Last Modified: 08-26-2024 6.11:8.1.0 Doc ID: RM100000000NCQG
Model Year Start: 2016 Model: Hilux Prod Date Range: [06/2015 - ]
Title: INTRODUCTION: HOW TO USE THIS MANUAL: GENERAL INFORMATION; 2016 - 2025 MY Hilux [06/2015 - ]
GENERAL INFORMATION
GENERAL DESCRIPTION
(a) Repair operations can be separated mainly into the following 3 processes:
(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 before and after performing any work.
INDEX
(a) An alphabetical INDEX section is provided at the end of the manual as a reference to help find the item to be repaired.
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 work procedure properly. A list of SST and
SSM is in the "Preparation" section of this manual.
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.
SYMBOL CONTENTS
Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping"
N*m (kgf*cm, ft.*lbf): Specified torque
● Non-reusable part
★ Precoated part
Apply Lubricant Here
Do not apply lubricants to the threaded parts
CAUTION:
"Major areas involving basic vehicle performance such as moving/turning/stopping" indicates areas that require a higher
degree of precision when tightening.
*A Example - -
*1 CYLINDER BOOT *2 PISTON SEAL
*3 FRONT DISC BRAKE PISTON *4 FRONT DISC BRAKE BLEEDER PLUG
*5
FRONT DISC BRAKE BLEEDER PLUG
CAP
*6 SET RING
*7 DISC BRAKE CYLINDER ASSEMBLY LH - -
Tightening torque for "Major areas
involving basic vehicle performance
such as moving/turning/stopping" :
N*m (kgf*cm, ft.*lbf)
N*m (kgf*cm, ft.*lbf): Specified
torque
● Non-reusable part Lithium soap base glycol grease
(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
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.
SERVICE SPECIFICATIONS
(a) Specifications are presented in boldface text throughout the manual. The specifications are also found in the
"Specifications" section for reference.
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.
INTERNATIONAL SYSTEM OF UNITS
(a) The units used in this manual comply with the International System of Units (SI UNIT) standard. Other units from the
metric system and English system are also provided.
Example:
Torque:
30 N·m {306 kgf·cm, 22 ft·lbf}
Last Modified: 08-26-2024 6.11:8.1.0 Doc ID: RM100000000NCQH
Model Year Start: 2016 Model: Hilux Prod Date Range: [06/2015 - 08/2017]
Title: INTRODUCTION: IDENTIFICATION INFORMATION: VEHICLE IDENTIFICATION AND SERIAL NUMBERS; 2016 - 2017 MY
Hilux [06/2015 - 08/2017]
VEHICLE IDENTIFICATION AND SERIAL NUMBERS
VEHICLE IDENTIFICATION NUMBER
(a) The vehicle identification number is stamped on the vehicle body and on the certification plate as shown in the
illustrations.
(1) Vehicle Body
(2) Certification Plate
(3) Identification Number Plate
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
*a Engine Serial Number
(2) Transmission Serial Number
*a Transmission Serial Number
Last Modified: 08-26-2024 6.11:8.1.0 Doc ID: RM1000000016MIX
Model Year Start: 2018 Model: Hilux Prod Date Range: [08/2017 - ]
Title: INTRODUCTION: IDENTIFICATION INFORMATION: VEHICLE IDENTIFICATION AND SERIAL NUMBERS; 2018 - 2025 MY
Hilux [08/2017 - ]
VEHICLE IDENTIFICATION AND SERIAL NUMBERS
VEHICLE IDENTIFICATION NUMBER
(a) The vehicle identification number is stamped on the vehicle body and on the certification plate as shown in the
illustrations.
(1) Vehicle Body
(2) Certification Plate
(3) Identification Number Plate
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
*A 2TR-FE *B 1GD-FTV
*a Engine Serial Number - -
(2) Transmission Serial Number
*A AC60F *B R151
*C RC61F - -
*a Transmission Serial Number - -
Last Modified: 08-26-2024 6.11:8.1.0 Doc ID: RM100000000NCQI
Model Year Start: 2016 Model: Hilux Prod Date Range: [06/2015 - 08/2017]
Title: INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION; 2016 - 2017 MY Hilux [06/2015 - 08/2017]
PRECAUTION
BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
1 Attire
Always wear a clean uniform.
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 any operation, prepare a tool stand, SST, necessary gauges, oil and any parts for
replacement.
5
Removal, installation,
disassembly and
assembly operations
Diagnose with a thorough understanding of proper procedures and of the reported
problem.
Before removing the 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 insure reassembly
of components in the 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 the removed parts in a separate box to avoid mixing them up with the new parts
or contaminating the 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.
*a Seal Lock Adhesive
(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 torque. Always use a torque wrench.
(2) Make sure that no foreign matter (burrs, paint, etc.) gets trapped under the heads of the bolts and nuts when
tightening them.
(f) FUSES
*a Incorrect
*b Correct
(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
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 a clip is damaged during a procedure, always replace the damaged clip with a new clip.
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2017 Toyota Hilux OEM Service & Repair Manual
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Description
2017 Toyota Hilux OEM Service & Repair Manual
Engines Covered:
- 2.8L 1GD-FTV (Turbo Diesel)
- 2.7L 2TR-FE (Gasoline)
- Includes 48V Mild Hybrid System
Transmissions Covered:
- AC60F 6-Speed Automatic
- R151 5-Speed Manual
- RC61F 6-Speed Manual
The 2017 Toyota Hilux OEM Service & Repair Manual is the official, in-depth documentation used by certified Toyota dealership technicians. This comprehensive guide provides complete, manufacturer-sourced procedures for the 8th generation Hilux, covering both the legendary 2.8L 1GD-FTV turbo-diesel and the reliable 2.7L 2TR-FE gasoline engine.
For any professional mechanic or owner working on this modern truck, this is the definitive resource. It contains the precise, step-by-step instructions needed to correctly diagnose, service, and overhaul every system on the vehicle, from the complex common-rail diesel and 48V hybrid system to the advanced electronic controls.
What’s Inside the 2017 Toyota Hilux Service & Repair Manual
General Information & Maintenance
Includes all fundamental vehicle data, diagnostic trouble code (DTC) indexes, and factory-recommended maintenance schedules required to keep your Hilux in peak working order.
Engine Service & Overhaul (Gasoline & Diesel)
Provides complete teardown and rebuild procedures for both the gasoline and turbo-diesel engines. Covers all aspects of engine mechanical service, cooling, lubrication, fuel, and emission control systems.
Hybrid & Power Source Systems
Crucial for modern service, this manual includes detailed diagnostics and procedures for the 48V Mild Hybrid system and the entire power source network.
Transmission, Drivetrain & 4WD
Detailed repair and overhaul instructions for all available transmissions (AC60F, R151, RC61F). Also includes full service information for the clutch, transfer case (VF2CM), and all 2WD/4WD driveline components.
Suspension, Steering & Brakes
Comprehensive service guides for all chassis components. Contains step-by-step instructions for servicing the suspension, steering system, and the complete ABS-equipped brake assembly.
Complete Electrical System with Wiring Diagrams
Features the full factory wiring diagrams for the vehicle. This section offers detailed schematics and diagnostic procedures for the entire electrical system, including the body control systems and all other modules.
Why Choose This OEM Manual?
For a modern truck with a common-rail diesel and a mild-hybrid system, generic guides are insufficient. This manual provides the proprietary diagnostic flowcharts, specific torque sequences, and detailed schematics that are absolutely essential for performing accurate and safe repairs.
Digital Format & Compatibility
Delivered as a high-resolution, fully searchable PDF, this manual works seamlessly on Windows, macOS, iOS, Android, and Linux systems. It is ideal for use on a workshop computer, tablet, or can be printed for hands-on reference right in the field.
Get Your Toyota Hilux Manual Today
Empower your workshop with the same data used by Toyota's own technicians. Whether you're diagnosing a D-4D fault or servicing the transmission, this is the ultimate resource for keeping your 2017 Hilux working hard.
Printable: Yes
Language: English
Compatibility: Windows, macOS, Linux, iOS, Android
Requirements: PDF Reader
