Download Print this page
Toyota PZQ44-89100 Installation Instructions Manual
Toyota PZQ44-89100 Installation Instructions Manual

Toyota PZQ44-89100 Installation Instructions Manual

Side step for hilux

Advertisement

Quick Links

Accessory Part No.
CAUTION—It is extremely important that bolts are tightened to the correct torques in the correct
sequence (refer to lettering in the layout diagram and parts list).
It is important that the cross-member nuts are torqued, not the bolts.
At the end, check that all bolts are fully torqued as per the fitment instructions.
Place these instructions in vehicle's glove box after installation is complete.
Important:
Read instructions carefully before installation - install side step as described. Do not use any other mounting location/
method other than described in this instruction.
Ensure that the weld nut assemblies are not inserted adjacent to brake lines
It is advisable to seek assistance of another person when installing this product.
Do not use this product in any other motor vehicle for which it is not designed.
Do not repair or modify the side step and/or its mounting bracket in any way - repair or modification may effect proper opera-
tion of the airbag resulting in serious injury.
PZQ44-89100
Dual Cab Side Step Assembly
Tools Required:
8,10,13,17,18,19mm Ring/Open Spanner
8,10,13,17,18, 19mm Sockets
Ratchet Wrench
4-77 Nm Capacity Torque Wrench
ISSUE 01 : 26/05/15
(Model code: GUN125R-C, GUN126-C, GUN125R-D,
GUN126R-D, GGN125R, GUN136R-D)
July 2015 Production Onwards
Side Step Installation Instructions
PZQ44-89100
See page 2 for the parts list
OE Nuts: Torque to 57
Trolley Jack
Clear Polyurethane Glue
1 Metre Rule or Straight Edge
Compact Power Drill
Part No: PZQ44-89100
Side Step
Accessory Part No. : PZQ44-89100
Installation Time : Approx. 45 min
Drill Bits 8.5mm, 10mm
Rust Inhibitor & Brush
Page 1 of 12

Advertisement

loading
Need help?

Need help?

Do you have a question about the PZQ44-89100 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for Toyota PZQ44-89100

  • Page 1 Side Step Accessory Part No. : PZQ44-89100 (Model code: GUN125R-C, GUN126-C, GUN125R-D, GUN126R-D, GGN125R, GUN136R-D) July 2015 Production Onwards Side Step Installation Instructions Accessory Part No. Installation Time : Approx. 45 min PZQ44-89100 CAUTION—It is extremely important that bolts are tightened to the correct torques in the correct sequence (refer to lettering in the layout diagram and parts list).
  • Page 2 Side Step Accessory Part No. : PZQ44-89100 Important: Check contents of kit before commencing fitment and report and discrepancies. Parts List Side Step PZQ44-89100 (Double Cab) Item Component Name Qty. Torque (Nm) Service Kit Part No. Step Side RHS Step Side LHS Packer 8mm Bolt Hex Head M12 x 1.25P x 135...
  • Page 3 Side Step Accessory Part No. : PZQ44-89100 NOTE For step 1 refer to the vehicle workshop manual Complete steps 1 - 27 for right hand side first, NOTE followed by left hand side. Item numbers listed in brackets () refer to left hand components.
  • Page 4 Side Step Accessory Part No. : PZQ44-89100 Step 4:  Remove 2 x M12 fastener sets from gearbox cross member as shown.  Retain OE M12 hex nuts, discard OE M12 bolts. Only remove crossmember bolts one side of CAUTION...
  • Page 5 Side Step Accessory Part No. : PZQ44-89100 Step 7:  Insert 2 x item 3 Packer 8mm between the front bracket section and the transmission cross member. A large flat blade screwdriver can be used to HINT lever and adjust bracket so shims can fit and...
  • Page 6 Side Step Accessory Part No. : PZQ44-89100 Step 10:  Slide 1 x item 5 Spacer Tube over item 25 Bolt M12 x 130 from inboard side of chassis frame as shown.  Ensure sleeve slides through completely until the end is flush...
  • Page 7 Side Step Accessory Part No. : PZQ44-89100 Step 13:  Using the bending instructions on page 13, bend 1 x item 10 Weld Nut assembly to match the diagram shown.  Feed Weld Nut assembly through access hole on outboard...
  • Page 8 Side Step Accessory Part No. : PZQ44-89100 Step 16:  Align side step to be parallel to vehicle sill.  Tighten fasteners installed in steps 8-15 to values listed below. Torque on M12x1.25P OE Nut Flange (Not bolt head M12...
  • Page 9 Side Step Accessory Part No. : PZQ44-89100 Step 19:  Measure gap between joining faces of side step bracket and item 17 (19) right angle bracket RHS (LHS). If it is equal to or exceeds 1mm, undo and remove fasteners to fit Item 19 Shim ...
  • Page 10 Side Step Accessory Part No. : PZQ44-89100 Step 22:  Drill perpendicular to front support bracket using an 8.5mm drill bit and the pre-drilled hole in item 17 (18) right angle bracket RHS (LHS) as a guide.  De-burr all sharp edges, remove swarf and apply rust inhibitor to bare metal surfaces.
  • Page 11 Side Step Accessory Part No. : PZQ44-89100 Step 25:  Secure Item 20 (21) Tread Plate RHS (LHS) to Item 1 (2) Side step RHS (LHS) brackets using the fasteners supplied as follows; 10 x Item 22 Bolt Cup Head M6 x 25, 10 x Item 8 Washer Flat M6 and 10 x Item 23 Nut Nyloc M6 using torque shown below.
  • Page 12 Side Step Accessory Part No. : PZQ44-89100 Weld Nut Assembly Bending Diagram, bending angles are approximate, and a guide only Instructions:  Bend weld nut stick 15 degrees down at notch 4.  Bend weld nut stick 15 degrees down at notch 9 as shown.