Toyota Hilux 2013 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
- **Gather Necessary Tools and Parts:**
- **Wrench Set:** Used for loosening and tightening bolts. A set with both metric and imperial sizes is ideal.
- **Screwdriver Set:** Flathead and Phillips screwdrivers may be needed for various clamps and covers.
- **Pliers:** Useful for gripping and pulling hoses or clamps.
- **Fuel Line Disconnect Tool:** This specialized tool helps separate fuel lines from connectors without damaging them. Essential for safely removing the line.
- **Rags/Paper Towels:** For cleaning up any spilled fuel and for safety.
- **Safety Goggles and Gloves:** Protect your eyes and hands when working with fuel.
- **Safety Precautions:**
- Ensure the vehicle is parked on a flat surface and the engine is cool.
- Disconnect the negative battery terminal to prevent any electrical shorts.
- Work in a well-ventilated area to avoid inhaling fuel vapors.
- **Remove the Fuel Line:**
- Locate the fuel line on the Hilux. It typically runs from the fuel tank to the engine bay.
- Use the fuel line disconnect tool to gently detach the line from the fuel rail or fuel filter. Insert the tool into the connector and push to release.
- If the line is clamped, use a wrench or pliers to loosen hose clamps first.
- **Inspect the Fuel Line:**
- Check for any signs of wear, cracks, or leaks. A damaged fuel line will need to be replaced.
- If the line is cracked or leaking, it’s essential to replace it to prevent fuel leaks and potential fire hazards.
- **Replacement Part:**
- If replacement is necessary, purchase a new fuel line specific to your Toyota Hilux model.
- Ensure the replacement line matches the diameter and length of the original.
- **Install the New Fuel Line:**
- Position the new fuel line in place and connect it to the fuel rail or filter.
- If clamps are used, tighten them securely with a wrench or pliers.
- Double-check all connections to ensure they are secure to prevent leaks.
- **Final Checks:**
- Reconnect the negative battery terminal.
- Turn the ignition to the "on" position (without starting) to pressurize the fuel system. Check for leaks around the new fuel line.
- If no leaks are detected, start the engine and let it run for a few minutes while monitoring for any issues.
- **Dispose of Old Parts and Rags:**
- Properly dispose of any old fuel lines and rags used to clean up fuel. Check local regulations for hazardous waste disposal.
By following these steps and using the necessary tools, you can safely replace the fuel line on a Toyota Hilux. rteeqp73
- **Understanding the Crankshaft Position Sensor**:
- The crankshaft position sensor (CKP) monitors the position and rotational speed of the crankshaft. This information is crucial for engine timing, fuel injection, and ignition.
- **Tools Required**:
- **Basic Hand Tools**:
- **Socket Wrench Set**: Used to remove bolts securing the sensor. Look for metric sizes (usually 10mm or 12mm for Toyota).
- **Ratchet Extension**: Helpful for reaching bolts in tight spaces.
- **Screwdriver Set**: May be needed if clips or covers need to be removed.
- **Additional Tools**:
- **Torque Wrench**: Ensures that bolts are tightened to the manufacturer's specifications upon reinstallation. This prevents damage to the sensor or surrounding components.
- **Multimeter**: Used to test the sensor's electrical output if you suspect it’s faulty before replacing. This tool measures voltage and resistance.
- **Safety Equipment**:
- **Safety Goggles**: Protects your eyes from debris.
- **Gloves**: Protects your hands from sharp edges and hot components.
- **Replacement Part**:
- If the crankshaft position sensor is faulty (indicated by poor engine performance, stalling, or diagnostic trouble codes), it will need to be replaced.
- **Replacement Part**: Purchase a compatible CKP sensor for the Toyota Hilux. Ensure it matches the year and engine model of your vehicle.
- **Procedure for Replacement**:
- **Disconnect Battery**:
- Use a socket wrench to remove the negative battery terminal to prevent electrical shorts.
- **Locate the Sensor**:
- Usually found near the crankshaft pulley or on the engine block. Refer to the vehicle’s manual or online diagrams for exact location.
- **Remove the Old Sensor**:
- Use the socket wrench to remove the bolts securing the sensor.
- If applicable, disconnect any wiring harness clips carefully using a screwdriver or by hand.
- **Test the Old Sensor** (optional):
- Use a multimeter to check for continuity and voltage output as per the specifications in your vehicle’s service manual.
- **Install the New Sensor**:
- Align the new sensor in place and secure it with bolts. Use a torque wrench to tighten according to the specifications (usually found in the service manual).
- **Reconnect Wiring**:
- Ensure that the wiring harness clips are fitted securely.
- **Reconnect Battery**:
- Reattach the negative battery terminal with a socket wrench.
- **Test the Vehicle**:
- Start the engine to ensure it runs smoothly. Check for any warning lights on the dashboard.
- **Final Check**:
- If the engine runs properly and no error codes appear, the replacement was successful. If issues persist, further diagnostics may be needed.
By following these steps and using the mentioned tools, you should be able to replace the crankshaft position sensor on a Toyota Hilux effectively. rteeqp73
### Muffler Replacement on a Toyota Hilux
#### Theory Behind Muffler Replacement
The muffler is a crucial component of the exhaust system in your Toyota Hilux. Its primary purpose is to reduce the noise produced by the engine's exhaust gases and to help control emissions. Over time, mufflers can corrode, develop holes, or become clogged, leading to louder engine noise, reduced performance, and increased emissions.
**Analogy:** Think of the muffler as the silencer on a vacuum cleaner. Just as the silencer helps reduce the loud noise of the vacuum while still allowing air to flow through, the muffler does the same for your vehicle's exhaust gases.
#### Components of the Exhaust System
1. **Exhaust Manifold**: Collects exhaust gases from the engine.
2. **Catalytic Converter**: Reduces harmful emissions.
3. **Muffler**: Reduces noise and helps with exhaust flow.
4. **Exhaust Pipes**: Direct exhaust gases away from the vehicle.
5. **Tailpipe**: The last section that exits at the back of the vehicle.
#### Tools and Materials Needed
- New muffler (specific to Toyota Hilux)
- Wrenches (socket and open-end)
- Ratchet and extensions
- Screwdriver (flathead and Phillips)
- Exhaust clamps (if necessary)
- Jack and jack stands
- Safety goggles
- Gloves
- Penetrating oil (like WD-40)
- Wire brush (for cleaning)
#### Steps to Replace the Muffler
1. **Safety First**:
- Park your Hilux on a flat surface.
- Engage the parking brake.
- Wear safety goggles and gloves.
2. **Lift the Vehicle**:
- Use a jack to lift the rear of the vehicle and secure it with jack stands. Ensure it's stable.
3. **Locate the Muffler**:
- Follow the exhaust pipe from the catalytic converter to the rear of the vehicle. The muffler is typically located in the midsection of the exhaust system.
4. **Inspect and Prepare**:
- Look for rust or any damage. If the muffler is damaged, it needs replacement.
- Spray penetrating oil on the clamp bolts and hangers to loosen them easily.
5. **Remove the Old Muffler**:
- **Disconnect the Exhaust Clamps**: Use a wrench to remove the bolts from the clamps securing the muffler to the exhaust pipe.
- **Remove Hangers**: You may need to slide the muffler off the rubber hangers that hold it in place. If they're stuck, use a screwdriver to pry them off gently.
6. **Clean the Exhaust Pipe**:
- Use a wire brush to clean any rust or debris on the exhaust pipe where the new muffler will attach.
7. **Install the New Muffler**:
- Position the new muffler in place, ensuring it aligns with the exhaust pipe.
- Slide the muffler onto the exhaust pipe and secure it with the clamps.
- Reattach the rubber hangers by pushing them into place.
8. **Check for Proper Fit**:
- Ensure that the muffler is not touching any other parts of the vehicle and is hanging securely.
9. **Reconnect Everything**:
- Tighten the clamps securely but avoid over-tightening, which can damage the muffler.
10. **Lower the Vehicle**:
- Carefully remove the jack stands and lower the vehicle back to the ground.
11. **Test the System**:
- Start the engine and listen for any unusual noises. Check for leaks around the connections.
### What Can Go Wrong?
- **Incorrect Fit**: Using a muffler that isn’t specific to your Hilux can cause fitment issues.
- **Leaking Exhaust**: Poor connections or damaged gaskets can lead to exhaust leaks, affecting performance and emissions.
- **Corrosion**: If the exhaust system is rusty, other parts may fail soon after replacing the muffler.
- **Noise**: If installed incorrectly, the muffler may not reduce noise effectively.
#### Conclusion
Replacing the muffler on your Toyota Hilux can improve performance and reduce noise. Understanding the exhaust system and following these steps carefully will help you successfully complete the task. Always consult your vehicle's manual for specific details and torque specifications if needed. rteeqp73