Toyota Hilux 2007 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
- **Socket Set**:
- **Description**: A collection of sockets in various sizes, typically 1/4", 3/8", and 1/2" drive.
- **Usage**: Used to remove bolts securing the alternator and any other components blocking access to the serpentine belt.
- **Ratchet Wrench**:
- **Description**: A tool that works with sockets to turn bolts.
- **Usage**: Attach the correct socket and use it to loosen and remove bolts.
- **Torque Wrench** (optional but recommended):
- **Description**: A wrench that measures the amount of torque applied when tightening bolts.
- **Usage**: Ensures bolts are tightened to the manufacturer’s specifications, preventing damage to components.
- **Belt Tensioner Tool or Breaker Bar**:
- **Description**: A long tool used to relieve tension on the serpentine belt.
- **Usage**: Use it to rotate the tensioner pulley to release belt tension for removal.
- **Pliers**:
- **Description**: A hand tool used for gripping and pulling.
- **Usage**: Helpful for removing any clips or fasteners that may be in the way.
- **Flashlight**:
- **Description**: A portable light source.
- **Usage**: Provides visibility in tight engine spaces.
### Procedure for Serpentine Belt Replacement
- **Safety First**:
- Ensure the engine is off and cool. Disconnect the negative battery terminal to prevent any electrical issues.
- **Locate the Serpentine Belt**:
- Find the belt under the hood. Refer to the engine diagram usually found on a sticker or in the owner’s manual.
- **Inspect the Existing Belt**:
- Check for wear, cracks, or fraying. If any damage is present, replacement is necessary to avoid belt failure.
- **Relieve Tension**:
- Use the belt tensioner tool or breaker bar:
- Locate the tensioner pulley.
- Insert the tool into the tensioner and rotate it clockwise or counterclockwise (depending on model) to relieve tension on the belt.
- **Remove the Old Belt**:
- With the tension relieved, slide the belt off the pulleys. Note the routing of the belt for reinstallation.
- **Inspect Other Components**:
- Check pulleys and tensioners for wear. If any pulleys are damaged or noisy, they should be replaced to ensure proper function and longevity of the new belt.
- **Install the New Serpentine Belt**:
- Refer to the routing diagram to correctly position the new belt on the pulleys.
- Ensure the belt is seated properly in the grooves of each pulley.
- **Reapply Tension**:
- Use the tensioner tool again to rotate the tensioner and slide the belt onto the last pulley. Release the tensioner to apply tension to the belt.
- **Reconnect Battery**:
- Reattach the negative battery terminal.
- **Start Engine**:
- Start the engine and observe the belt in operation to ensure it runs smoothly without noise or misalignment.
### Replacement Parts
- **Serpentine Belt**:
- If the existing belt shows signs of wear or damage, it must be replaced to ensure proper operation of engine accessories (alternator, power steering, etc.).
- **Idler Pulley/Tensioner**:
- If the pulley or tensioner shows signs of wear, those should also be replaced to prevent future issues.
### Additional Notes
- **Why Replacement is Necessary**:
- A worn or damaged serpentine belt can lead to loss of power steering, overheating, or battery drainage, as it drives multiple components in the engine.
- **Consult Manual**:
- Always refer to the vehicle’s service manual for specific instructions, torque specifications, and belt routing diagrams. rteeqp73