Engine Mechanicals:
Complete engine disassembly, inspection, and reassembly procedures for all covered engine variants. Includes cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing systems, and related components.
Efi Systems:
Detailed diagnostics and repair procedures for Electronic Fuel Injection systems, including sensors (MAP, TPS, O2, coolant temp), injectors, fuel pump, ECU operation, and troubleshooting common issues.
Fuel System:
Covers fuel tank, fuel pump, fuel filter, fuel lines, pressure regulator, and associated components. Includes diagnostic procedures and replacement instructions.
Emission Control Systems:
Information on emission control devices such as catalytic converters, EGR systems, and evaporative emission control (EVAP) systems. Troubleshooting related to emissions testing.
Cooling System:
Radiator, water pump, thermostat, hoses, coolant types, capacities, and troubleshooting for overheating or cooling system leaks.
Lubrication System:
Oil pump, oil filter, oil pan, oil passages, oil viscosity recommendations, and capacities. Includes troubleshooting for low oil pressure.
Ignition System:
Spark plugs, ignition coils (or distributor for earlier models), ignition timing, ECU control, and diagnostic procedures for ignition system faults.
Starting System:
Starter motor, starter solenoid, battery testing, and related circuitry. Troubleshooting for starting issues.
Charging System:
Alternator, voltage regulator, battery, and charging circuit diagnostics. Troubleshooting for battery not charging or overcharging.
Transmission Manual:
Clutch system, gear shift mechanism, gearbox internal components, lubrication, and troubleshooting for manual transmissions.
Transmission Automatic:
Automatic transmission operation, fluid types, capacities, torque converter, valve body, electronic controls (if applicable), and troubleshooting.
Drivetrain 4Wd:
Likely includes information on the transfer case, differentials (front and rear), drive shafts, CV joints, and 4WD system engagement mechanisms, as the Terios is known for its 4WD capability.
Suspension:
Front and rear suspension components (struts, shocks, springs, control arms, bushings), alignment specifications, and troubleshooting of suspension noise or handling issues.
Steering:
Steering rack, power steering pump, fluid, hoses, steering column, and troubleshooting steering problems.
Brakes:
Front and rear brake systems (disc or drum depending on specification), brake pads, rotors, calipers, wheel cylinders, brake fluid, ABS components (if equipped), and bleeding procedures.
Body And Chassis:
Body panel removal and installation, door mechanisms, glass, interior trim, exterior trim, chassis components, and frame structure.
Electrical System:
Comprehensive coverage of the vehicle's electrical system, including battery, fuses, relays, lighting, power windows, power locks, wipers, horn, and basic body electrical components.
Wiring Diagrams:
Detailed wiring diagrams for all major electrical systems, crucial for diagnosing electrical faults and component replacement.
Routine Maintenance:
Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid level checks and top-offs, lubrication points, and tire rotations.
Engine Overhaul:
Detailed steps for complete engine disassembly, cleaning, inspection, measurement of wear, and reassembly with specifications.
Transmission Repair:
Procedures for clutch replacement, manual gearbox disassembly/reassembly, and automatic transmission overhaul or component replacement.
Brake Service:
Pad and rotor replacement, caliper service, brake line replacement, bleeding procedures, and drum brake servicing.
Suspension Component Replacement:
Replacement of shocks, struts, ball joints, tie rod ends, and control arm bushings.
Diagnostics Troubleshooting:
Systematic approaches to diagnose common and uncommon problems across all major vehicle systems using symptoms and logical steps.
Component Replacement:
Detailed instructions for removing and installing various components, from minor items like sensors and bulbs to major items like the engine or transmission.
Electrical Troubleshooting:
Utilizing wiring diagrams to trace circuits, test components, and diagnose electrical faults.
Wheel Alignment Specifications:
Includes camber, caster, toe-in/toe-out specifications for front and rear wheels, crucial for proper handling and tire wear.
Tire Pressure Specifications:
Recommended tire pressures for various load conditions and tire sizes.
Diagnostic Information:
Includes diagnostic trouble codes (DTCs), testing procedures for sensors and actuators, and likely OBD-II information for later models (post-1996).
Repair Procedures:
Step-by-step instructions for most repairs, including special tool requirements and safety precautions.
Specifications:
Extensive list of technical specifications, including torque values, clearances, fluid capacities, and performance data.
Ssts Required:
Lists and descriptions of Special Service Tools (SSTs) needed for specific repairs, although many can be substituted with common tools.
Diagnostic Trouble Codes:
Likely includes a section on OBD-II diagnostic trouble codes (DTCs) for models equipped with the system, with descriptions and troubleshooting steps.
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type used. Consult manual for exact specification.
Air Filter Replacement:
Recommended every 20,000-40,000 km or as needed based on inspection.
Spark Plug Replacement:
Intervals vary by spark plug type (standard vs. platinum/iridium), typically ranging from 30,000 km to 100,000 km. Consult manual for correct type and interval.
Timing Belt Replacement:
Crucial for engines with timing belts (like the HCE-J). Intervals are typically around 100,000 km. The K3-VE engine uses a timing chain, which generally requires less frequent maintenance but should still be inspected.
Engine Oil Grade:
Likely API SF/SG or higher, with viscosity grades like 5W-30, 10W-30, or 10W-40 depending on climate. Manual will specify exact grade and capacity.
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Manual will specify capacity and type (e.g., Toyota Super Long Life Coolant or equivalent).
Transmission Fluid Manual:
Manual transmission fluid, likely GL-4 specification, 75W-85 or similar. Capacity around 2.0-2.5 liters.
Transmission Fluid Automatic:
ATF Dexron II or III compatible fluid. Capacity around 5.0-6.0 liters for a drain and refill. Manual will specify exact type and capacity.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Engine Minor Issues:
Potential for minor oil leaks from valve cover or oil pan gaskets over time. Some early models might experience slightly rough idling if sensors are dirty.
Suspension Wear:
As a compact SUV that might be used off-road, suspension components like bushings, ball joints, and tie rod ends can experience wear and require periodic inspection and replacement.
Exhaust System Corrosion:
Depending on climate and road salt usage, the exhaust system can be susceptible to rust and corrosion over time.
Electrical Corrosion:
Connections in the wiring harness, especially in humid or coastal environments, can sometimes corrode, leading to intermittent electrical issues.