Powertrain:
Engine overhaul and rebuilding, timing belt replacement, engine performance tuning, fuel system diagnostics, cooling system service, exhaust system repair.
Drivetrain:
Transmission removal and installation, in-car transmission servicing, U-joint and CV-joint service procedures.
Chassis:
Brakes (servicing procedures, diagnostics), suspension system service, front-end alignment procedures and specifications, steering system.
Body And Interior:
Sunroof servicing, climate control (air conditioning service and capacities).
Electrical And Electronics:
Wiring diagrams, computer diagnostic trouble tree charts, troubleshooting and diagnostics, computer diagnostic codes.
Specific Procedures Engine:
Engine overhaul and rebuilding, cylinder head removal and installation, piston and connecting rod service, crankshaft service, lubrication system service, cooling system service, fuel system diagnostics and repair, emission control systems.
Maintenance:
Factory maintenance schedules and charts, routine checks, fluid changes, filter replacements.
Repair And Rebuild:
Complete engine overhaul and rebuilding, transmission repairs, brake system overhauls, suspension component replacements.
Diagnostics:
Trouble codes, computer diagnostic codes, troubleshooting guides, diagnostic trouble tree charts, engine performance analysis.
Level Of Detail:
Comprehensive, covering everything from basic maintenance to complete disassembly, rebuilding, and advanced diagnostics.
Illustrations And Diagrams:
Detailed illustrations, diagrams, wiring schematics, vacuum diagrams, serpentine belt routings with diagrams, hundreds of photos.
Torque Specifications:
Complete torque specifications for virtually every fastener in the vehicle, crucial for proper assembly and component longevity.
Vacuum Diagrams:
Vacuum routing diagrams for engine and emissions control systems, essential for diagnosing vacuum leaks and related performance issues.
Specific Procedures Drivetrain
Transmission:
Clutch inspection and replacement, manual transmission internal overhaul, automatic transmission internal overhaul, transfer case service, propeller shaft and differential service.
Specific Procedures Chassis
Brakes:
Brake disc and pad replacement, brake caliper service, brake shoe and drum service, brake line and hose replacement, parking brake adjustment, bleeding the brake system.
Suspension:
Front and rear suspension component inspection and replacement (shocks, struts, springs, control arms, ball joints), wheel bearing service, steering system overhaul, power steering system service.
Specific Procedures Electrical
Wiring Schematics:
Detailed wiring diagrams for engine control, body electrical, lighting, power windows, central locking, ignition, and charging systems.
Specific Procedures Diagnostics
Trouble Shooting:
Systematic troubleshooting guides for various symptoms, including engine performance issues, starting problems, electrical faults, and HVAC malfunctions.
Engine Options:
Covers all engines for the 2005-2011 Hilux. This typically includes: 2.5L D-4D Diesel (2KD-FTV), 3.0L D-4D Diesel (1KD-FTV), 2.7L VVT-i Petrol (2TR-FE), 4.0L VVT-i V6 Petrol (1GR-FE).
Engine Code Examples:
2KD-FTV (2.5L Turbo Diesel), 1KD-FTV (3.0L Turbo Diesel), 2TR-FE (2.7L VVT-i Petrol), 1GR-FE (4.0L VVT-i V6 Petrol).
Horsepower Range:
Varies by engine; for example, 2KD-FTV typically 102-120 HP, 1KD-FTV typically 163-171 HP, 2TR-FE typically 158 HP, 1GR-FE typically 236 HP.
Torque Range:
Varies by engine; for example, 2KD-FTV typically 200-260 Nm, 1KD-FTV typically 343-360 Nm, 2TR-FE typically 240 Nm, 1GR-FE typically 376 Nm.
Fuel Delivery:
Common Rail Direct Injection (Diesel), Electronic Fuel Injection (Petrol).
Firing Order:
Provided for all covered engines.
Timing Belt Servicing:
Detailed procedures for timing belt replacement where applicable (some engines may use chains).
Oil Change Interval:
Typically every 5,000-10,000 km or 6 months, depending on driving conditions and engine type (refer to manual for specifics).
Timing Belt Replacement Interval:
If applicable (some engines have chains), typically around 100,000-150,000 km or as specified in the manual.
Engine Oil:
API SG or higher; viscosity typically 5W-30 or 10W-30 for diesel, 5W-30 for petrol (refer to manual for exact specifications and capacities).
Transmission Fluid:
Manual transmission: GL-4 SAE 75W-90. Automatic transmission: ATF Type T-IV or equivalent (refer to manual for precise specifications and capacities).
Coolant:
Toyota Super Long Life Coolant (SLLC) or equivalent, typically a pink ethylene glycol-based coolant with organic acid technology (OAT).
Brake Fluid:
DOT 3 or DOT 4 brake fluid, depending on specific system requirements (refer to manual).
Differential Oil:
Hypoid gear oil, SAE 80W-90 GL-5 for rear differentials and manual front differentials (4WD models). Transfer case oil specification varies. Refer to manual.
Power Steering Fluid:
Toyota Genuine Power Steering Fluid or equivalent automatic transmission fluid (ATF) Type T-IV may be specified for some models. Confirm with manual.
Common Wear Items:
Clutch wear (manual transmissions), DPF regeneration issues (early diesel models under specific conditions), possible injector issues (diesel), suspension wear (especially under heavy use).
Electrical Quirks:
Generally robust, but older units may experience minor electrical connector issues or sensor failures over time.
