Instruction/ maintenance manual of the product 5613 Toyota
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3651 N Highway 89 • Chino V alley , AZ 86323 (928) 636-7080 • www .p-a-g .net T O Y O TA TA C O M A (AUT O. & MANUAL TRANS., 2 & 4WD, EXT .
2 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Before S t arting Inst allation 1. Carefully read all warning s and instructions com- pletely before beginning. 2. V erify all parts have been received in this kit by checking the part s list at th e end of this docume nt.
3 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Front of V ehicle 1. Front bumper a. Remove wiring harnesses from fog lights, if equipped. b. Remove two pop-up clips, two bolts and grill from core support. c. Remove seven pop-up clips from front bumper .
4 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 g. Remove six nuts and two front bumper brackets from frame ra ils . Engine Comp artment 1. 6 cyl. models: Loosen airb ox clamp, two clip s and remove airbox cover from engine. 2. 6 cyl. models: AC Line a.
5 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 6. 4 cyl. models: Remove nut a nd AC line from pas- senger side AC line bracket. 7. 4 cyl. models: Remove lower AC line from two clip s and passenger side body . 8. Remove vent tubes from driver side body bracket.
6 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 11 . Remove ABS wire harnesses from driver and p as- senger side brackets. 12. Remove wire harness and two clips from alternator bracket and driver side b ody bracket. ABS Wire Harnesse s Driver Side Passenger Side Battery Body Bracket Wire Harness Alternator Bracket 13.
7 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 14. S teer ing Shaft a. S trap steer ing wheel to prevent accidental movement. b. Mark upper steering shaft in relation to cou pler and lower steering shaft. c. Remove coupler bolts, slide coupler up onto upper steering sha ft and disconnect steering shaft.
8 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 b. Remove dead pedal. c. Remove driver and passenger kick p anels. d. Pull driver and passenger carpet back from cor- ner and expose body mount bolt access cover . e. Remove driver and passenger body mount b olt access cover .
9 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 e. Remove four bolts, and driver and passenger body mount access plates. f. Remove driver and passenger body mount b olt access covers. 4. Crew cab models: Rear interior trim panels a. Remove three headrests from seatbacks and fold seatbacks down.
10 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 3. Remove two bolts and brake line brackets from driver and passenger side frame rails. 4. Remove two bolts and parking brake cable brackets from crossmember .
1 1 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Rear of V eh icle 1. Fuel filler a. Remove fuel filler cap. b. Loosen two hose clamps and disconnect vent hose connector . c. Remove bolt and fuel filler from vehicle. W ARNING Use extreme caution when working nea r the fuel lines and the fuel tank.
12 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Inst all Kit Cab 1. Lift cab a. Loosen, but DO NOT REMOVE, cab mounting bolts on driver side. b. Remove bolt, nut, and lower washer from each cab mount on passenger side. NOTE The number of ca b mounting bo lts may va ry with the length of the cab.
13 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 c. Install kit block (2” dia.) on upper bushings on front core support cab mount. d. Install kit blocks (3” dia.) on upper bu shings on each remaining cab mount. e. Lower cab onto kit blocks .
14 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 3. Cab driver sid e a. Repeat previous steps on driver side of cab. b. Set cab-to-bed spacing according to previo us measurement. c. Remove front core support cab mo unt kit bolts (3/8” x 8”) and app ly a few drops of kit Loctite ® to threads.
15 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 2. Remove bolt from each bed mount on passenger side. 3. Bed passenger side a. Remove ca ptive washer s from each factory be d mount bolt. b. Using a hydraulic jack and a wood block, slowly lift passenger side of bed a little more than 3”.
16 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 f. At rear bed mount, install kit bolt (M12-1.25 x 180mm) and factory captive w asher . DO NOT TIGHTEN. g. Repeat previous steps on driver side of bed. h. Set bed-to-cab spacing according to previo us measurement.
17 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 b. Apply a small amount of kit Loctite ® onto threads of two factory bolts and install kit bracket (rear bump er , passenger) and kit bracket (bumper , spacer) to passenger side bumper with two factory b olts.
18 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 h. Install kit bracket (rear bumper , middle) onto O.E. trailer hitch with two ki t bolt s (1/2” x 1” ), four kit washers (1/2” SAE), and two kit nuts (1/ 2” stover). DO NOT TIGHTEN. i. Install license plate lights on rear bumper .
19 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 d. Install kit extension (1/4” x 6” hose) b etween cut breather tube on fuel filler with two kit clamp s (#6 hose). DO NOT TIGHTEN. e. Install kit extension (5/8” x 6” hose) b etween cut vent tube on fuel filler with two kit clamp s (#10 hose).
20 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Underside of V e hicle 1. Parking brake cable a. Install kit bracket (3” w/ stud) to driver side crossmember with factory bolt. b. Install driver side parking brake cable to kit bracket with kit nut (1/4” Nylock) and kit washer (1/4” SAE).
21 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 3. Carefully bend brake lines and in stall bolt and brake line bracket to frame. 4. Brake lines a.
22 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 2. Crew cab models: Rear interior trim panels a. Install body mount access covers. b. Install passenger side rear panel onto cab with pop-clips and bolt. c. Install driver side rear panel onto cab with pop- clips and three bolts.
23 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 e. Install driver and p a ss enger door sill plates. 4. Manual transmission a. Remove plastic cap from end of shift lever . b. Mark alignment and cut lines on shifter lever below bend. c. Cut shifter lever along marked cut line.
24 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Engine Comp artment 1. S teer ing shaft a. Install upper steering sh aft into kit extension (steering), ensurin g marks on upper and lower steering shaft are aligned. b. Position kit extension (steering) into stee ring coupler .
25 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 c. Install radiator and fo ur kit brackets to core sup- port with four kit washers (1/4” SAE) and four kit nut s (1/4” Nylock). DO NOT TIGHTEN. d. Assemble kit plates (radiator block off) with kit bolt (1/4” x 1”), two kit washers (1/4” SAE) and kit nut (1/4” Nylock).
26 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 3. Install wire harness and clips to alternator bracket and driver side body bracket. Adjust clips if neces- sary . 4. Install vent hoses to driver side body bracket with kit tie (zip). Battery Body Bracket Wire Harness Alternator Bracket Kit Tie (Zip) Bracket Vent Hoses 5.
27 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 8. 6 cyl. models: Power st eering re servoi r a. Remove reservoir cap an d drain contents into drain p an. b. Remove two clamps and power steering lines from reservo ir . c. Mark power st eering lines .
28 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 9. 4 cyl. models: Power steering requires no modifica- tion. 10. 6 cyl. models: AC Line a. Install rubber isolator to body . b. Install AC line and cla mp onto rubber isolator with nut. 1 1. 4 cyl.
29 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 b. Apply a small amount of kit Loc tite ® to six kit bolts (3/8” x 1”) and install front bumper to kit brackets (front bumper) with twelve kit washers (3/8” USS) and six kit nut s (3/8” Nylock).
30 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Af ter Completing Inst allation Inside Cab 1. Install airbag fuse and fu se block cover . Engine Comp artment 1.
31 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Accessories The following accessories are also available: Kit # 6337: Gap Guards.
32 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Kit Part s List Qty . Description NOTE Depending on th e vehicle configuration (auto matic or manual transmission, 2WD or 4W D, cab length, bed length, etc.
An important point after buying a device Toyota 5613 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Toyota 5613 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Toyota 5613 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Toyota 5613 you will learn all the available features of the product, as well as information on its operation. The information that you get Toyota 5613 will certainly help you make a decision on the purchase.
If you already are a holder of Toyota 5613, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Toyota 5613.
However, one of the most important roles played by the user manual is to help in solving problems with Toyota 5613. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Toyota 5613 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
