2004 Toyota Hilux Service & Repair Manual

010YM−06 N17080 Filler Cap Float Reservoir Tank z Grommet Clip Slotted Spring Pin : Specified torque z Non−reusable part Cylinder Piston Push Rod Washer Snap Ring Boot z Gasket Lock Nut Clevis Pin Clevis N·m (kgf·cm, ft·lbf) 12 (120, 9) 15 (155, 11) − INTRODUCTION HOW TO USE THIS MANUAL 01−1 1 Author: Date: HILUX REPAIR MANUAL (Argentina) (DR201E) HOW TO USE THIS MANUAL GENERAL INFORMATION 1. GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (1) Diagnosis (2) Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting (3) Final Inspection (b) This manual explains (1) (see ”Diagnostics” section) and (2). (3) is omitted. (c) The following procedures are omitted from this manual. However, these procedures must be performed. (1) Use a jack or lift to perform operations (2) Clean all removed parts (3) Perform a visual check 2. INDEX (a) An alphabetical INDEX section is provided at the end of this manual as a reference to help you find the item to be repaired. 3. PREPARATION (a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is located in the ”Preparation” section of this manual. 4. REPAIR PROCEDURES (a) A component illustration is placed under the title where necessary. (b) Non−reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. Example:

Illustration: what to do and where Component part No. Explanation text: how to perform task Task heading: what you will be doing Set part No. INSTALL FRONT AXLE HUB BEARING D32545 01−2 − INTRODUCTION HOW TO USE THIS MANUAL 2 Author: Date: HILUX REPAIR MANUAL (Argentina) (DR201E) (c) Torque specifications, grease application areas and non−reusable parts are also emphasized in the procedures. HINT: There are cases where such information can only be explained by using an illustration. In these cases, torque, oil and other information are described in the illustration. (d) Only items with key points are described in the text. What to do and other details are explained using illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. (e) Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be differ- ent from the actual vehicle. (f) Procedures are presented in a step−by−step format: (1) The illustration shows what to do and where to do it. (2) The task heading briefly describes what work will be performed. (3) The explanation text tells how to perform the task. It also has information such as specifications and warnings, which are written in boldface text. Example: 5. SERVICE SPECIFICATIONS (a) SPECIFICATIONS are presented in boldface text throughout this manual. The specifications are also found in the ”Service Specifications” section for reference. 6. TERM DEFINITIONS CAUTION Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs. 7. INTERNATIONAL SYSTEM OF UNITS (a) The units used in this manual comply with the International System of Units (SI) standard. Units from the metric system and the English system are also provided. Example: Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)

0111P−01 D33376 1 2 3 4 5 6 01−4 − INTRODUCTION REPAIR INSTRUCTION 4 Author: Date: HILUX REPAIR MANUAL (Argentina) (DR201E) REPAIR INSTRUCTION PRECAUTION 1. BASIC REPAIR HINTS (a) HINTS ON OPERATIONS 1 Attire S Always wear a clean uniform. S Hat and safety shoes must be worn. 2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. 3 Safe operation S When working with 2 or more persons, be sure to check safety for one another. S When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. S If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. S When jacking up the vehicle, be sure to support the specified location with a safety stand. S When lifting up the vehicle, use appropriate safety equipment. 4 Preparation of tools and measuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly and assembly operations S Diagnose with a thorough understanding of proper procedures and of the reported problem. S Before removing the parts, check the general condition of the assembly and for deformation and damage. S When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed. S Clean and wash the removed parts if necessary and assemble them after a thorough check. 6 Removed parts S Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts. S For non−reusable parts such as gaskets, O−rings, and self−locking nuts, replace them with new ones as instructed in this manual. S Retain the removed parts for customer inspection, if requested.

Z11554 Seal Lock Adhesive − INTRODUCTION REPAIR INSTRUCTION 01−5 5 Author: Date: HILUX REPAIR MANUAL (Argentina) (DR201E) (b) JACKING UP AND SUPPORTING VEHICLE (1) 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 01−16). (c) PRECOATED PARTS (1) Precoated parts are bolts and nuts that are coated with seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive. (3) When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part. (4) Some seal lock adhesives harden slowly. You may have to wait for the seal lock adhesives to harden. (d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks. (e) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always use a torque wrench.

V35007 INCORRECT CORRECT D25628 D25628 V35008 Illustration Symbol Part Name Abbreviation FUSE MEDIUM CURRENT FUSE HIGH CURRENT FUSE FUSIBLE LINK CIRCUIT BREAKER FUSE M−FUSE H−FUSE FL CB 01−6 − INTRODUCTION REPAIR INSTRUCTION 6 Author: Date: HILUX REPAIR MANUAL (Argentina) (DR201E) (f) FUSES (1) When inspecting a fuse, check that the wire of the fuse is not broken. (2) When replacing a fuse, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating.

D33976 Shape (Example) Removal/Installation Clip Remover Pliers Screwdriver Scraper Protective Tape Clip Protective Tape Remove clips from front or rear using a clip remover or pliers. Remove fasteners with a clip remover or screwdriver. Remove clips with a wide scraper to prevent panel damage. − INTRODUCTION REPAIR INSTRUCTION 01−7 7 Author: Date: HILUX REPAIR MANUAL (Argentina) (DR201E) (g) CLIPS (1) The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT: If clips are damaged during a procedure, always replace the damaged clip with a new clip.

D32182 Shape (Example) Removal/Installation Removal Installation Removal Installation Removal Installation Screwdriver Screwdriver Screwdriver Clip Remover Clip Remover Clip Remover Push Push Push Small Clip Remover Remove rivet by pushing the center pin through and prying out the rivet shell. Remove rivet by unscrewing the center pin and prying out the rivet shell. Remove rivet by prying out the pin and then prying out the rivet shell. 01−8 − INTRODUCTION REPAIR INSTRUCTION 8 Author: Date: HILUX REPAIR MANUAL (Argentina) (DR201E)

D31750 INCORRECT CORRECT D25064 L1 L2 L1 L2 D02612 L2 L1 L2 L1 D01201 − INTRODUCTION REPAIR INSTRUCTION 01−9 9 Author: Date: HILUX REPAIR MANUAL (Argentina) (DR201E) (h) REMOVAL AND INSTALLATION OF VACUUM HOSES (1) To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage. (2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected. (3) After completing any hose related repairs, double check that the vacuum hoses are properly con- nected. The label under the hood shows the proper layout. (4) When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, it may leak air. Use a step−down adapter if necessary. (i) TORQUE WHEN USING TORQUE WRENCH WITH EX- TENSION TOOL (1) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench. Formula: T’ = T x L2/(L1 + L2) T’ Reading of torque wrench {N⋅m (kgf⋅cm, ft⋅lbf )} T Torque {N⋅m (kgf⋅cm, ft⋅lbf )} L1 Length of SST or extension tool {cm (in.)} L2 Length of torque wrench {cm (in.)} NOTICE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque speci- fication in this manual, the actual torque will be excessive and parts will be damaged.

D30401 Mark 01−10 − INTRODUCTION REPAIR INSTRUCTION 10 Author: Date: HILUX REPAIR MANUAL (Argentina) (DR201E) 2. FOR VEHICLES EQUIPPED WITH SRS AIRBAG The HILUX is equipped with a Supplemental Restraint System (SRS). CAUTION: Failure to carry out the service operations in the correct sequence could cause the SRS to unexpect- edly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to oper- ate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following section carefully. (a) GENERAL NOTICE (1) As the malfunction symptoms of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery (see page 05−499). (2) Work must be started at least 90 seconds after the ignition switch is turned OFF and after the cable is disconnected from the negative (−) battery terminal. (The SRS is equipped with a backup power source. If work is started within 90 seconds after turn- ing the ignition switch OFF and disconnecting the cable from the negative (−) battery terminal, the SRS may deploy.) When the cable is disconnected from the negative (−) battery terminal, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio systems as before. CAUTION: Never use a backup power source (battery or other) to avoid erasing system memory. The backup power source may inadvertently power the SRS and cause it to deploy. (3) In minor collisions where the SRS does not deploy, the horn button assembly (see page 60−15), and front passenger airbag assembly (see page 60−28) should be inspected before fur- ther use of the vehicle. (4) Never use SRS parts from another vehicle. When replacing parts, use new parts. (5) Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensors during repairs. (6) Never disassemble and attempt to repair the airbag sensor assemblies, horn button assembly or front passenger airbag assembly. (7) Replace the airbag sensor assemblies, horn button assembly and front passenger airbag assembly if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present. (8) Do not directly expose the airbag sensor assemblies, horn button assembly or instrument panel to hot air or flames. (9) Use a voltmeter/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting electrical circuits. (10) Information labels are attached to the SRS components. Follow the instructions on the labels. (11) After work on the SRS is completed, check the SRS warning lamp (see page 05−493). (b) SPIRAL CABLE (in Combination Switch) (1) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other prob- lems may occur. Refer to page 60−25 for information about correct installation of the steering wheel.

D25096 CORRECT INCORRECT Z13950 NEVER USE AN OHMMETER ON AN AIRBAG − INTRODUCTION REPAIR INSTRUCTION 01−11 11 Author: Date: HILUX REPAIR MANUAL (Argentina) (DR201E) (c) HORN BUTTON ASSEMBLY (with Airbag) (1) Always place a removed or new horn button with the pad surface facing upward as shown in the illustration. Placing the horn button with the pad surface facing down could cause a serious accident if the airbag inflates. Also, do not place anything on top of the horn button. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. (3) Grease or detergents of any kind should not be applied to the steering wheel pad. (4) Store the horn button in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring. (6) When disposing of the vehicle or the horn button by itself, the airbag should be deployed using SST before disposal (see page 60−15). Activate the airbag in a safe place away from electrical noise. Example: (d) FRONT PASSENGER AIRBAG ASSEMBLY (1) Always place a removed or new airbag assembly with the airbag inflation direction facing upward as shown in the illustration. Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. (3) Grease or detergents of any kind should not be applied to the airbag assembly. (4) Store the airbag in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.

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2004 Toyota Hilux Service & Repair Manual

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