Day: April 21, 2019

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Toyota Highlander 2001-2016 Workshop Repair & Service Manual

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Toyota Highlander 2001-2016. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Toyota Highlander 2001-2016 is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

EXCERPT:
INTAKE – INTAKE AIR CONTROL SYSTEM (3MZ-FE)
INSPECTION
1. INSPECT INTAKE AIR CONTROL VALVE ASSY NO.2
(a) Apply 26.7 kPa (200 mmHg, 7.9 in.Hg) of vacuum to the actuator. Check if the actuator rod pulls the lever and causes the valve to rotate open, as shown in the illustration.
(b) One minute after applying the vacuum, check that the actuator rod does not return.
If the result is not as specified, replace the IAC valve assy No. 2.
2. INSPECT AIR CLEANER CAP SUB-ASSY
(a) Cover port C with your finger and blow air into port B.
Check that air flows out of port A.
(b) Cover port C with your finger and blow air into port A.
Check that air does not flow out of port B.
(c) Cover ports A and C with your fingers, and apply 60 kPa
(450 mmHg, 18 in.Hg) of vacuum to port B. Check that there is no change in the vacuum after one minute.
If the result is not as specified, replace the air cleaner cap.
3. INSPECT VACUUM SWITCHING VALVE ASSY FOR IAC VALVE NO. 2
(a) Measure the VSV resistance.
Standard:
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Toyota HiAce 1989-2016 Factory Service & Shop Manual
Complete workshop & service manual with electrical wiring diagrams for Toyota HiAce 1989-2016. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Toyota HiAce 1989-2016 service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

EXCERPT:
HIACE / TRH20#,213,22# KDH20#,212,22# LH20#,212,222 (RM04Z5E)
ELECTRONIC CONTROLLED AUTOMATIC TRANSMISSION SYSTEM > MECHANICAL SYSTEM TESTS

for Preparation Click here

PERFORM MECHANICAL SYSTEM TESTS
Measure the stall speed.
The object of this test is to check the overall performance of the transmission and engine by measuring the stall speeds in the D position.

NOTICE:
Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F).
Do not continuously run this test for longer than 5 seconds.
To ensure safety, do this test in a wide, clear level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.

Chock the 4 wheels.

Connect an intelligent tester to the DLC3.

Fully apply the parking brake.

Using your left foot, keep the brake pedal firmly depressed.

Start the engine.

Shift into the D position. Press all the way down on the accelerator pedal with your right foot.

Quickly read the stall speed at this time.

Stall speed (1KD-FTV):
2,110 to 2,410 rpm
Stall speed (2KD-FTV):
2,050 to 2,350 rpm

Evaluation:
Test Result
Possible cause
Stall speed is lower than standard value
Engine power output may be insufficient
Stator one-way clutch is not operating properly
HINT:
If the value is less than the specified value by 600 rpm or more, the torque converter could be faulty.
Stall speed is higher than standard value
Line pressure is too low
Forward clutch slipping
No.2 one-way clutch not operating properly
O/D one-way clutch not operating properly
Improper fluid level
Measure the time lag.

When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the direct clutch, forward clutch, and 1st and reverse brake.

NOTICE:
Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F).
Be sure to allow for a 1 minute interval between tests.
Perform the test three times, and measure the time lags. Calculate the average value of the three time lags.
Connect an intelligent tester to the DLC3.

Fully apply the parking brake.

Start and warm up the engine and check idle speed in N position and A/C OFF.

Idle speed:
700 to 800 rpm
Shift the lever from the N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt.

Standard value:
D position time lag is less than 0.7 second
In the same way, measure the time lag for N → R.

Standard value:
R position time lag is less than 1.2 second

Evaluation:
Test Result
Possible cause
D position time lag exceeds standard value
Line pressure is too low
Forward clutch worn
O/D one-way clutch not operating properly
R position time lag exceeds standard value
Line pressure is too low
Direct clutch worn
1st and reverse brake worn
O/D one-way clutch not operating properly
…

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Toyota FJ Cruiser 2005-2016 Workshop Repair & Service Manual

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Toyota FJ Cruiser 2005-2016. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Toyota FJ Cruiser 2005-2016 is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

EXCERPT:
1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–1
SFI SYSTEM – PRECAUTION
1. INITIALIZATION
NOTICE:
• Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission
assembly, engine assembly or ECM (See page AT-19).
• Perform the REGISTRATION (VIN registration) when replacing the ECM (See page ES-15).
• If the ECM has been replaced or RESET MEMORY (AT initialization) has been performed, set up the function of the ATF (Automatic Transmission Fluid) temperature warning light (See page AT-19).
HINT: Initialization can not be completed by only removing the battery.
2. FOR USING INTELLIGENT TESTER
CAUTION: Observe the following items for safety reasons:
• Read its instruction books before using the tester.
• Prevent the tester cable from being caught on the
pedals, shift lever and steering wheel when driving with the tester connected to the vehicle.
• When driving the vehicle for testing purposes using the tester, two persons are required. One is for driving the vehicle, and the other operates the tester.
3. DISCONNECT AND RECONNECT CABLE OF NEGATIVE BATTERY TERMINAL
(a) Before performing electronic work, disconnect the cable from the negative (-) battery terminal in order to prevent it from shorting and burning out.
(b) Before disconnecting and reconnecting the battery cable, turn the ignition switch OFF and the headlight dimmer switch OFF. Then loosen the terminal nut completely. Do not damage the cable or terminal.
(c) When the battery cable is disconnected, the clock and radio settings and stored DTCs are erased. Therefore, before disconnecting the battery cable, make a notes of them.
NOTICE:
When the cable is disconnected from the negative (-) battery terminal, initialize the following system(s) after the cable is reconnected.
DEFINITION OF TERMS
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Toyota Engines Workshop Repair & Service Manual

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Toyota Engines. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your engines like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Toyota Engines is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

FILELIST:
1KZ-T Engine Repair Manual
4A-F, 4A-GE Engine Repair Manual
7MGE, 7M-GTE Engine Repair Manual
1C, 2C, 2C-T Engine Repair Manual.pdf
1HD-FT Engine Repair Manual.pdf
1KZ-TE Engine Repair Manual.pdf
1PZ, 1HZ, 1HD-T Engine Repair Manual.pdf
2H, 12H-T Engine Repair Manual.pdf
2JZ-GE, 2JZ-GTE Engine Repair Manual.pdf
2L-T, 3L Supplement Engine Repair Manual.pdf
2L, 2L-T, 3L, 5L Engine Repair Manual Supplement (FR).pdf
2ZZ-GE Engine Repair Manual.pdf
3S-FE Engine Repair Manual.pdf
3ZZ-FE, 4ZZ-FE Engine Repair Manual.pdf
4A-F, 4A-GE Engine Repair Manual.pdf
B, 2B Engine Repair Manual.pdf
B, 3B, 11B, 13B, 13B-T Engine Repair Manual (’86).pdf
B, 3B, 11B, 13B, 13B-T Engine Repair Manual.pdf
B, 3B, 11B, 14B Engine Repair Manual.pdf
F (97213) Engine Repair Manual.pdf
F (98087) Engine Repair Manual.pdf
L, 2L, 2L-T Engine Repair Manual.pdf
Taro 2L 2.4ltr. Diesel Engine Repair Manual.pdf
Taro 2Y_4Y 1.8-2.2ltr. Engine Repair Manual.pdf

EXCERPT:

ENGINE MECHANICAL – Cylinder Block

PREPARATION FOR DISASSEMBLY
1. (M/T)
REMOVE CLUTCH COVER AND DISC
2. (M/T)
REMOVE FLYWHEEL
3. (A/T)
REMOVE DRIVE PLATE AND FLYWHEEL
Remove the drive plate rear spacer, drive plate and flywheel.
4. REMOVE REAR END PLATE
Remove the bolt, end plate and dust cover.
5. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
6. REMOVE TIMING BELT AND PULLEYS
(See page EM-33)
7. REMOVE CYLINDER HEAD (See page EM-55)
8. REMOVE WATER PUMP (See page CO-6)
9. REMOVE ALTERNATOR
10. REMOVE TIMING GEARS (See page EM-43)
11. REMOVE INJECTION PUMP (See page FU-27)
12. REMOVE OIL PAN AND TIMING GEAR CASE (OIL PUMP)
(See page LU-8)
13. REMOVE OIL COOLER (See page LU-14)
14. REMOVE WATER INLET AND THERMOSTAT
15. REMOVE ENGINE MOUNTING
DISASSEMBLY OF CYLINDER BLOCK
(See page EM-84)
1. REMOVE REAR OIL SEAL RETAINER
Remove the six bolts and retainer.
2. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.10-0.20 mm
(0.0038-0.0079 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.
3. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Using paint, place the matchmarks on the connecting rod and cap to ensure correct reassembly.
(b) Using SST, remove the connecting rod cap bolts.
SST 09011-381 21
(c) Using the removed connecting rod cap bolts, pry the connecting rod cap back and forth, and remove the connecting cap.
HINT: Keep the lower bearing inserted with the connecting rod cap.
(d) Clean crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings.
If necessary, grind or replace the crankshaft.
(f) Lay a strip of Plastigage across the crank pin.
(g) Install the connecting rod cap.
(See step 8 on page EM-111)
Torque: 1st 375 kg-cm (27 ft-lb, 37 Nm)
2nd turn 90°
HINT: Do not turn the crankshaft.
(h) Remove the connecting rod cap.
(See procedure (b) and (c) above)
(i) Measure the Plastigage at widest point.
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Toyota DYNA 1984-1995 Workshop Repair & Service Manual

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Toyota DYNA 1984-1995. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your Toyota DYNA like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for 1984-1995 Toyota DYNA Truck is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

MAKE: Toyota
YEAR: 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995
MODEL: DYNA Truck (U60-U90 Series)

EXCERPT:

BRAKE SYSTEM – Checks and Adjustments

CHECKS AND ADJUSTMENTS
CHECK AND ADJUSTMENT OF BRAKE PEDAL
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height:
Regular cab 200.0 mm (7.874 in.)
Wide cab 198.5 mm (7.815 in.)
If incorrect, adjust the pedal height.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Sufficiently loosen the stop light switch.
(b) Sufficiently loosen the pedal stopper.
(c) Adjust the pedal height by turning the pedal push rod.
(d) Lock the pedal stopper at the position where it lightly strikes the pedal.
(e) Return the stop light switch until its body lightly contacts the idler arm.
(f) After adjusting the pedal height, check and adjust the pedal freeplay.
3. CHECK THAT PEDAL FREEPLAY IS CORRECT
(a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
(b) Push in the pedal until the beginning of resistance is felt. Measure the distance, as shown.
Pedal freeplay: 3- 6 mm (0.12- 0.24 in.)
NOTE: The pedal freeplay is the amount of the stroke until the booster air valve is moved by the pedal push rod.
If incorrect, adjust the pedal freeplay.
4. IF NECESSARY, ADJUST PEDAL FREEPLAY
(a) Adjust the pedal freeplay by t1:1rning the pedal push rod.
(b) Start the engine and confirm that pedal freeplay exists.
(c) After adjusting the pedal freeplay, check the pedal height.
5. CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT
Depress the pedal and measure the pedal reserve distance, as shown.
Pedal reserve distance from floor panel at 50 kg (11 0.2 lb, 490 N): More than 60 mm (2.36 in.)
If incorrect, troubleshoot the brake system.

OPERATIONAL TEST OF BRAKE BOOSTER
NOTE: If there is leakage or lack of vacuum, repair before testing.
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off, and check that there is no change in the pedal reserve distance.
(b) Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal.
2. AIR TIGHTNESS
(a) Start the engine and stop it after one or two minutes Depress the brake pedal several times slowly. If the
pedal goes far down the first time, but gradually rises after the second or third time, the booster is air tight
(b) Depress the brake pedal while the engine is running and stop it with the pedal depressed. If there is no change in pedal reserve travel after holding the pedal for thirty seconds, the booster is air tight.
BLEEDING OF BRAKE SYSTEM
NOTE: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air.
CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately.
1. FILL BRAKE RESERVOIRS WITH BRAKE FLUID
Check the reservoir after bleeding each wheel. Add fluid, if necessary.
2. CONNECT VINYL TUBE TO WHEEL CYLINDER
BLEEDER PLUG
Insert other end of the tube in a half-filled container of brake fluid.
NOTE: Begin air bleeding from the wheel cylinder with the longest hydraulic line.
3. BLEED BRAKE LINE
(a) Slowly pump the brake pedal several times.
(b) While having an assistant press on the pedal, loose the bleeder plug until fluid starts to runout. Then close the bleeder plug.
(c) Repeat this procedure until there are no more air bubbles in the fluid.
…