2009 Toyota Hilux Service & Repair Manual

Last Modified: 3-25-2019 6.8:8.0.48 Doc ID: RM000000UYV08CX Model Year Start: 2006 Model: Hilux Prod Date Range: [04/2005 - ] Title: INTRODUCTION: HOW TO USE THIS MANUAL: GENERAL INFORMATION; 2006 - 2011 MY Hilux [04/2005 - ] 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) 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 the 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 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. The following illustration is an example. (c) Torque specifications, grease application areas and non-reusable parts are 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. Illustration What to do and where to do it Task heading What work will be performed Explanation text How to perform the task Also has information such as specifications and warnings, which are written in boldface text (e) Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle. (f) Procedures are presented in a step-by-step format. 5. SERVICE SPECIFICATIONS (a) SPECIFICATIONS are presented in boldface text throughout the 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 English systems are also provided. The following is an example. Torque: 30 N·m {310 kgf·cm, 22ft·lbf}

Last Modified: 3-25-2019 6.8:8.0.48 Doc ID: RM000000UYW09SX Model Year Start: 2006 Model: Hilux Prod Date Range: [04/2005 - ] Title: INTRODUCTION: IDENTIFICATION INFORMATION: VEHICLE IDENTIFICATION AND SERIAL NUMBERS; 2006 - 2011 MY Hilux [04/2005 - ] VEHICLE IDENTIFICATION AND SERIAL NUMBERS 1. VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the vehicle body and on the certification label, as shown in the illustrations. (1) Vehicle Body (2) Certification Label 2. ENGINE SERIAL NUMBER AND TRANSMISSION SERIAL NUMBER (a) The engine serial number is stamped on the cylinder block of the engine and the transmission serial number is stamped on the housing as shown in the illustrations. (1) Engine Serial Number (2) Transmission Serial Number

Last Modified: 3-25-2019 6.8:8.0.48 Doc ID: RM000000UYX09YX Model Year Start: 2006 Model: Hilux Prod Date Range: [04/2005 - ] Title: INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION; 2006 - 2011 MY Hilux [04/2005 - ] PRECAUTION 1. BASIC REPAIR HINT (a) HINTS ON OPERATIONS 1 Attire Always wear a clean uniform. A 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 Use wheel chocks to secure the vehicle. When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. When removing or installing heavy parts, such as the engine, transmission, differential, etc., before starting work make sure there are no problems with the equipment that will be used. When working with 2 or more persons, be sure to check safety for one another. 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. 4 Preparation of tools and measuring gauge Before starting the operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly and assembly operations Diagnose with a thorough understanding of proper procedures and of the reported problem.

Before removing parts, check the general condition of the assembly and for deformation and damage. When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to ensure reassembly of components to their original positions. Temporarily mark hoses and their fittings if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check. 6 Removed parts Place removed parts in a separate box to avoid mixing them up with new parts or contaminating new parts. For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual. Retain the removed parts for customer inspection, if requested. 7* Checks to perform after work is finished Make sure that removed and installed parts (oil filler cap, level dipstick, floor mat, etc.) are properly installed/tightened. Make sure that none of the cloths or tools that were used have been left in the engine compartment or within the vehicle. Check that there are no oil leaks. CAUTION: *: Be sure to perform these checks properly. Not performing these checks properly after finishing work can lead to serious accident or injury. (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. (c) PRECOATED PARTS (1) Precoated parts are bolts and nuts that are coated with a 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 agents harden slowly. You may have to wait for the seal lock adhesive 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. (f) FUSES

(1) When inspecting a fuse, check that the wire of the fuse is not broken. (2) If the wire of a fuse is broken, confirm that there are no shorts in its circuit. (3) When a fuse is replaced, a fuse with the same amperage rating must be used. ILLUSTRATION SYMBOL PART NAME ABBREVIATION FUSE FUSE MEDIUM CURRENT FUSE M-FUSE HIGH CURRENT FUSE H-FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB (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 clips with new clips.

SHAPE (EXAMPLE) ILLUSTRATION PROCEDURES 1. Remove the clip with a clip remover or pliers. 1. Remove the clip with a clip remover or screwdriver. 1. Remove the clip with a wide scraper to prevent panel damage. 1. Remove the clip by pushing the center pin through and prying out the shell. 1. Remove the clip by unscrewing the center pin and prying out the shell. 1. Remove the clip by prying out the pin and then prying out the shell.

(h) CLAWS (1) The removal and installation methods of typical claws used for vehicle body parts are shown in the table below. HINT: If claws are damaged during a procedure, always replace the caps or covers with new ones. SHAPE (EXAMPLE) ILLUSTRATION PROCEDURES 1. Using a screwdriver, detach the claws and remove the cap or cover. 1. Using a screwdriver, detach the claws and remove the cap or cover. 1. Using a screwdriver, detach the claws and remove the cap or cover. (i) HINGE, GUIDE, CLAMP, PIN ETC. (1) The removal and installation methods of typical hinges, guides, clamps and pins used for vehicle body parts are shown in the table below. HINT: If clamps are damaged during a procedure, always replace the cap or cover that has damaged clamps with a new one. SHAPE (EXAMPLE) ILLUSTRATION PROCEDURES 1. Disengage the pins by pulling

SHAPE (EXAMPLE) ILLUSTRATION PROCEDURES 1. Disengage the pins by pulling. 1. Remove the clamps with pliers. 1. Disengage the pins by pulling. (j) 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 connected. 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.

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2009 Toyota Hilux Service & Repair Manual

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