Reconnect the No.1 and No.2 fuel pipe.
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.
Reinstall the 2 fuel pipe clamps.
28. RECONNECT THE FUEL VAPOR FEED HOSE
29. RECONNECT THE FRONT DIFFERENTIAL BREATHER
TUBES (4WD ONLY)
Reconnect the front differential breather tubes.
NOTE: There may be 2 different breather tubes
depending on the vehicle spec.
30. RECONNECT THE NO.2 ENGINE WIRE HARNESS
Remove the upper relay block cover.
Reconnect the 3 connectors.
Reconnect fuse box wire harness with the nut and torque
to spec.
Torque Spec: 11 N∙m (112 kgf∙cm, 8 ft∙lbf)
Reinstall the No.1 upper relay block cover.
Reconnect the No.2 engine wire harness with the 2
clamps.
Reconnect the (+) positive battery cable with the nut and
torque to spec.
Torque Spec: 7.6 N∙m (77 kgf∙cm, 67 in∙lbf)
Reconnect the ground wire with the bolt and torque to
spec.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
31. REINSTALL THE FOLLOWING PARTS
• Air Cleaner Assy (1GR-FE Only)

Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
• Air Cleaner Hose and Air Cleaner Assy (2TR-FE Only)

Torque Spec: 12 N∙m (122 kgf∙cm, 9 ft∙lbf)
• V-Bank Cover (1GR-FE Only)

Torque Spec: 7.5 N∙m (76 kgf∙cm, 66 in∙lbf)
32. REINSTALL THE FOLLOWING PARTS (ACCESS CAB ONLY)
• Rear Floor Side Service Hole Cover LH/RH
• Seat Floor Box
• Floor Board No.1/No.2

• No.1 w/ Box Speaker Assy (If Equipped)
• Rear Seat Cushion Assy
• Rear Lower Console Box

74

33. RECONNECT THE PARKING BRAKE CABLES
For Separate Seat Type:
Reconnect the 2 parking brake cables.
Reinstall the 2 clips.

For Bench Seat Type:
Reconnect the 2 parking brake cables.
Reinstall the 2 clips.

Reinstall the parking brake cable joint protector with the 3
bolts and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Turn back the floor carpet.

34. REINSTALL THE FOLLOWING PARTS
• Manual Transmission Shift Lever (Manual Trans Only)
• Voltage Inverter Assy (If Equipped)

• Front Console Box(Manual Trans Only)
• Rear Console Box (for Separate Seat Type)

35. RECONNECT THE ENGINE WIRE HARNESS
Reconnect each connector and clamp to the ECM and
engine wire harness.
NOTE: The number of connectors may differ depending
on the model.

36. REINSTALL THE GLOVE BOX AND THE LOWER
INSTRUMENT PANEL FINISH PANEL
Reconnect the radio setting condenser connector
(If Equipped).
Reinstall the lower instrument panel finish panel with the
bolt.
Reinstall the glove box.
37. RECONNECT THE NO.2 FRAME WIRE HARNESS
(IF EQUIPPED)

For Frame Connecting Type:
Reconnect the 2 connectors and clamp.

Part #
90119-A0148

NEW Replacement Parts
Part Name
Bolt
*Individual Part(s)

Kit
#
NA*

Qty
2

Reinstall the wiring harness protector cover with the 2
NEW bolts and torque to spec.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
75

For Floor Connecting Type:
Insert the No.2 frame wire harness into the cab assy.
Reinstall the No.2 frame wire harness grommet to the cab
assy.
Reconnect the 2 connectors.

Reinstall the wiring harness protector with the bolt and
torque to spec.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 ft∙lbf)
Turn back the floor carpet.
Reinstall the passenger side seat with the 4 bolts and
torque to spec.
Torque Spec: 37 N∙m (377 kgf∙cm, 27 ft∙lbf)
38. RECONNECT THE FRAME WIRE HARNESS
Insert the frame wire harness into the cab assy.
Reinstall the frame wire harness grommet to the cab assy.
Reconnect the connector(s).
Reconnect the 5 clamps.
NOTE: The number of connectors may differ depending
on the model.

39. REINSTALL THE FOLLOWING INTERIOR COMPONENTS
• Instrument Panel Box
• Cowl Side Trim Board LH/RH

• Front Floor Footrest
• Front Door Scuff Plate LH/RH

76

40. REINSTALL THE FOLLOWING BODY COMPONENTS
• Front No.2 Bumper Extension Sub-assy LH/RH

Reinstall the front No.2 bumper extension with 6
NEW nuts and torque to spec.

Torque Spec: 58 N∙m (591 kgf∙cm, 43 ft∙lbf)
• Front Bumper Reinforcement

Reinstall the front bumper reinforcement with 6 nuts
and torque to spec.

Torque Spec: 58 N∙m (591 kgf∙cm, 43 ft∙lbf)
• Front Bumper Assy (2011MY):

Reinstall the front bumper assy with the 6 screws
and 9 clips.
• Front Bumper Assy (2012-2015MY):

Reinstall the front bumper assy with the 2 bolts, 6
screws and 5 clips.
• Front Fender Mudguard LH/RH
• Front Bumper Filler LH/RH (Except 2011MY)
• Radiator Grille

NEW Replacement Parts
Front No.2 Bumper Extension Sub-Assy LH/RH
Part #
Part Name
Kit # Qty
90178-A0044
Nut
2
6

J. REINSTALL THE BED ASSY
1.

REINSTALL THE BED ASSY
Using a Torx® T55H Socket, reinstall the bed assy Torx ®
bolts and torque to spec.
Torque Spec: 60 N∙m (612 kgf∙cm, 44 ft∙lbf)
NOTE:
• Use 4 or more people to lift the bed assy.
• Evenly support the bed assy when reinstalling it.
• Be careful not to damage or hit the fuel inlet pipe
when reinstalling the bed assy.
• Protect the front side of the bed assy to not
damage the cab assy.

2.

REINSTALL THE FUEL INLET PIPE SUB-ASSY
Reinstall the fuel inlet pipe sub-assy with the bolt and
torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)

3.

RECONNECT THE FRAME WIRE HARNESS
Reconnect the clamps to the bed assy.
NOTE:
• The number of connectors will differ depending on
the vehicle spec.
• Use new clamps if the original ones are damaged.

77

4.

NEW Replacement Parts
Left Rear Wheel Well Liner
Part #
Part Name
Kit # Qty
90189-A0002
8
8
Clip**
90189-A0002
9
6
**Only 1 part used, part number varies by vehicle type.
Quarter Panel Wheel Opening Moulding
Part #
Part Name
Kit # Qty
90189-A0002
Clip
8
2
75395-35070
Clip
8
3
75396-35020
Clip
8
7
Part #
75395-35070
75396-35020
90189-A0002

Body Rocker Panel Moulding Assy LH
Part Name
Kit #
Clip
9
Clip
9
Clip
9

Qty
2
1
1

Outside LH Back Door Moulding Sub-Assy
Part #
Part Name
Kit # Qty
75395-35070
Clip
9
2
75396-35020
Clip
9
1
90189-A0002
Clip
9
1
Part #
75395-04010
75396-04010
Part #
90119-A0192

Rocker Panel Moulding LH/RH
Part Name
Kit #
Clip
9
Clip
9
Rear Bumper Assy
Part Name
Bolt

Kit #
2

REINSTALL THE FOLLOWING PARTS
•
•
•
•
•
•
•
•
•

Power Outlet Socket Assy (If Equipped)
Left Rear Wheel Well Liner
Quarter Panel Wheel Opening Moulding LH (If Equipped)
Body Rocker Panel Moulding Assy LH (If Equipped)
Outside LH Back Door Moulding Sub-Assy (If Equipped)
Side Step Assy LH/RH (If Equipped)
Rocker Panel Moulding LH/RH (If Equipped)
Rear Mudguard LH/RH (If Equipped)
Rear Bumper Assy

Reinstall the rear bumper assy with the 10 NEW
bolts and torque to spec. (Trailer Hitch Equipped Vehicles


Only)

Reinstall the rear bumper assy with the 6 NEW
bolts and torque to spec.

Torque Spec: 90 N∙m (918 kgf∙cm, 66 ft∙lbf)
• Rear Tail/Combination Light LH/RH

Qty
4
14
Qty
6

78

K. FINAL ASSEMBLY
1.

RECONNECT THE NEGATIVE (-) BATTERY TERMINAL
2.

NEW Replacement Parts

art #
12157-10010
90430-24003

Front Differential
Part Name
Gasket, Front Differential Filler
Plug
Gasket, Front Differential Drain
Plug

Kit #

Qty

3

1

3

1

REFILL THE FOLLOWING FLUIDS
• 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: 19.5 N*m (199 kgf*cm, 14 ft.*lbf)

Refill with Toyota Dot 3 Brake Fluid.

Bleed the brake system at each wheel and torque
the bleeder screws to spec.

Torque Spec: 10.8 N∙m (110 kgf∙cm, 8 ft∙lbf)
• Clutch Fluid (1GR-FE Manual Trans Only)

Refill with Toyota Dot 3 Brake Fluid.

Bleed the clutch system and torque the bleeder
screws to spec.

Torque Spec: 10.8 N∙m (110 kgf∙cm, 8 ft∙lbf)
NOTE: 2TR-FE Manual Trans uses master cylinder
reservoir for clutch.
• Coolant

Refill with Toyota Long Life Coolant.

Bleed the cooling system.
• Front Differential Fluid (4WD Only)

Install the NEW drain plug washer and torque to
spec.

Torque Spec: 64.7 N·m (660 kgf·cm, 48 ft·lbf)

Refill with Hypoid Gear Oil API GL-5 75W-90.

Install the NEW filler plug washer and torque to
spec.

Torque Spec: 39.2 N·m (400 kgf·cm, 29 ft·lbf)

3.

START THE VEHICLE AND INSPECT THE FOLLOWING FOR LEAKS

4.
5.

• 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
• Clutch System (1GR-FE Manual Trans Only)
• Front Differential System
RECHARGE THE A/C SYSTEM AND CHECK FOR PROPER OPERATION AND REFRIGERANT LEAKS
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.

6.

• Parking Brake Travel
• Shift Control Lever (Automatic Trans Only)
• Clutch Pedal (Manual Trans Only)
CHECK ALL FLUID LEVELS AND ADJUST AS NEEDED
79

Part #
95381-04045
43514-28010

NEW Replacement Parts
Part Name
Kit #
Cotter Pin
3
Cap, front Axle Hub Grease,
3
LH/RH

Qty
2
2

7.

TORQUE THE FRONT AXLE NUT (4WD ONLY)
Remove the front wheels.
Torque the front axle nut to spec.
Torque Spec: 235 N∙m (2396 kgf∙cm, 173 ft∙lb)
Reinstall the lock cap with the NEW cotter pin.
NOTE: If the holes for the cotter pin are not aligned,
tighten the axle nut further, up to 60°.
Install the NEW grease cap.
Repeat the procedure on the opposite side.
Reinstall the front wheels and torque to spec.
Torque Spec: 113 N∙m (1152 kgf∙cm, 83 ft∙lbf)

8.

PERFORM A WHEEL ALIGNMENT

9.

CHECK THE HEADLIGHT AIM AND ADJUST AS NEEDED
10. REINSTALL THE ENGINE UNDER COVERS

Part #
90080-11373
90080-11373

NEW Replacement Parts
Part Name
Kit #
Bolt
8
Bolt
8

Qty
4
4

Reinstall the engine under cover with 8 NEW bolts and
torque to spec.
Torque Spec: 30 N∙m (306 kgf∙cm, 22 ft∙lbf)

11. CHECK FOR DTC’S AND REPAIR AS NEEDED
12. PERFORM INITIALIZATION
13. FINAL INSPECTION
Check the operation of the following systems:
• 4WD System (4WD Only)
• Power Windows
• Interior Lights
• Power Door Locks
• Exterior Lights
• All Gauges, Indicators and Warning Lights
• HVAC System
• Etc.
• Audio System
14. TEST DRIVE THE VEHICLE AND DOCUMENT FINAL REPAIR STATUS
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.

80

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.

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