Toyota PZQ44-89100 User manual

ISSUE 01 : 26/05/15 Page 1 of 12
Part No: PZQ44-89100
Side Step
Accessory Part No. : PZQ44-89100
Accessory Part No. PZQ44-89100
Place these instructions in vehicle’s glove box after installation is complete.
Installation Time : Approx. 45 min
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.
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.
(Model code: GUN125R-C, GUN126-C, GUN125R-D,
GUN126R-D, GGN125R, GUN136R-D)
July 2015 Production Onwards
Side Step Installation Instructions
Tools Required:
 8,10,13,17,18,19mm Ring/Open Spanner  Trolley Jack  Drill Bits 8.5mm, 10mm
 8,10,13,17,18, 19mm Sockets  Clear Polyurethane Glue  Rust Inhibitor & Brush
 Ratchet Wrench  1 Metre Rule or Straight Edge
 4-77 Nm Capacity Torque Wrench  Compact Power Drill
See page 2 for the parts list
PZQ44-89100
Dual Cab Side Step Assembly
OE Nuts: Torque to 57

ISSUE 01 : 26/05/15 Page 2 of 12
Part No: PZQ44-89100
Side Step
Accessory Part No. : PZQ44-89100
Parts List Important: Check contents of kit before commencing fitment and report and discrepancies.
Side Step PZQ44-89100 (Double Cab)
Item Component Name Qty. Torque (Nm) Service Kit Part No.
1Step Side RHS 1
2Step Side LHS 1
3Packer 8mm 4
4Bolt Hex Head M12 x 1.25P x 135 4
5Spacer Tube 2
6Washer Flat M12 x 26 x 4 4
7Screw Hex Head M8 x 1.25P x 30 10 22
8Washer Flat M8 x 26 x 4 22
9Nut Nyloc Hex Head M8 x 1.25P 822
10 Weld Nut Assembly M8 x 1.25P 2
11 Washer Flat M6 x 25 x 2.8 20
12 Bolt Hex Head M8 x 1.25P x 35 222
13 Spacer M8 x 20 x 10.4 2
14 Screw Hex Head M10 x 1.5P x 40 244
15 Washer Flat M10 x 25 x 4 4
16 Nut Nyloc Hex Head M10 x 1.5P 2
17 Right Angle Bracket RH 1
18 Right Angle Bracket LH 1
19 Shim 1mm 4
20 Tread Plate RH 1
21 Tread Plate LH 1
22 Bolt Cup Head M6 x 1.0P x 25 20
23 Nut Nyloc Hex Head M6 x 1.0P 20 4
24 Bung Rubber 4
25 Bolt Hex Head M12 x 1.75P x 130 2
26 Nut Nyloc Hex Head M12 x 1.75P 277
27 Bracket Horizontal RH 1
28 Bracket Horizontal LH 1

ISSUE 01 : 26/05/15 Page 3 of 12
Part No: PZQ44-89100
Side Step
Accessory Part No. : PZQ44-89100
Step 1:
 If fitted, remove OE side step.
 Remove 6 x M8 fasteners from OE side step.
 Discard side step and fasteners.
Figure 1: Remove OE side step
Figure 2: Remove park brake line bracket bolt
Figure 3: Support gearbox cross member
Step 2:
 Remove M8 bolt from parking brake line bracket and discard.
Step 3:
 Use a trolley jack to support gearbox cross member.
NOTE For step 1 refer to the vehicle workshop manual
Vehicle Front
NOTE
Complete steps 1 - 27 for right hand side first,
followed by left hand side. Item numbers listed
in brackets () refer to left hand components.
NOTE View shown in figure 2 is of right hand chassis,
M8 Bolt

ISSUE 01 : 26/05/15 Page 4 of 12
Part No: PZQ44-89100
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.
Figure 4: OE gearbox crossmember bolt removal
Figure 6: Side step fitment
Step 6:
 Lift item 1 (2) side step RHS (LHS) into position ensuring the
rear of the step is supported.
 Align the front bracket section over the transmission cross
member.
Step 5:
 Apply a wipe of clear polyurethane glue inside rear end of
tube.
 Insert 1 x item 24 bung rubber into end of step frame.
Figure 5: Installation of rubber bung
SAFETY When using polyurethane glue, avoid
breathing fumes and contact with skin
CAUTION Only remove crossmember bolts one side of
the vehicle at a time with the crossmember

ISSUE 01 : 26/05/15 Page 5 of 12
Part No: PZQ44-89100
Side Step
Accessory Part No. : PZQ44-89100
Figure 8: Fit cross-member bolts
Step 9:
 Insert 1 x item 25 Bolt M12 x 130 through 1 x item 6 Washer
M12 through outboard side of mid support bracket on side
step.
Figure 9: Install mid support outboard
Figure 7: Insert packers
Step 7:
 Insert 2 x item 3 Packer 8mm between the front bracket
section and the transmission cross member.
Step 8:
 Assemble step using 2 x item 4 Bolt Hex Head M12 x 135 and
2 x retained OE Nut Hex Head M12 as shown.
 Nip up fasteners, do not tighten at this stage.
HINT
A large flat blade screwdriver can be used to
lever and adjust bracket so shims can fit and
align with holes in bracket and crossmember

ISSUE 01 : 26/05/15 Page 6 of 12
Part No: PZQ44-89100
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
with the outboard wall of the chassis
Figure 10: Install mid support
Figure 11: Install mid support
Step 12:
 Attach the horizontal bracket to side step using 2 x item 7
Screw M8 x 30, 4 x item 8 Washer Flat M8, and 2 x item 9
Nut Nyloc M8 as shown.
 Nip up screws only do not tighten.
Figure 12: Install mid support
Step 11:
 Assemble item 27 (28) Bracket horizontal RHS (LHS) over the
M12 Bolt and Spacer Tube from inboard side of chassis frame
as shown.
 Assemble 1 x item 6 Washer Flat M12 and 1 x item 26 Nut
Nyloc M12 onto the M12 Bolt previously placed in Step 9.
 Nip up bolt, do not tighten.
WARNING Be careful not drop spacer tube into chas-
sis frame.

ISSUE 01 : 26/05/15 Page 7 of 12
Part No: PZQ44-89100
Side Step
Accessory Part No. : PZQ44-89100
Step 14:
 Fasten mid support on inboard side using 1 x item 7 screw M8
x 30 and 1 x item 8 washer flat M8, screwed into pre existing
captive nut in chassis and nip up screw, do not tighten.
Figure 14: Install mid support inboard
Figure 15: Install rear support
Step 15:
 Assemble step rear mount bracket (upper joint) to chassis
outboard over the OE park brake bracket, inserting 1 x item
13 M8 washer spacer between the park brake bracket and
step rear mount bracket, then securing with 1 x item 12 bolt
M8 x 35 and 1 x item 8 washer flat M8 into chassis weld nut
provided.
 Assemble step rear mount bracket (lower joint) to out board
chassis face using 1 x item 14 screw M10 x 40, 1 x item 15
washer flat M10,
 Pass through the chassis dropper then secure inside with
another 1 x item 15 washer flat M10 and 1 x item 16 nut
nyloc M10 as shown.
 Nip up fasteners. Do not tighten at this stage.
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
side of chassis frame as shown rearward of the mount bracket
and fasten using 1 x item 7 Screw M8 x 30 and 1 x item 8
Washer Flat M8.
 Nip up fastener only do not tighten.
Figure 13: Install mid support outboard
HINT
Use a large screwdriver through lower
bracket hole to aid in positioning top hole
alignment to insert M8 x 35 bolt.
Suspension components not shown for clarity
RH chassis rail shown
WARNING Keep away from brake lines
Packer

ISSUE 01 : 26/05/15 Page 8 of 12
Part No: PZQ44-89100
Side Step
Accessory Part No. : PZQ44-89100
Figure 16: Tighten fasteners
Step 16:
 Align side step to be parallel to vehicle sill.
 Tighten fasteners installed in steps 8-15 to values listed below.
Step 17:
 Apply a wipe of clear polyurethane glue to tube end and insert
1 x item 24 bung rubber into end of tube per step 5.
 Insert item 17 (19) right angle bracket RHS (LHS) into side
step as shown.
 Take care not to mark vehicle surfaces.
Figure 17: Install step return
Step 18:
 Connect using 1 x item 7 Screw M8 x 30, 2 x item 8 Washer
Flat M8, and 1 x item 9 Nut Nyloc M8 as shown.
 Nip up fasteners. Do not tighten.
Figure 18: Install step return
Bolt Flange Head M12 x 130 torque: 77 Nm
Screw M8 x 30 torque: 22 Nm
Torque on M12x1.25P OE Nut Flange (Not bolt head M12
Screw M10 x 40 torque: 44 Nm
NOTE
If fitting Side Rail PZQ44-89110 please refer to
separate fitting instructions supplied with the
parts.
Steps 17-23 are for side step fitment ONLY.
If NOT fitting PZQ44-89110 continue at Step 17
NOTE SAFETY: When using Polyurethane glue,
avoid breathing fumes and contact with skin

ISSUE 01 : 26/05/15 Page 9 of 12
Part No: PZQ44-89100
Side Step
Accessory Part No. : PZQ44-89100
Figure 20: Install shims
Figure 21: Check parallelism
Step 20:
 Re-fit 1 x Item 7 Screw M8 x 30, 2 x Item 8 Washer Flat M8,
and 1 x Item 9 Nut Nyloc M8 at first hole position closest to
side step rail. (As per Step 18)
 Nip up but do not tighten.
Step 21:
 Use a rule or straight edge to check and align parallelism of
top surface of item 17 (18) right angle bracket RHS (LHS) to
the top faces of the side step tread plate mounts. Take care
not to mark surfaces.
 Tighten Item 7 screw M8 x 30.
Vehicle components hidden for clarity.
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
1mm
 If gap is less than 1mm, do not fit shim.
 If gap is greater than 1mm but less than 2mm, fit 1 x 1mm
shim.
 If gap is greater than 2mm, fit 2 x 1mm shim.
 Nip up the joint and remeasure the gap.
Figure 19: Check return step gap
Vehicle components hidden for clarity.
STRAIGHT EDGE
Screw M8 x 30 torque: 22 Nm
Skip step 20 if gap in step 19 is less than 1mm

ISSUE 01 : 26/05/15 Page 10 of 12
Part No: PZQ44-89100
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.
Figure 22: Drill pinning hole
Step 23:
 Finalise connection of item 17 (18) Right Angle Bracket RHS
(LHS) to the step using 1 x Item 7 Screw M8 x 30, 2 x Item 8
Washer Flat M8 and 1 x Item 9 Nut Nyloc M8.
 Tighten fasteners.
Figure 23: Install pinning bolt
Step 24:
 Run a bead of clear polyurethane glue all the way along the
top face of the side step rail to eliminate any vibration of the
tread plate (item 20/21) against the side step.
 Take care not to apply too much polyurethane glue that may
spread to visible surfaces after the tread plate (item 20/21)
has been installed.
Figure 24: Apply anti vibration adhesive layer
Screw M8 x 30 torque: 22 Nm
Vehicle components hidden for clarity.
SAFETY When using polyurethane glue, avoid
breathing fumes and contact with skin.
SAFETY Wear suitable ear and eye protection when
operating power drill.

ISSUE 01 : 26/05/15 Page 11 of 12
Part No: PZQ44-89100
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.
 Tighten fasteners to the specified torque indicated below.
Figure 25: Fit tread plate
Step 26:
 Push weld nut sticks into the hole and bend to secure in
chassis access hole. Check to ensure it does not rattle.
 Do not break off nut stick
Figure 26: Secure weld nut extension sticks
Nut Nyloc M6 torque: 4 Nm
Step 27:
 Completed assembly shown (dual cab step - LHS with side rail
fitted) .
 Clean up any polyurethane glue that may have spilled onto
visible surfaces.
Figure 27: Product fitted to vehicle
END
NOTE Ensure weld nut sticks are still accessible if
removal is required

ISSUE 01 : 26/05/15 Page 12 of 12
Part No: PZQ44-89100
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.
 Bend weld nut stick 15 degrees up at notch 12.