Month: April 2019

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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.
…

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Toyota Cressida 1976-1992 Workshop Repair & Service Manual

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Toyota Cressida 1976-1992. 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 Cressida 1976-1992 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:

3.0L 6-CYL & 3.0L 6-CYL TURBO – VIN [M] 1992 ENGINES Toyota – 3.0L & 3.0L Turbo 6-Cylinder

Removal (Supra)
1. Disconnect negative battery cable. Drain cooling system. Disconnect accelerator cable, throttle valve cable (A/T models) and cruise control cable.
WARNING: To prevent air bag deployment (if equipped), disconnect negative
battery cable at least 60 seconds before working on vehicle.
2. Remove air cleaner hose and intake air pipes. Disconnect necessary electrical connections, coolant hoses, control cables, fuel lines and vacuum hoses. Remove alternator.
3. On turbo models, remove power steering fluid reservoir. On all models, remove PCV tubing with hoses.
Remove support braces and air intake connector. See Fig. 7.
4. Place suitable container under cold start injector fuel line. Cover fuel line connection using shop towel.
Slowly loosen fuel line union bolt to release fuel pressure. Once fuel pressure is released, remove union bolts, gaskets and cold start injector fuel line.
5. Remove EGR pipe retaining bolts. On non-turbo models, remove EGR vacuum modulator from bracket. On all models, remove necessary piping, retaining bolts/nuts, air intake chamber and gasket. See Fig. 7.
6. Remove fuel pipes from delivery pipe, fuel pressure regulator or pulsation damper, and fuel filter.
Disconnect spark plug wires.
7. Remove retaining bolt and distributor (non-turbo models) or camshaft position sensor (turbo models). Remove oil dipstick and necessary piping to access valve covers. Disconnect exhaust pipe from exhaust manifold or turbocharger outlet elbow (if equipped).
8. On turbo models, remove turbocharger (if necessary). See TURBOCHARGER under REMOVAL & INSTALLATION. Remove ignition coil assembly and bracket.
9. On all models, remove retaining nuts, exhaust manifold and gasket. Remove coolant outlet housing (if necessary). Remove No. 1, No. 2 and No. 3 valve covers, and gaskets. See Fig. 7.
10. Remove spark plugs. Remove timing belt and camshaft timing pulleys. See TIMING BELT.
11. Using Hex Adapter (09043-38100), loosen cylinder head bolts in sequence using several steps. See Fig. 8 and Fig. 9 . Remove cylinder head bolts. Lift cylinder head upward, and disconnect coolant by-pass hose from union. Remove cylinder head and gasket.
12. Remove No. 2 timing belt cover, delivery pipe, insulators and spacers from cylinder head. DO NOT allow injectors to fall from delivery pipe during removal.
13. Remove retaining bolts/nuts, intake manifold and gasket, and EGR cooler. See Fig. 7. Remove bolt and heater union, which heater coolant line connects to, from rear of cylinder head. Remove camshafts. See CAMSHAFT under REMOVAL & INSTALLATION.
Inspection (Supra)
1. Inspect cylinder head warpage at cylinder block and manifold areas. Replace cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
2. Check intake manifold, air intake chamber and exhaust manifold warpage. If warpage exceeds specification, replace appropriate components. See WARPAGE SPECIFICATIONS TABLE (SUPRA).
3. Inspect cylinder block deck surface for warpage. Replace cylinder block if deck warpage exceeds specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. Inspect camshaft and components. See CAMSHAFT under REMOVAL & INSTALLATION.
…

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Toyota Corolla 1983-2016 Workshop Repair & Service Manual

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the 1983-2016 Toyota Corolla & 1992-1998 Toyota Carina E. 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 1983-2016 Toyota Corolla & 1992-1998 Toyota Carina E 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:
COOLING SYSTEM (April, 2003)
ON–VEHICLE INSPECTION
1. INSPECT COOLING SYSTEM FOR LEAKS
CAUTION: To avoid the danger of being burned, do not remove the radiator
cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure.
(a) Fill the radiator with coolant and attach a radiator cap tester.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop.
HINT: If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant level should be between the ”LOW” and ”FULL” line.
HINT: If low, check for leaks and add ”Toyota Long Life Coolant” or equivalent up to the ”FULL” line.
3. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure.
(b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole; the coolant should be free from oil.
HINT: If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.
4. INSPECT FINS BLOCKAGE
(a) If fins are clogged, wash them with water or a steam cleaner and dry with compressed air.
NOTICE: If the distance between the steam cleaner and core is too close, there is a possibility of damaging the fins, so keep the following injection distance.
…

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Toyota Camry 1986-2006 Workshop Repair & Service Manual

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Toyota Camry 1986-2006. 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 Camry 1986-2006 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:
DRIVE SHAFT, PROPELLER SHAFT, AXLE
ON–VEHICLE INSPECTION
1. REMOVE FRONT WHEEL
2. DISCONNECT FRONT DISC BRAKE CALIPER ASSY LH(See page 30–21)
3. REMOVE FRONT DISC
4. INSPECT FRONT AXLE HUB BEARING BACKLASH
(a) Using a dial indicator, check the backlash near the center of the axle hub.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the bearing.
5. INSPECT FRONT AXLE HUB DEVIATION
(a) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the axle hub.
6. INSTALL FRONT DISC
7. INSTALL FRONT DISC BRAKE CALIPER ASSY LH(See page 30–21)
8. INSTALL FRONT WHEEL
Torque: 103 Nm
9. REMOVE REAR WHEEL
10. DISCONNECT REAR DISC BRAKE CALIPER ASSY LH(DISC REAR BRAKE TYPE)
(See page 30–28)
11. REMOVE REAR DISC(DISC REAR BRAKE TYPE)
12. REMOVE REAR BRAKE DRUM SUB–ASSY(DRUM REAR BRAKE TYPE)
13. INSPECT REAR AXLE HUB BEARING BACKLASH
(a) Set a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the axle hub assembly.
14. INSPECT REAR AXLE HUB DEVIATION
(a) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt.
Maximum: 0.07 mm (0.0027 in.)
If the backlash exceeds the maximum, replace the axle hub assembly.
15. INSTALL REAR DISC(DISC REAR BRAKE TYPE)
16. INSTALL REAR DISC BRAKE CALIPER ASSY LH(DISC REAR BRAKE TYPE)
(See page 30–28)
17. INSTALL REAR BRAKE DRUM SUB–ASSY(DRUM REAR BRAKE TYPE)
18. INSTALL REAR WHEEL
Torque: 103 Nm
…