Toyota HILUX 1993 Betriebsanleitung

INTRODUCTION

–INTRODUCTION IN–1

HOW TO USE THIS MANUAL

INDEX

An INDEX is provided on the first page of each section to guide you to the item to be repaired.

To assist you in finding your way through the manual, the Section Title and major heading are

given at the top of every page.

GENERAL DESCRIPTION

At the beginning of each section, a General Description is given that pertains to all repair

operations contained in that section.

Read these precautions before starting any repair task.

TROUBLESHOOTING

TROUBLESHOOTING tables are included for each system to help you diagnose the problem and

find the cause.

PREPARATION

Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and

SSM (Special Service Materials) which should be prepared before beginning the operation and

explains the purpose of each one.

REPAIR PROCEDURES

Most repair operations begin with an overview illustration. It identifies the components and

shows how the parts fit together.

Example:

–INTRODUCTION HOW TO USE THIS MANUAL

IN–2

The procedures are presented in a step–by–step format:

Example:

•The illustration shows what to do and where to do it.

•The task heading tells what to do.

•The detailed text tells how to perform the task and gives other information such as

specifications and warnings.

SPECIFICATIONS

Specifications are presented in bold type throughout the text where needed. You never have to

leave the procedure to look up your specifications. They are also found at the end of each section,

for quick reference.

This format provides the experienced technician with a FAST TRACK to the information needed.

The upper case task heading can be read at a glance when necessary, and the text below it

provides detailed information. Important specifications and warnings always stand out in bold

type.

REFERENCES

References have been kept to a minimum. However, when they are required you are given the

page to refer to.

–INTRODUCTION HOW TO USE THIS MANUAL IN–3

CAUTIONS, NOTICES, HINTS:

•CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or

other people.

•NOTICES are also presented in bold type, and indicate the possibility of damage to the

components being repaired.

•HINTS are separated from the text but do not appear in bold. They provide additional

information to help you perform the repair efficiently.

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is stamped on the

vehicle identification number plate and certification

label.

A. Vehicle Identification Number Plate

B. Certification Label

The UNITS given in this manual are primarily expressed according to the SI UNIT(Internationai

System of Unit), and alternately expressed in the metric system and in the English System.

Example:

Torque: 30 N–m (310 kgf–cm, 22 ft–lbf)

ENGINE SERIAL NUMBER

The engine serial number is stamped on the engine

block as shown.

SI UNIT

–INTRODUCTION IDENTIFICATION INFORMATION

IN–4

GENERAL REPAIR INSTRUCTIONS

1. Use fender, seat and floor covers to keep the vehicle

clean and prevent damage.

2. During disassembly, keep parts in the appropriate

order to facilitate reassembly.

3. Observe the following:

(a) Before performing electrical work, disconnect.

the negative cable from the battery terminal.

(b) If it is necessary to disconnect the battery for

inspection or repair, always disconnect the cable

from the negative (–) terminal which is grounded

to the vehicle body.

loosen the terminal nut and raise the cable str–

aight up without twisting or prying it.

(d) Cleah the battery terminal posts and cable ter–

minals with a clean shop rag. Do not scrape them

with a file or other abrasive objects.

(e) Install the cable terminal to the battery post with

the nut loose, and tighten the nut after installa–

tion. Do not use a hammer to tap the terminal

onto the post.

(f) Be sure the cover for the positive (+) terminal is

properly in place.

4. Check hose and wiring connectors to make sure that

they are secure and correct.

5. Non–reusable parts

(a) Always replace cotter pins, gaskets, 0– rings and

oil seals etc. with new ones.

(b) Non–reusable parts are indicated in the com–

ponent illustrations by the“♦” symbol.

6. Precoated parts

Precoated parts are bolts and nuts, etc. that are

coated with a seal lock adhesive at the factory.

(a) If a precoated part is retightened, loosened or

caused to move in any way, it must be recoated

with the specified adhesive.

–INTRODUCTION GENERAL REPAIR INSTRUCTIONS IN–5

(b) When reusing precoated parts, clean off the old

adhesive and dry with compressed air. Then

apply the specified seal lock adhesive to the bolt,

nut or threads.

illustrations by the ”*” symbol.

7. When necessary, use a sealer on gaskets to prevent

leaks.

8. Carefully observe all specifications for bolt tightening

torques. Always use a torque wrench.

9. Use of special service tools (SST) and special service

materials (SSM) may be required, depending on the

nature of the repair. Be sure to use SST and SSM

where specified and follow the proper work proce–

dure. A list of SST and SSM can be found in the

preparation part at the front of each section in this

manual.

10. When replacing fuses, be sure the new fuse has the

correct amperage rating. DO NOT exceed the rating or

use one with a lower rating.

MEDIUM CURRENT FUSE

HIGH CURRENT FUSE

CIRCUIT BREAKER

FUSIBLE L!1VK

Abbreviation

Illustration Part Name

Symbol

M–FUSE

H–FUSE

FUSE

–INTRODUCTION GENERAL REPAIR INSTRUCTIONS

IN–6

(b) To disconnect vacuum hoses, pull on the end, not

the middle of the hose.

connector itself, not the wires.

(d) Be careful not to drop electrical components,

such as sensors or relays. If they are dropped on

a hard floor, they should be replaced and not

reused.

(e) When steam cleaning an engine, protect the

distributor, air filter, and VCV from water.

(f) Never use an impact wrench to remove or install

temperature switches or temperature sensors.

(g) When checking continuity at the wire connector,

insert the tester probe carefully to prevent ter–

minals from bending.

(h) When using a vacuum gauge, never force the

hose onto a connector that is too large. Use a

step–down adapter instead. Once the hose has

been stretched, it may leak.

11. Care must be taken when jacking up and supporting

the vehicle. Be sure to lift and support the vehicle at

the proper locations (See page IN–9).

(a) If the vehicle is to be jacked up only at the front

or rear end, be sure to block the wheels at the

opposite end in order to ensure safety.

(6) After the vehicle is jacked up, be sure to support

it on stands. It is extremely dangerous to do any

work on a vehicle raised on a jack alone, even for

a small job that can be finished quickly.

12. Observe the following precautions to avoid damage to

the parts:

(a) Do not open the cover or case of the ECU, ECM,

PCM or TCM unless absolutely necessary. (If the

IC terminals are touched, the IC may be destr–

oyed by static electricity.)

13. Tag hoses before disconnecting them:

(a) When disconnecting vacuum hoses, use tags to

identify how they should be reconnected.

(b) After completing a job, double check that the

vacuum hoses are properly connected. A label

under the hood shows the proper layout.

–INTRODUCTION GENERAL REPAIR INSTRUCTIONS IN–7

PRECAUTION

FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER

CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create

a fire hazard. To prevent this, observe the following precautions and explain them to your customer.

1. Use only unleaded gasoline.

2. Avoid prolonged idling.

Avoid running the engine at idle speed for more than 20 minutes.

3. Avoid spark jump test.

(a) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.

(b) While testing, never race the engine.

4. Avoid prolonged engine compression measurement.

Engine compression tests must be done as rapidly as possible.

5. Do not run engine when fuel tank is nearly empty.

This may cause the engine to misfire and create an extra load on the converter.

6. Avoid coasting with ignition turned off and prolonged braking.

7. Do not dispose of used catalyst along with parts contaminated with gasoline or oil.

IN=–01

FOR VEHICLES WITH AN AUDIO SYSTEM

WITH BUILT–IN ANTI–THEFT SYSTEM

Audio System displaying the sign ”ANTI –THEFT

SYSTEM” shown on the left has a built–in anti–theft

system which makes the audio system soundless if

stolen.

If the power source for the audio system is cut even

once, the anti–theft system operates so that even if

the power source is reconnected, the audio system

will not produce any sound unless the ID number

selected by the customer is input again. Accordingly,

when performing repairs on vehicles equipped with

this system, before disconnecting the battery termi–

nals or removing the audio system the customer

should be asked for the ID number so that the tech–

nician can input the ID number afterwards, or else a

request made to the customer to input the ID number.

For the method to input the ID number or cancel the

anti–theft system, refer to the Owner’s Manual.

–INTRODUCTION PRECAUTION

IN–8

VEHICLE LIFT AND SUPPORT LOCATIONS

–INTRODUCTION VEHICLE LIFT AND SUPPORT LOCATIONS IN–9

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