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
Bolt
2
Qty
2
51. REINSTALL THE FUEL TANK
Reinstall the fuel tank with the 2 NEW bolts and torque to
spec.
Torque Spec: 62 N∙m (632 kgf∙cm, 46 ft∙lbf)
Reconnect the connector.
52. REINSTALL THE NO.2 FUEL TANK PROTECTOR (IF EQUIPPED)
53. REINSTALL THE NO.1 FUEL TANK PROTECTOR ASSY
(IF EQUIPPED)
Part #
90179-08241
NEW Replacement Parts
Part Name
Kit #
Nut
NA*
*Individual Part(s)
Qty
4
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)
Part #
77285-35760
90105-A0066
Part #
17451-0D020
NEW Replacement Parts
Part Name
Kit #
Clamp. Fuel Tube, No.1
1
Bolt
NA*
*Individual Part(s)
NEW Replacement Parts
Part Name
Kit #
Gasket, Exhaust Pipe
6
Qty
1
1
54. REINSTALL THE CHARCOAL CANISTER ASSY
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)
Reconnect the fuel tank vent hose.
Reconnect the fuel hose.
Reconnect the main tube support and reconnect the filter
hose.
Reconnect the connector.
w/ Rear Differential Lock:
Install the NEW bolt and connect the skid control sensor
wire bracket and torque to spec.
w/o Rear Differential Lock:
Install the bolt and reconnect the skid control sensor wire
bracket and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Install the NEW clamp.
55. REINSTALL THE EXHAUST SYSTEM
Qty
1
(1GR-FE ONLY)
Reconnect the 2 exhaust pipe supports to the frame.
Install the NEW exhaust pipe gasket.
66
Part #
90080-10291
NEW Replacement Parts
Part Name
Kit #
Bolt
6
Reconnect the 4 exhaust pipe supports to the frame and
reinstall the center exhaust pipe assy.
Install the 2 NEW bolts and 2 springs, then torque to spec.
Qty
2
Torque Spec: 43 N∙m (438 kgf∙cm, 32 ft∙lbf)
56. REINSTALL THE EXHAUST SYSTEM
Part #
90080-43033
90080-10064
90177-A0004
NEW Replacement Parts
Part Name
Kit #
Gasket
7
Bolt
7
Nut
7
(2TR-FE ONLY)
Qty
1
2
2
Reconnect the exhaust pipe support to the frame.
Reconnect the 2 oxygen sensor wire harness clamps.
Install the NEW exhaust pipe gasket.
Reconnect the 4 exhaust pipe supports to the frame and
reinstall the center exhaust pipe assy.
Install the 2 NEW bolts and 2 NEW nuts then torque to
spec.
Torque Spec: 48 N∙m (489 kgf∙cm, 35 ft∙lbf)
57. REINSTALL THE EXHAUST PIPE STOPPER BRACKET
(IF EQUIPPED)
Part #
90080-11180
Part #
90119-A0151
NEW Replacement Parts
Part Name
Kit #
Bolt
6
NEW Replacement Parts
Part Name
Kit #
Bolt
NA*
*Individual Part(s)
Qty
2
Reinstall the exhaust pipe stopper bracket with the 2 NEW
bolts and torque to spec.
Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf)
58. REINSTALL THE PROPELLER SHAFT HEAT INSULATOR
Qty
2
(IF EQUIPPED)
Reinstall the propeller shaft heat insulator with the 2 NEW
bolts and torque to spec.
Torque Spec: 15.7 N∙m (160 kgf∙cm, 12 ft∙lbf)
67
59. REINSTALL THE REAR PROPELLER SHAFT ASSY
Remove the SST. (2WD Only)
Referencing the matchmarks, reinstall the rear propeller
shaft assy to the transmission / transfer case.
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)
Reinstall the center support bearing to the frame as shown
in the illustration with 2 washers and 2 bolts, then torque to
spec. (3-Joint Type Only)
Torque Spec: 36.2 N∙m (369 kgf∙cm, 27 ft∙lbf)
Referencing the matchmarks, reinstall the rear 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)
60. RECONNECT THE FRONT PROPELLER SHAFT ASSY (4WD ONLY)
Referencing the matchmarks, reconnect the front propeller shaft assy to the transfer case and the front
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)
61. REMOVE THE FRAME FROM THE LIFT
Remove the ratcheting tie down strap from the frame.
Lower the frame to the ground.
68
I.
REINSTALL THE CAB BODY ASSY
Before lowering the cab assembly ensure that you install the NEW brakelines onto the bulk
head.
NEW Replacement Parts
Part Name
Kit # Qty
10
1
11
1
Tube, Front Brake, No.3**
NA*
1
NA*
1
10
1
11
1
Tube, Front Brake, No.5**
NA*
1
NA*
1
10
1
11
1
Tube, Rear Brake, No.3**
NA*
1
NA*
1
10
1
11
1
Tube, Rear Brake, No.4**
NA*
1
NA*
1
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.
Part #
47313-04200
47313-04231
47313-04210
47313-04241
47315-04170
47315-04171
47315-04180
47315-04191
47323-04170
47323-04171
47323-04180
4732304191
47324-04130
47324-04131
47324-04140
47324-04151
2.
1.
INSTALL THE NEW ENGINE COMPARTMENT BRAKE
TUBES
Install the NEW No.3 and NEW No.5 front brake tubes.
Install the NEW No.3 and NEW No.4 rear brake tubes.
Torque all brake tubes to spec.
Torque Spec:
Flare Nut (M10) - 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
Flare Nut (M12) - 19.5 N∙m (199 kgf∙cm, 14 ft∙lbf)
REINSTALL THE CAB BODY ASSY
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 and line the tires up with the alignment marks.
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 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)
Reinstall the 4 hole plugs.
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.
69
Part #
90412-10276
90119-A0169
NEW Replacement Parts
Part Name
Kit #
Way, 2 (For Rear Brake Tube)
2
14
or
Bolt
15
or
NA*
*Individual Part(s)
Qty
1
3.
RECONNECT THE PARKING BRAKE CABLE
4.
CONNECT THE REAR BRAKE TUBES
Temporarily install the NEW 2 way with the NEW bolt.
Temporarily install the 4 rear brake tubes.
Torque the bolt to spec.
1
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
Torque the 4 rear brake tubes to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
5.
RECONNECT THE FUEL TANK TUBES
Reconnect the 2 fuel tank tubes.
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
Reconnect the No.2 fuel hose with the clip.
7.
RECONNECT THE SHIFT CABLE (AUTO TRANS ONLY)
Cable Type (Shown):
Reconnect the shift cable with the nut and torque to spec.
NEW Replacement Parts (Rod Type)
Part Name
Kit # Qty
Clip
NA*
1
Pin, W/ Hole (For Transmission
90240-08054
NA*
1
Control Rod)
*Individual Part(s)
Part #
90468-14033
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
Install the clip.
Rod Type:
Reconnect the shift cable with the NEW pin and NEW clip.
70
8.
RECONNECT THE CLUTCH RELEASE CYLINDER ASSY
(2TR-FE MANUAL TRANS ONLY)
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)
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)
Reconnect the No.1 clutch hose with the clip.
Reconnect the clutch release cylinder tube to the clutch
hose.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
Part #
90080-11555
NEW Replacement Parts
Part Name
Kit #
Bolt
2
LH Side
10. RECONNECT THE STEERING SLIDING YOKE
Qty
2
Make sure the front wheels are in a straight-ahead position
and the steering wheel is centered.
Referencing the match marks, reconnect the steering
sliding yoke to the No.2 intermediate shaft with the NEW
bolt (B).
Remove bolt (A) and install the NEW bolt (A).
Torque all bolts to spec.
Torque Spec: 35 N∙m (357 kgf∙cm, 26 ft∙lbf)
Disconnect the seat belt that is holding the steering wheel.
11. RECONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS
Reconnect the harness clamp and front skid control sensor
connector.
Repeat the procedure on the opposite side.
RH Side
RH Side
12. RECONNECT THE NO.2 FRAME WIRE HARNESS
(IF EQUIPPED)
Reconnect the harness clamp and connector.
71
LH Side
13. CONNECT THE FRONT BRAKE TUBES
Connect 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.
RH Side
Part #
90210-A0002
90210-A0004
NEW Replacement Parts
Part Name
Kit #
O Ring
2
O Ring
2
Qty
1
1
14. RECONNECT THE AIR CONDITIONING DISCHARGE AND
SUCTION HOSES TO THE COMPRESSOR
Install a NEW o-ring to the A/C discharge and suction
hoses.
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)
15. RECONNECT THE SUCTION HOSE BRACKET
Reconnect the suction hose bracket with the bolt and
torque to spec.
Torque Spec: 7.5 N∙m (76 kgf∙cm, 66 in∙lbf)
LH Side
16. REINSTALL THE FRONT FENDER APRON SEALS
4WD, Pre-Runner Only (Shown):
Reinstall the 4 front fender apron seals with the 20 clips.
2WD Only:
Reinstall the 4 front fender apron seals with the 22 clips.
RH Side
17. RECONNECT THE WATER / HEATER HOSES, ENGINE SIDE
72
18. RECONNECT THE ENGINE WIRE HARNES
Reinstall the engine wire harness container to the cowl
panel.
Reconnect the clamp.
19. RECONNECT THE NO.1 HOSE
2TR-FE Only (Shown):
Reconnect the ground wire with the bolt.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
Reconnect the No.1 hose to the air pump assy.
2012-2015MY (1GR-FE Only):
Reconnect the No.1 hose to the air pump assy.
20. RECONNECT THE POWER STEERING PUMP OIL
RESERVOIR ASSY (1GR-FE ONLY)
Reconnect the power steering pump oil reservoir assy.
21. RECONNECT THE GROUND WIRE (1GR-FE ONLY)
Reconnect the ground wire with the bolt.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
Reconnect the clamp.
22. REINSTALL THE FAN SHROUD
Part #
90069-08019
NEW Replacement Parts
Part Name
Kit #
Packing (For Radiator Drain
2
Cock)
23. REINSTALL THE RADIATOR ASSY
Qty
1
Install the NEW o-ring to the drain plug.
Tighten the radiator drain plug.
Reinstall the radiator with 4 bolts and torque to spec.
Torque Spec: 18 N∙m (184 kgf∙cm, 13 ft∙lbf)
Reinstall the automatic transmission cooler lines (Auto Trans
Only).
Reinstall the fan shroud with the 2 bolts.
Torque Spec: 5.0 N∙m (51 kgf∙cm, 44 in∙lbf)
24. RECONNECT THE RADIATOR HOSES
25. REINSTALL THE RADIATOR SUPPORT TO FRAME SEAL
26. RECONNECT THE VACUUM HOSE
Reconnect the vacuum hose.
73
27. RECONNECT THE FUEL PIPES
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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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