NHTSA ID Number: 10166366
Manufacturer Communication Number: ZKA-TI-090519
TSB/Document Date: 2019-10-21
Summary
Technical Instructions: TECHNICAL INSTRUCTIONS FOR CUSTOMER SUPPORT PROGRAM ZKA CERTAIN 2011 THROUGH 2015 MODEL YEAR TACOMA COVERAGE FOR VEHICLE FRAME CORROSION PERFORATION
Install the NEW bracket with the NEW bolt and torque to
spec.
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft.∙lbf)
27. REINSTALL THE POWER STEERING LINK ASSY W/
POWER STEERING VANE PUMP
Reinstall the power steering link assy w/ power steering
vane pump with the bolts and nuts, then torque to spec.
Torque Spec: 2TR-FE 4WD
Bolt A - 95 N∙m (969 kgf∙cm, 70 ft∙lbf)
Bolt B - 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
Torque Spec: Except 2TR-FE 4WD
Bolt A - 92 N∙m (938 kgf∙cm, 68 ft∙lbf)
Bolt B - 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
NOTE:
• When reinstalling the power steering link with the
pump, have one person support the power steering
link and the other support the pump.
• Keep the power steering pump reservoir upright to
prevent the fluid from leaking out.
28. RECONNECT THE FRONT DIFFERENTIAL BREATHER
TUBE (4WD ONLY)
Reconnect the front differential breather tube with the bolt
and 2 clamps, then torque to spec.
Torque Spec: 12.7 N∙m (130 kgf∙cm, 9 ft∙lbf)
59
Part #
90080-17215
NEW Replacement Parts
Part Name
Kit #
Nut
2
Qty
6
29. REINSTALL THE FRONT SHOCK ABSORBER ASSY
Install the 3 NEW nuts (A) and torque to spec.
Reinstall the front shock absorber assy with the bolt and
nut (B), then torque to spec.
Torque Spec:
Nut A - 64 N∙m (653 kgf∙cm, 47 ft∙lbf)
Nut B - 83 N∙m (846 kgf∙cm, 61 ft∙lbf)
Repeat the procedure on the opposite side.
Part #
90119-A0161
NEW Replacement Parts (2WD Only)
Part Name
Kit # Qty
Bolt
NA*
4
*Individual Part(s)
30. REINSTALL THE FRONT STABILIZER BAR
Reinstall the stabilizer bar with 2 brackets and 4 NEW
bolts, then torque to spec. (2WD Only)
Reinstall the stabilizer bar with 2 brackets and 4 bolts, then
torque to spec. (4WD, Pre-Runner Only).
Torque Spec:
2WD - 21 N∙m (214 kgf∙cm, 15 ft∙lbf)
4WD, Pre-Runner - 40 N∙m (408 kgf∙cm, 30 ft∙lbf)
31. REINSTALL THE FRONT SUSPENSION MEMBER BRACE
SUB-ASSY
2WD Only
Reinstall the suspension member brace sub-assy with 8
bolts (2WD Only) or 7 bolts (4WD, Pre-Runner Only), then torque
to spec.
Torque Spec: 45 N∙m (459 kgf∙cm, 33 ft∙lbf)
4WD, Pre-Runner Only
Part #
90311-47026
90311-47027
43425-04040
NEW Replacement Parts
Part Name
Kit #
3
Seal, Oil (For Differential Side
Gear Shaft)
3
Ring, Shaft Snap (For Front
NA*
Drive Inner Shaft Outer)
*Individual Part(s)
Qty
1
1
2
32. REINSTALL THE FRONT DRIVE SHAFT ASSY (4WD ONLY)
Remove the type T oil seal.
Install the NEW type T oil seal.
Install a NEW snap ring.
Reinstall the front drive shaft assy.
Repeat the procedure on the opposite side.
NOTE:
Be careful not to damage the dust cover and oil seal.
60
33. REINSTALL THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (2WD ONLY)
Reinstall the front suspension upper arm w/ steering
knuckle with the 2 bolts, 2 nuts and 2 washers, then torque
to spec.
Torque Spec: Bolt - 82 N∙m (836 kgf∙cm, 60 ft∙lbf)
Repeat the procedure on the opposite side.
34. REINSTALL THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (4WD, PRE-RUNNER ONLY)
Reinstall the front suspension upper arm w/ steering
knuckle with the bolt, nut and 2 washers, then torque to
spec.
Torque Spec: Nut - 115 N∙m (1173 kgf∙cm, 85 ft∙lbf)
Repeat the procedure on the opposite side.
NEW Replacement Parts
Part #
90171-A0005
95381-03230
Lower Ball Joint Attachment
Part Name
Kit #
Nut, Castle (For Front Lower
2
Ball Joint LH/RH)
4
Cotter Pin
or
5
Qty
2
2
Tie Rod End
Part #
Part Name
Kit # Qty
95381-03025
4
2
Cotter Pin**
95381-03225
5
2
** Only 1 part used, part number varies by vehicle type.
35. REINSTALL THE FOLLOWING PARTS
• Lower Ball Joint Attachment
Reinstall the lower ball joint attachment with the
NEW nut and 2 bolts, then torque to spec.
Install the NEW cotter pin.
Repeat the procedure on the opposite side.
Torque Spec:
Nut - 140 N∙m (1428 kgf∙cm, 103 ft.∙lbf)
Bolt - 160 N∙m (1632 kgf∙cm, 118 ft∙lbf)
• Front Stabilizer Link Assy (2WD Only)
Reinstall the front stabilizer link assy with 2
retainers, 2 cushions and nut, torque to spec.
Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf)
Reinstall the nut, then torque to spec.
Torque Spec: 69 N∙m (704 kgf∙cm, 51 ft∙lbf)
Repeat the procedure on the opposite side.
• Front Stabilizer Link Assy (4WD, Pre-Runner Only)
Reinstall the front stabilizer link assy with the 2
nuts, torque to spec.
Torque Spec: 70 N∙m (714 kgf∙cm, 52 ft∙lbf)
Repeat the procedure on the opposite side.
• Tie Rod End
Reinstall the tie rod end with the nut and torque to
spec.
Torque Spec:
2WD - 49 N∙m (500 kgf∙cm, 36 ft∙lbf)
4WD, Pre-Runner - 91 N∙m (928 kgf∙cm, 67 ft∙lbf)
Install the NEW cotter pin.
Repeat the procedure on the opposite side.
• Front Axle Shaft Nut (4WD Only)
Temporarily reinstall the front axle shaft nut.
Nut will be tightened when the vehicle is completed.
Repeat the procedure on the opposite side.
61
NEW Replacement Parts
Part Name
Kit # Qty
12
1
Tube, Front Brake, No.4**
13
1
12
1
Tube, Front Brake, No.6**
13
1
Way (For Front Brake Tube)
1
2
Bolt
NA*
2
*Individual Part(s)
** Only 1 part used, part number varies by vehicle type.
36. INSTALL THE NEW FRONT BRAKE TUBE AND
NEW WAY (2WD ONLY)
Temporarily install the NEW front brake tube and NEW
way.
Install the NEW bolt to the NEW way and torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
NEW Replacement Parts
Part Name
Kit # Qty
14
1
Tube, Front Brake, No.4**
15
1
14
1
Tube, Front Brake, No.6**
15
1
Way (For Front Brake Tube)
1
2
14
90119-A0169
Bolt
or
2
15
**Only 1 part used, part number varies by vehicle type.
37. INSTALL THE NEW FRONT BRAKE TUBE AND
NEW WAY (4WD, PRE-RUNNER ONLY)
Temporarily install the NEW front brake tube and NEW
way.
Install the NEW bolt to the NEW way and torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
Repeat the procedure on the opposite side.
Part #
47314-04140
47314-04141
47316-04140
47316-04141
90412-10289
90119-A0169
Part #
47314-04150
47314-04151
47316-04150
47316-04151
90412-10289
Part #
90119-A0169
90468-A0007
Part #
90119-A0169
90468-A0007
NEW Replacement Parts
Part Name
Kit #
Bolt
NA*
Clip
2
*Individual Part(s)
NEW Replacement Parts
Part Name
Kit #
14
Bolt
or
15
Clip
2
Qty
4
2
Qty
2
2
Repeat the procedure on the opposite side.
38. RECONNECT THE FRONT BRAKE HOSE
(2WD ONLY)
Reinstall the flexible hose bracket with the NEW bolt and
torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
Reconnect the front brake hose with a NEW clip.
Reconnect the front brake tube and torque to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
Reinstall the NEW bolt and torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
Repeat the procedure on the opposite side.
39. RECONNECT THE FRONT BRAKE HOSE
(4WD, PRE-RUNNER ONLY)
Reinstall the flexible hose bracket with the NEW bolt and
torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
Reconnect the front brake hose with a NEW clip.
Reconnect the front brake tube and torque to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
Repeat the procedure on the opposite side.
62
Part #
90105-A0064
NEW Replacement Parts
Part Name
Kit #
Bolt
NA*
*Individual Part(s)
Qty
1
40. RECONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (2WD ONLY)
2011MY RH Side:
Remove the clamp from the front skid control sensor wire
harness.
Install the NEW bolt (A) and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Reconnect the front skid control sensor wire harness with
bolt and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Except 2011MY RH Side:
Reconnect the front skid control sensor wire harness with
the 2 bolts.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Repeat the procedure on the opposite side.
41. RECONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (4WD, PRE-RUNNER ONLY)
Reconnect the front skid control sensor wire harness with
bolt and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Repeat the procedure on the opposite side.
42. REINSTALL THE WHEELS
43. REINSTALL THE FRONT PROPELLER SHAFT ASSY
(4WD ONLY)
Referencing the matchmarks, reinstall the propeller shaft
assy to the front differential.
Reinstall the 4 bolts, 4 washer and 4 nuts, them torque to
spec.
Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf)
44. REINSTALL THE ENGINE AND TRANSMISSION ASSY
Reinstall engine and transmission assy.
NOTE:
• Hang up the front exhaust pipe with string to avoid
applying pressure at the joint part. (2TR-FE only)
• Use 2 engine hoists/cranes to lift engine & trans
assy.
• DO NOT use 1 engine hoist/crane to lift the engine
& trans assy, the unbalanced weight may lead to
an accident or injury.
• ONLY use engine hoists/cranes that can properly
support the weight of the engine & trans.
• Carefully adjust the 2 engine hoists/cranes used so
that the engine & trans assy is balanced.
63
Part #
90910-03001
94151-21001
NEW Replacement Parts
Part Name
Kit #
Bolt
1
Nut
1
LH Side
Qty
4
4
Attach the engine mounts with the 4 NEW bolts and 4 NEW
nuts, then torque to spec.
2011MY:
Torque Spec: 38 N∙m (387 kgf∙cm, 28 ft∙lbf)
2012-2015MY:
Torque Spec: 40 N∙m (408 kgf∙cm, 30 ft∙lbf)
RH Side
Part #
91671-80814
NEW Replacement Parts
Part Name
Kit #
Bolt
1
Qty
4
Attach the transmission mount with 4 NEW bolts and
torque to spec.
2011MY:
Torque Spec: 18.5 N∙m (189 kgf∙cm, 14 ft∙lbf)
2012-2015MY:
Torque Spec: 30 N∙m (306 kgf∙cm, 22 ft∙lbf)
Remove the bolt(s) and the engine hangers.
Reinstall the items/parts that were removed during the
engine and transmission assy removal.
LH Side
Reinstall the bolt and reconnect the ground wire. (LH Side)
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Reconnect the connector and clamp. (4WD Only)
Reconnect the clamp. (2TR-FE Only)
RH Side (4WD Only)
RH Side (2TR-FE Only)
64
45. RECONNECT THE OIL COOLER TUBE (AUTO TRANS ONLY)
Reconnect the oil cooler tube with the 2 bolts and torque to
spec.
Torque Spec: 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
46. REINSTALL THE INTAKE AIR SURGE TANK (1GR-FE ONLY)
Part #
17176-0P030
NEW Replacement Parts
Part Name
Kit #
Gasket, Air Surge Tank to
6
Intake Manifold
Qty
1
Install a NEW gasket onto the intake air surge tank.
Using a 8mm hexagon socket, reinstall the intake air surge
tank with the 4 bolts and torque to spec.
Torque Spec: 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
Reinstall the 2 intake air surge tank nuts and torque to
spec.
Torque Spec: 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
Reinstall the 2 surge tank stays with the 4 bolts, then
torque to spec.
Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf)
Reinstall oil baffle plate with the bolt and torque to spec.
Torque Spec: 9.0 N∙m (92 kgf∙cm, 80 in∙lbf)
Reinstall the throttle body bracket with the 2 bolts, then
torque to spec.
Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf)
Reconnect the 3 wire harness clamps and hose clamp.
Reconnect the throttle body w/ motor connector.
Reconnect the 2 VSV connectors.
Reconnect the ventilation hose.
Reconnect the fuel vapor feed hose.
Reconnect the 2 water by-pass hoses.
47. REINSTALL THE INTAKE AIR CONNECTOR (2TR-FE ONLY)
Reinstall the intake air connector with the 3 bolts, then torque to spec.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
Tighten the hose clamp bolts.
Reconnect the vacuum hose.
Reconnect the No.2 ventilation hose.
Reconnect the vacuum hose.
Reconnect the wire harness clamp.
Reconnect the pressure sensor connector.
48. REINSTALL THE POWER STEERING VANE PUMP
Reinstall the bolt and reconnect the ground wire and torque to spec. (1GR-FE Only)
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
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)
Reconnect the connector.
Reconnect the clamp. (1GR-FE Only)
49. REINSTALL THE V-BELT
65
50. REINSTALL THE FUEL TANK STRAPS
Reinstall the fuel tank straps with the 2 pins and 2 clips.
Part #
90119-A0249
NEW Replacement Parts
Part Name
Kit #
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TSB/Document ID: ZKA-TI-090519
Replacement Service Bulletin Number:
MFR Communication Date: 2019-09-05
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
MFR Component System:
MFR Component Subsystem:
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