2009 toyota hilux service repair manual

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CAUTION This content does not include all the necessary items about repair and service. This content is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non-specialized or uncertified technicians perform repair or service only using this content or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer's vehicle. In order to prevent dangerous operation and damages to your customer's vehicle, be sure to follow the instruction shown below.

• Must read this content thoroughly. It is especially important to have a good understanding of all the contents shown in the PRECAUTION of INTRODUCTION.

• The service method shown in this content is very efective to perform repair and service. When performing the operations following the procedures using this content, be sure to use tools specified and recommended. If using non-specified or recommended tools and service method, be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer's vehicle before starting the operation.

• If part replacement is necessary, must replace the part with the same part number or equivalent part. Do not replace it with inferior quality.

• It is important to note that this content includes various 'Cautions' and 'Notices' that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that these 'Cautions' and 'Notices' are not exhaustive, because it is important to warn of all the possible hazardous consequences that might result from failure to follow these instructions. All information in this content is based on the latest product information at the time of release. However, specifications and procedures are subject to change without notice.

TOYOTA MOTOR CORPORATION

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HOW TO USE THIS MANUAL > GENERAL INFORMATION GENERAL DESCRIPTION a. This manual is written in accordance with SAE J2008. i. Diagnosis ii. Removing / Installing, Replacing, Disassembling / Reassembling, Checking and Adjusting iii. Final Inspection b. The following procedures are omitted from this manual. However, these procedures must be performed. i. Use a jack or lift to perform operations ii. Clean all removed parts iii. Perform a visual check

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.

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.

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.

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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.

SERVICE SPECIFICATIONS a. SPECIFICATIONS are presented in boldface text throughout the manual. The specifications are also found in the "Service Specifications" section for reference.

TERM DEFINITIONS CAUTION

Possibility of injury to you or other people.

NOTICE

Possibility of damage to components being repaired.

HINT

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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) standard. Units from the metric system and the English systems are also provided. Below is an example. Torque: 30 N*m{ 310 kgf*cm , 22 ft.*lbf }

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