement Sub-Assy
° Reinstall with 6 NEW nuts.
° Torque Spec: 52 ft∙lbf (71 N∙m, 724 kgf∙cm)
Front Bumper Cover Assy
° Reinstall with the 2 screws and 8 clips.
° Disconnect the ultrasonic sensor connectors and
fog light connectors (If Equipped).
Front Fender Splash Shield Sub-Assy LH/RH
Front End Panel LH/RH
Wheels

31. RECONNECT THE QUARTER TRIM PANEL ASSY
a) Reconnect the 2 clips and the quarter trim panel assy.
b) Reinstall the package holder net hook.
c) Repeat the procedure on the opposite side.

32. REINSTALL THE FOLLOWING PARTS
•
•
•
•
•
•
•

Rear Floor Mat Support Plate
Luggage Compartment Trim Box
Rear Door Scuff Plate LH/RH
No.3 Dash Panel Insulator Pad
No.2 Dash Panel Insulator Pad
Cowl Side Trim Board LH/RH
Front Door Scuff Plate LH/RH

94

H. 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
3

Qty
1
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∙lbf (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∙lbf (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·lbf (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·lbf (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

95

7. TORQUE THE FRONT AXLE NUT (4WD ONLY)
NEW Replacement Parts
Part Number
43514-34020
43514-34020
95381-04050

Part Name
Kit #
Cap, Front Axle Hub Grease, RH
3
Cap, Front Axle Hub Grease, LH
3
Cotter Pin
3

a) Remove the front wheels.
b) Torque the front axle nut to spec.

Qty
1
1
2

Torque Spec: 249 ft∙lbf (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∙lbf (131 N∙m, 1336 kgf∙cm)
Steel Wheel - 154 ft∙lbf (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

Part Name
Bolt

Kit #
2

Qty
5

a) Reinstall the engine under cover No.1 with 5 NEW
bolts and 3 screws, then torque to spec.
Torque Spec: 21 ft∙lbf (29 N∙m, 296 kgf∙cm)

11. REINSTALL THE SIDE STEP ASSY LH/RH (IF EQUIPPED)
12. CHECK FOR DTC’S AND REPAIR AS NEEDED
13. PERFORM INITIALIZATION
14. 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
Power Back Door System
All Gauges, Indicators and Warning Lights
Cooling Fans
Vehicle Height
Etc.

96

15. 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.
16. 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 2008 Sequoia ZH9 from the pick list.

c) Enter the VIN of the vehicle.

97

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.
I.

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.

98