Month: April 2019

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Toyota Pickup 1979-1995 Workshop Repair & Service Manual

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Toyota Pickup 1979-1995. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your Pickup 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 Pickup 1979-1995 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:

1995 Toyota Pickup SR5
3.0L V6 VIN [V] 1995 Engines – 3.0L V6

ADJUSTMENT
VALVE CLEARANCE ADJUSTMENT

NOTE: Adjust valve clearance with engine cold.

1. Disconnect electrical connector from throttle position sensor. Release fuel pressure. See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Disconnect vacuum hoses and fuel line at fuel pressure regulator.
2. Disconnect PCV hose. Drain cooling system. Disconnect necessary coolant hoses, electrical connections and vacuum hoses for removal of air intake chamber located above valve cover. See Fig. 7.
3. Remove union bolt and gaskets at cold start injector. Power steering pump bracket may need to be removed for access to valve cover. If necessary, remove power steering pump with hoses attached and secure aside. Remove power steering pump bracket.
4. Disconnect hose from PAIR valve. See Fig. 7. Remove engine hanger and support for air intake chamber.
Remove EGR valve assembly. Remove bolts/nuts, air intake chamber and gasket. Disconnect electrical connectors for removal of wiring assembly, located across engine, in front of valve cover. Remove bolts and wiring assembly.
5. Remove spark plugs, valve covers and gaskets. Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder on right side when viewed from rear of engine.
Ensure timing mark on crankshaft pulley aligns with “0” mark on timing belt cover.
6. Ensure valve lifters on cylinder No. 1 are loose and valve lifters on cylinder No. 4 are tight. If conditions are not as described, rotate crankshaft clockwise one complete revolution.
7. Using feeler gauge, measure and record valve clearance between valve lifter and camshaft on exhaust valve of cylinder No. 2 and intake valve of cylinder No. 6. See Fig. 1.
Fig. 1: Identifying Cylinder Numbers & Valve Locations
8. Rotate crankshaft clockwise an additional 120 degrees (1/3 revolution). Measure and record valve clearance on exhaust valve of cylinder No. 3 and intake valve of cylinder No. 1.
9. Rotate crankshaft clockwise an additional 120 degrees (1/3 revolution). Measure and record valve clearance on exhaust valve of cylinder No. 4 and intake valve of cylinder No. 2.
10. Rotate crankshaft clockwise an additional 120 degrees (1/3 revolution). Measure and record valve clearance on exhaust valve of cylinder No. 5 and intake valve of cylinder No. 3.
11. Rotate crankshaft clockwise an additional 120 degrees (1/3 revolution). Measure and record valve clearance on exhaust valve of cylinder No. 6 and intake valve of cylinder No. 4.
12. Rotate crankshaft clockwise an additional 120 degrees (1/3 revolution). Measure and record valve clearance on exhaust valve of cylinder No. 1 and intake valve of cylinder No. 5. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table.
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Toyota Hilux 1988-1995 Workshop Repair & Service Manual

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Toyota Hilux Pickup 1988-1995. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your truck 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 Hilux 1988-1995 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:

TRANSFER – Component Parts (Rear Output Shaft Assembly)

DISASSEMBLY OF REAR OUTPUT SHAFT ASSEMBLY
1. MEASURE DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard clearance: 0.10 – 0.25 mm
(0.0039 – 0.0098 in.)
Maximum clearance: 0.25 mm (0.0098 in.)
If the clearance exceeds the limit, replace the drive sprocket.
2.–1 (MT)
REMOVE HIGH AND LOW HUB SLEEVE ASSEMBLY
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the hub sleeve and shifting keys.
(c) Using a press, remove the clutch hub, key springs and key retainer.
2.–2 (AT)
REMOVE HIGH AND LOW HUB SLEEVE ASSEMBLY
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the hub sleeve.
(c) Using a press, remove the clutch hub.
3.–1 (w/ A.D.D.)
REMOVE REAR BEARING, SPACER AND DRIVE SPROCKET WITH FRONT DRIVE HUB SLEEVE ASSEMBLY
(a) Using SST and a press, remove the bearing.
SST 09950–00020
(b) Remove the spacer and ball.
(c) Remove the drive sprocket with front drive hub and hub sleeve.
(d) Remove the needle roller bearing.
(e) Remove the synchronizer ring.
3.–2 (w/o A.D.D.)
REMOVE REAR BEARING, SPACER AND DRIVE SPROCKET WITH FRONT DRIVE HUB SLEEVE ASSEMBLY
(a) Using SST and a press, remove the bearing.
SST 09950–00020
(b) Remove the spacer and ball.
(c) Remove the drive sprocket with front drive hub and hub sleeve.
(d) Remove the needle roller bearing.
4. (w/ A.D.D.)
REMOVE SHIFTING KEYS AND KEY SPRINGS FROM FRONT DRIVE HUB ASSEMBLY
Using screwdriver, remove the two shifting key springs and three shifting keys.

INSPECTION OF REAR OUTPUT SHAFT
ASSEMBLY
1. INSPECT REAR OUTPUT SHAFT
Using a micrometer, measure the outer diameter of the rear output shaft journal surface.
Minimum diameter:
Part A 27.98 mm (1.1016 in.)
B 36.98 mm (1.4559 in.)
2. CHECK OIL CLEARANCE OF DRIVE SPROCKET
Using a dial indicator, measure the oil clearance between the sprocket and shaft with the needle roller bearing installed.
Standard clearance: 0.010 – 0.055 mm
(0.0004 – 0.0022 in.)
Maximum clearance: 0.055 mm (0.022 in.)
If the clearance exceeds the limit, replace the drive sprocket, rear output shaft or needle roller bearing.
3. MEASURE CLEARANCE OF FRONT DRIVE SHIFT FORK AND HUB SLEEVE
Using a feeler gauge, measure the clearance between the front drive shift fork and hub sleeve.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the limit, replace the shift fork or hub sleeve.
4. MEASURE CLEARANCE OF HIGH AND LOW SHIFT FORK AND HUB SLEEVE
Using a feeler gauge, measure the clearance between the high and low shift fork and hub sleeve.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the limit, replace the shift fork or hub sleeve.
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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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