Toyota Hilux 2006 factory workshop and repair manual download
Toyota Hilux AN10, AN20 2005-2013 factory workshop and repair manual
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File size is large at 170 Mb with some PDF documents with bookmarks.
Covers the AN10, AN20 Toyota Hilux
Petrol/Gasoline engines:
2.0 L 1TR-FE
2.7 L 2TR-FE
4.0 L 1GR-FE V6
Diesel:
2.5 L 2KD-FTV turbodiesel
2.5 L 2KD-FTV intercooled turbodiesel
3.0 L 1KD-FTV intercooled VNT diesel
The camshaft position sensor (CMP sensor) is a vital component in a vehicle's engine management system. It helps determine the position of the camshaft, which in turn informs the engine control unit (ECU) about the timing of the intake and exhaust valves. This information is crucial for proper fuel injection and ignition timing, ensuring optimal engine performance.
#### Components of the Camshaft Position Sensor System
1. **Camshaft Position Sensor**:
- **Function**: Monitors the position of the camshaft.
- **Types**: Typically Hall effect or magnetic sensors.
- **Location**: Usually located near the camshaft pulley or at the top of the engine.
2. **Engine Control Unit (ECU)**:
- **Function**: The computer that processes information from the CMP sensor and other sensors to control the engine's functions.
- **Importance**: Ensures the engine runs efficiently and meets emissions standards.
3. **Wiring Harness**:
- **Function**: Connects the sensor to the ECU, transmitting the position data.
- **Components**: Wires and connectors that can wear out or corrode over time.
4. **Timing Components**:
- **Function**: Includes timing belts or chains that synchronize the camshaft and crankshaft.
- **Importance**: Proper timing is essential for the engine to function correctly.
#### Theory Behind the Repair
When the camshaft position sensor fails, the ECU may not receive accurate information about the camshaft's position. This can lead to several issues, including:
- **Poor Engine Performance**: Incorrect timing can cause misfires, reduced power, and poor acceleration.
- **Increased Emissions**: The engine may run rich or lean, leading to higher emissions.
- **Check Engine Light**: A faulty sensor can trigger diagnostic trouble codes (DTCs), illuminating the check engine light.
#### How the System Works
1. **Rotational Movement**: As the engine runs, the camshaft rotates. The camshaft position sensor detects this movement through a series of notches or teeth on the camshaft.
2. **Signal Generation**: The sensor generates an electrical signal (voltage) that corresponds to the camshaft's position. A Hall effect sensor produces a square wave signal, while a magnetic sensor creates a sine wave.
3. **Data Transmission**: The generated signal travels through the wiring harness to the ECU.
4. **ECU Processing**: The ECU interprets the signal to determine the camshaft's position, adjusting fuel injection and ignition timing accordingly.
#### What Can Go Wrong
1. **Sensor Failure**:
- **Symptoms**: Engine misfires, stalling, poor fuel economy.
- **Cause**: Wear and tear, exposure to heat, or physical damage.
3. **Timing Problems**:
- **Symptoms**: Rough idling, backfiring.
- **Cause**: A slipped timing belt or chain can throw off the sensor's readings.
#### Repair Process
1. **Diagnosis**:
- Use an OBD-II scanner to check for DTCs related to the CMP sensor.
- Inspect the sensor and wiring for visible damage.
2. **Removal**:
- Disconnect the battery to prevent electrical shorts.
- Remove the sensor by unscrewing it from its mounting location using appropriate tools (usually a socket or wrench).
3. **Installation of New Sensor**:
- Position the new sensor in place and secure it with screws.
- Reconnect the wiring harness.
4. **Testing**:
- Reconnect the battery and start the engine.
- Use the OBD-II scanner to ensure there are no new error codes and check for proper engine performance.
### Analogy
Think of the camshaft position sensor like a conductor in an orchestra. Just as a conductor ensures that all musicians play in harmony at the right time, the CMP sensor ensures that the engine's various components (like fuel injectors and spark plugs) work together in perfect timing. If the conductor is missing or out of sync, the music (or engine performance) will suffer.
### Conclusion
Understanding the camshaft position sensor is crucial for maintaining a Toyota Hilux's engine performance. By recognizing its components, functionality, and potential issues, you can effectively diagnose and repair problems related to this critical sensor. rteeqp73
### Understanding the Oil Pump in a Toyota Hilux
#### Theory Behind Oil Pump Repair
The oil pump is a vital component in your Toyota Hilux's engine. Its primary function is to circulate engine oil throughout the engine. This oil lubricates moving parts, reduces friction, cools the engine, and helps clean it by carrying away contaminants. If the oil pump fails, it can lead to inadequate lubrication, resulting in increased wear and tear on engine components, overheating, and potential engine failure.
### Components of the Oil Pump System
1. **Oil Pump**: The heart of the system, it pumps oil from the oil pan through the engine. It can be a gear-type or rotor-type pump.
2. **Oil Pan**: A reservoir at the bottom of the engine that holds the oil. It collects oil that drains from the engine after use.
3. **Oil Filter**: Removes contaminants from the oil before it circulates through the engine. It's crucial for maintaining oil quality.
4. **Oil Pickup Tube**: A tube that draws oil from the oil pan and delivers it to the oil pump.
5. **Oil Gallery**: Channels within the engine that distribute oil to various components like bearings, camshafts, and other moving parts.
6. **Pressure Relief Valve**: Prevents excessive pressure in the oil system by returning excess oil back to the oil pan.
7. **Oil Pressure Sending Unit**: Monitors oil pressure and sends the information to the dashboard gauge.
### How the System Works
1. **Oil Circulation**: The oil pump is driven by the engine (usually by a chain or belt). When the engine runs, the pump draws oil from the oil pan via the pickup tube.
2. **Pressurization**: The pump pressurizes the oil and sends it through the oil filter, where contaminants are removed.
3. **Distribution**: Once filtered, the oil travels through the oil gallery, reaching components that need lubrication.
4. **Pressure Regulation**: If the oil pressure exceeds a certain level, the pressure relief valve opens, redirecting excess oil back to the oil pan, preventing damage.
### Common Issues
1. **Oil Pump Failure**: Can be due to wear and tear, lack of lubrication, or contamination. Symptoms include low oil pressure, engine noise, or warning lights.
2. **Clogged Oil Filter**: A dirty filter can restrict oil flow, causing low oil pressure and potentially damaging the engine.
3. **Worn Oil Pump Gears**: Over time, the gears in the pump can wear out, leading to decreased efficiency and oil pressure.
4. **Oil Leaks**: Can occur at seals or gaskets, leading to low oil levels and insufficient lubrication.
### Repair Steps
1. **Gather Tools and Materials**:
- Socket set
- Torque wrench
- Oil filter wrench
- Clean rags
- New oil pump (if needed)
- New oil filter
- Engine oil
2. **Prepare the Vehicle**:
- Ensure the car is on a level surface, and disconnect the battery.
- Raise the vehicle with jack stands for better access.
3. **Drain the Oil**:
- Remove the oil drain plug and let old oil drain into a pan. Replace the plug afterward.
4. **Remove the Oil Pan**:
- Unbolt the oil pan from the engine block.
- Carefully detach it, ensuring you don’t damage the gasket.
5. **Access the Oil Pump**:
- Locate the oil pump. It’s usually mounted near the oil pan.
- Remove any bolts securing the pump and disconnect the oil pickup tube.
6. **Replace the Oil Pump**:
- Install the new oil pump by reversing the removal steps. Ensure the pump is aligned correctly.
- Torque the bolts to the manufacturer’s specifications.
7. **Reinstall the Oil Pan**:
- Clean the surface of the engine and the oil pan.
- Apply a new gasket or sealant, then bolt the oil pan back in place.
8. **Replace the Oil Filter**:
- Use an oil filter wrench to remove the old filter. Lubricate the rubber seal of the new filter with a bit of oil and install it.
9. **Add New Oil**:
- Fill the engine with new oil through the oil filler cap.
- Use the correct type and amount as specified in the owner’s manual.
10. **Reconnect the Battery and Start the Engine**:
- Check for leaks around the oil pump and oil filter.
- Monitor the oil pressure gauge and listen for any unusual noises.
### Conclusion
Replacing the oil pump in a Toyota Hilux is a straightforward process if you follow the steps carefully. By understanding the components and their functions, you can appreciate why maintaining the oil pump is crucial for engine health. Regular oil changes and monitoring oil levels can help prevent many issues related to the oil pump. rteeqp73