Hilux 2015 2018 manual general information thong tin chung

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MAINTENANCE BRAKE GENERAL MAINTENANCE

PROCEDURE

HINT:

Work in a well-lighted area Turn the front wheels fully to the right or left before beginning the inspection

1.INSPECT BRAKE PEDAL AND PARKING BRAKE

Inspect the brake pedal and parking brake

a.

2.INSPECT BRAKE LINE PIPES AND HOSES

Using a mirror, check the entire circumference and length of the brake lines and hoses for:

a.

Damage

·Wear

·Deformation

·Cracks

·Corrosion

·Leaks

·Bends

·Twists

3.INSPECT BRAKE PADS AND DISCS

Check the front brake pads and discs

a.

for 4WD and

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for 16 inch Front Disc

4.INSPECT BRAKE LININGS AND DRUMS

Check the rear brake linings and drums

5.INSPECT BRAKE FLUID

Inspect the brake fluid

6.REPLACE BRAKE FLUID

Replace the brake fluid

7.INSPECT VACUUM PUMP

Inspect the vacuum pump

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MAINTENANCE CHASSIS GENERAL MAINTENANCE

PROCEDURE

1.INSPECT CLUTCH FLUID

Inspect the clutch fluid

Click hereDrivetrain>CLUTCH>CLUTCH SYSTEM>BLEEDING

a.

2.INSPECT POWER STEERING FLUID

Inspect the power steering fluid

Click hereSteering>POWER ASSIST SYSTEMS>POWER STEERING SYSTEM>ON-VEHICLE INSPECTION

a.

3.INSPECT STEERING LINKAGE AND GEAR HOUSING

Check the steering wheel free play

4.LUBRICATE PROPELLER SHAFT AND TIGHTEN BOLTS (for TMT Made)

Lubricate the propeller shaft by referring to the lubrication chart Before pumping in grease, wipe off any

mud and dust on the grease fitting

a.

Tighten the bolts of the propeller shaft

b.

5.LUBRICATE PROPELLER SHAFT AND TIGHTEN BOLTS (for TSAM Made)

Lubricate the propeller shaft by referring to the lubrication chart Before pumping in grease, wipe off any

mud and dust on the grease fitting

a.

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Tighten the bolts of the propeller shaft

b.

6.INSPECT DRIVE SHAFT BOOTS

Check the drive shaft boots for loose clamps, grease leakage, kinks or damage

a.

7.INSPECT BALL JOINTS AND DUST COVERS

Inspect the ball joints for excessive looseness

Using a lever, pry up the end of the lower arm Check the amount of play

Maximum ball joint vertical play:

8.INSPECT MANUAL TRANSMISSION OIL

Visually check the transmission for fluid leaks If fluid is leaking, find the cause and repair it

9.REPLACE MANUAL TRANSMISSION OIL

Replace the manual transmission fluid

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10.INSPECT AUTOMATIC TRANSMISSION FLUID

Visually check the transmission for fluid leaks If fluid is leaking, find the cause and repair it

a.

11.REPLACE AUTOMATIC TRANSMISSION FLUID

Replace the automatic transmission fluid

13.INSPECT TRANSFER OIL

Visually check the transfer for fluid leaks If fluid is leaking, find the cause and repair it

a.

Inspect the transfer oil

Click hereDrivetrain>VF2CM TRANSFER / 4WD / AWD>TRANSFER OIL>ON-VEHICLE INSPECTION

b.

14.REPLACE TRANSFER OIL

Replace the transfer oil

Click hereDrivetrain>VF2CM TRANSFER / 4WD / AWD>TRANSFER OIL>REPLACEMENT

a.

15.INSPECT FRONT DIFFERENTIAL OIL

Visually check the differentia for fluid leaks If fluid is leaking, find the cause and repair it

a.

Inspect the front differential oil

Click hereDrivetrain>AXLE AND DIFFERENTIAL>DIFFERENTIAL OIL>REPLACEMENT

b.

16.REPLACE FRONT DIFFERENTIAL OIL

Replace the front differential oil

a.

17.INSPECT REAR DIFFERENTIAL OIL

Visually check the differentia for fluid leaks If fluid is leaking, find the cause and repair it

a.

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18.REPLACE REAR DIFFERENTIAL OIL

Replace the rear differential oil

a.

19.INSPECT FRONT AND REAR SUSPENSION

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MAINTENANCE BODY GENERAL MAINTENANCE

PROCEDURE

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>ON-VEHICLE INSPECTION

1.TIGHTEN BOLTS AND NUTS

Tighten the bolts and nuts on the chassis parts listed below, if necessary

a.

Front axle and suspension

·Drivetrain

·Rear axle and suspension

·Brake system

·Engine mounting

·Other chassis parts

·Doors and hood

·Body mountings

·Fuel tank

·Exhaust pipe system

·Other body parts

·

Check the tires for wear and proper inflation pressure

Click hereSuspension>TIRE / WHEEL>TIRE AND WHEEL SYSTEM>INSPECTION

a.

3.INSPECT LIGHTS, HORN, WIPERS AND WASHERS

4.CLEAN OR REPLACE AIR CONDITIONING FILTER

Remove the air conditioning filter

Click hereVehicle Interior>HEATING / AIR CONDITIONING>AIR CONDITIONING FILTER>REMOVAL

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Check that the brakes work properly and do not drag

·Front doors

ii.

Door locks operate properly

·Doors close properly

·Rear doors

iii.

·Doors close properly

·Tail gate

iv.

·Seats

v.

Seat adjusts easily and locks securely in any position

·Front seatbacks lock securely in any position

·Fold-down rear seatbacks lock securely

·All switches and knobs

·Door handles

·Seats

·

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MAINTENANCE ENGINE GENERAL MAINTENANCE

CAUTION / NOTICE / HINT

1.INSPECT TIMING BELT (for 1KD-FTV, 2KD-FTV)

2.REPLACE TIMING BELT

3.INSPECT TIMING BELT PULLEY (for 1KD-FTV, 2KD-FTV)

4.CLEAN TIMING BELT COVER (for 1KD-FTV, 2KD-FTV)

Remove the timing belt cover

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5.INSPECT VALVE CLEARANCE

6.INSPECT DRIVE BELT

7.REPLACE DRIVE BELT (for 5L-E)

Replace the drive belt

Click hereEngine / Hybrid System>5L-E ENGINE MECHANICAL>DRIVE BELT>REMOVAL

a.

8.REPLACE ENGINE OIL AND OIL FILTER

9.INSPECT COOLING AND HEATER SYSTEM

Check that the radiator, condenser and/or intercooler is not blocked with leaves, dirt or insects, and clean

them if necessary Also check the hose connection for the installation condition, corrosion, etc

a.

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10.INSPECT ENGINE COOLANT

11.REPLACE ENGINE COOLANT

12.INSPECT ENGINE OIL COOLER HOSES AND CONNECTIONS (for 1GR-FE)

Check the oil cooler hoses for cracks, leakage, loose connections and deformation

a.

13.INSPECT EXHAUST PIPES AND MOUNTINGS

Visually check the pipes, hangers and connections for severe corrosion, leaks or damage

15.REPLACE SPARK PLUGS

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16.INSPECT BATTERY ELECTROLYTE LEVEL

17.INSPECT WATER SEDIMENT ACCUMULATOR

18.REPLACE FUEL FILTER

19.INSPECT AIR CLEANER FILTER

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20.INSPECT FUEL TANK CAP GASKET

21.INSPECT FUEL LINES, FUEL LINE CONNECTIONS, FUEL TANK VAPOR VENT SYSTEM HOSES

AND FUEL TANK BAND

Visually check the fuel lines and hoses for cracks, leakage, loose connections and deformation Also,

visually check the tank band for looseness

a.

22.INSPECT CHARCOAL CANISTER

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MAINTENANCE INSIDE VEHICLE GENERAL MAINTENANCE

Performing the following maintenance checks on the vehicle is the owner's responsibility The owner may performthe maintenance or take the vehicle to a service center Check the parts of the vehicle described below on a dailybasis In most cases, special tools are not required It is recommended that the owner perform these checks Theprocedures for general maintenance are as follows

Determine the appropriate time to service the vehicle using either distance driven or time (months)

elapsed, whichever reaches the specification first

Check that the headlights, stop lights, taillights, turn signal lights and other lights illuminate or blink

properly Also, check that they have enough brightness

a.

3 WARNING LIGHTS AND BUZZERS

Check that all the warning lights and buzzers are working

6 WINDSHIELD WIPER AND WASHER

Check that the washers are aimed properly Also, check that the washer fluid hits the windshield in the

center of the operating range of each wiper

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8 REAR VIEW MIRROR

Check that the rear view mirror is securely mounted

*c Front Vertical Function

*d Rear Lifter Function

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Operate the power seat switches and check that the following functions work:

Sliding

·Reclining

·Front vertical

·Rear lifter

17 AUTOMATIC TRANSMISSION "PARK" MECHANISM

Check the lock release button of the shift lever for proper and smooth operation

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MAINTENANCE OUTSIDE VEHICLE GENERAL MAINTENANCE

PROCEDURE

Performing the following maintenance checks on the vehicle is the owner's responsibility The owner may

perform the maintenance or take the vehicle to a service center Check the parts of the vehicle described

below on a daily basis In most cases, special tools are not required It is recommended that the owner

perform these checks The procedures for general maintenance are as follows

Determine the appropriate time to service the vehicle using either distance driven or time (months)

elapsed, whichever reaches the specification first

5 WINDSHIELD WIPER BLADES

Check the blades for wear or cracks when they are unable to wipe the windshield clean Replace them if

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Check that all of the doors operate smoothly, and that all the latches lock securely

a.

When the engine hood primary latch is released, check that the engine hood secondary latch prevents thehood from opening

b.

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MAINTENANCE UNDER HOOD GENERAL MAINTENANCE

Determine the appropriate time to service the vehicle using either distance driven or time elapsed,

whichever reaches the specification first

2 WINDSHIELD WASHER FLUID

Check that there is sufficient fluid in the tank

a.

3 ENGINE COOLANT LEVEL

Check that the coolant level is between the "FULL" and "LOW" lines on the see-through reservoir

a.

4 RADIATOR AND HOSES

Check that the front of the radiator is clean and free of leaves, dirt and bugs

a.

Check the hoses for cracks, kinks, rotting or loose connections

b.

5 BATTERY ELECTROLYTE LEVEL

Check that the electrolyte level of all the battery cells is between the upper and lower lines on the case

HINT:

If the electrolyte level is difficult to see, lightly shake the vehicle

a.

6 BRAKE FLUID LEVEL

Check that the brake fluid levels are near the upper level line on the see-through reservoirs

a.

7 ENGINE DRIVE BELT

Check the drive belt for fraying, cracks, wear or oiliness

a.

8 ENGINE OIL LEVEL

Check the oil level on the dipstick with the engine stopped

a.

9 POWER STEERING FLUID LEVEL

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Check the level on the dipstick

a.

The level should be in the "HOT" or "COLD" range depending on the fluid temperature

b.

10 AUTOMATIC TRANSMISSION FLUID

Visually check the overflow plug and oil pan for fluid leaks or traces of fluid

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INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS ELECTRONIC CIRCUIT

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Do not damage the terminals by moving the inserted tester needle

Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside

of the connector Look for unlatched terminals, missing terminals, loose crimps or broken conductorwires Visually check for corrosion, metallic or foreign matter and water, and bent, rusted, overheated,contaminated or deformed terminals

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CONNECTOR TERMINAL REPAIR METHOD

*a Correct

*b Incorrect

If there is any foreign matter on the terminal, clean the contact point with compressed air or a cloth

Never rub the contact point using sandpaper as the plating may come off

i.

If there is abnormal contact pressure, replace the female terminal If the male terminal is gold-plated(gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-platedfemale terminal

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CHECK FOR OPEN CIRCUIT

replace the wire harness

For an open circuit in the wire harness in Fig 1, measure the resistance and voltage as follows:

Disconnect connectors A and C, and measure the resistance between the terminals of the connectors

Standard Resistance (Fig 2):

Connector Aterminal 1 -Connector Cterminal 1

Always 10 kΩ orhigherConnector A

terminal 2 Connector Cterminal 2

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connector A and terminal 1 of connector C

Disconnect connector B and measure the resistance between the terminals of the connectors

Connector Aterminal 1 -Connector B1terminal 1

Connector B2terminal 1 -Connector Cterminal 1

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CHECK FOR SHORT CIRCUIT

With each connector still connected, measure the voltage between body ground and the followingterminals (in this order): 1) terminal 1 of connector A, 2) terminal 1 of connector B, and 3) terminal 1

of connector C

Standard Voltage (Fig 4):

Tester Connection Condition Condition Specified

Connector Aterminal 1 -Body ground

Ignition

Connector Bterminal 1 -Body ground

Ignition

Connector Cterminal 1 -Body ground

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CHECK AND REPLACE ECU

NOTICE:

Check the resistance to body ground

Disconnect connectors A and C, and measure the resistance

HINT:

Measure the resistance while lightly shaking the wire harness vertically and horizontally

i.

Tester Connection Condition Condition Specified

Connector Aterminal 1 -

10 kΩ orhigher

If the results match the values specified above, a short circuit exists between terminal 1 ofconnector A and terminal 1 of connector C

Disconnect connector B and measure the resistance

10 kΩ orhigherConnector B2

terminal 1

If the results match the values specified above, a short circuit exists between terminal 1 ofconnector B2 and terminal 1 of connector C

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The connector should not be disconnected from the ECU Perform the inspection from the backside of theconnector on the wire harness side

·

When no measuring condition is specified, perform the inspection with the engine stopped and the

ignition switch ON

·

Check that the connectors are fully seated Check for loose, corroded or broken wires

·

First, check the ECU ground circuit If it is faulty, repair it If it is normal, the ECU could be faulty

Temporarily replace the ECU with a known good one and check if the problem symptoms occur If the

trouble symptoms disappear, replace the original ECU

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INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO PROCEED WITH

TROUBLESHOOTING

OPERATION FLOW

HINT:

Perform troubleshooting in accordance with the procedure below The following is an outline of basic

troubleshooting procedure Confirm the troubleshooting procedure for the circuit you are working on before

beginning troubleshooting

1.VEHICLE BROUGHT TO WORKSHOP

2.CUSTOMER PROBLEM ANALYSIS

3.INSPECT BATTERY VOLTAGE

4.SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK

DTC is not output Go to step 6

Find the output DTC in the DTC chart Look at the Trouble Area column for a list of potentially

malfunctioning circuits and/or parts

Result:

a.

Proceed to

Go to step 7

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6.PROBLEM SYMPTOMS CHART

7.CIRCUIT INSPECTION OR PARTS INSPECTION

8.ADJUST, REPAIR OR REPLACE

The diagnostic system in this vehicle has various functions

Find the problem symptoms in the problem symptoms table Look at the Suspected Area column for a list

of potentially malfunctioning circuits and/or parts

After the adjustment, repairs or replacement of components, confirm that the malfunction no longer exists

If the malfunction does not recur, perform a confirmation test under the same conditions and in the same

environment as when the malfunction first occurred

a.

END

b.

When troubleshooting, confirm that the problem symptoms have been accurately identified

Preconceptions should be discarded in order to make an accurate judgment To clearly understand whatthe problem symptoms are, it is extremely important to ask the customer about the problem and the

conditions at the time the malfunction occurred

Under what conditions? Driving conditions, weather conditions

The first function is the Diagnostic Trouble Code (DTC) check A DTC is a code stored in the ECU memorywhenever a malfunction in the signal circuits to the ECU occurs In a DTC check, DTCs stored by a

previous malfunction can be checked by a technician during troubleshooting

·

Another function is the Input Signal Check, which checks if the signals from various switches are sent tothe ECU correctly

By using these functions, the problem areas can be narrowed down and troubleshooting can be more

effective Diagnostic functions are incorporated in the following systems of this vehicle

·

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Check (Normal Mode)

DTC Check (Check Mode)

Freeze Frame Data

Check/Test Mode (Input Signal Check)

Data List Active Test Customize Parameter

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-AutomaticTransmissionSystem (AC60E, for1GR-FE)

-AutomaticTransmissionSystem (AC60E, for1GD-FTV)

-Automatic

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2GD-FTV)AutomaticTransmissionSystem (AC60E, for2TR-FE)

-AutomaticTransmissionSystem (AC60F, for1GR-FE)

-AutomaticTransmissionSystem (AC60F, for1GD-FTV)

-AutomaticTransmissionSystem (AC60F, for2GD-FTV)

-AutomaticTransmissionSystem (AC60F, for2TR-FE)

-Manual TransmissionSystem (RC60F /

-Touch Select 2-4and High-Low

-Differential System(w/ Differential

-Differential System(w/o Differential

-Rear View Monitor

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System (forNavigation ReceiverType)

-Immobiliser System(w/o Entry and Start

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1.DTC CHECK

2.MAKE A NOTE OF DTC DISPLAYED AND THEN CLEAR DTCs

-Seat Belt Warning

Air ConditioningSystem (forAutomatic AirConditioningSystem)

Air ConditioningSystem (for ManualAir ConditioningSystem)

-Air ConditioningSystem (for Manual

-Manual HeadlightBeam Level Control

-In the DTC check, it is very important to determine whether the problem indicated by the DTC either: 1)still occurs, or 2) occurred in the past but has returned to normal In addition, the DTC should be

compared to the problem symptom to see if they are related For this reason, DTCs should be checked

before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determinecurrent system conditions, as shown in the flowchart below

·

Never skip the DTC check Failing to check for DTCs, depending on the case, may result in unnecessary

troubleshooting for systems operating normally or lead to repairs not related to the problem Follow theprocedure listed in the flowchart in the correct order

·

The following flowchart shows how to proceed with troubleshooting using the DTC check Directions fromthe flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of eachproblem symptom

·

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The most difficult case in troubleshooting is when no problem symptoms occur In such a case, a thorough

problem analysis must be carried out A simulation of the same or similar conditions and environment in which

the problem occurred in the customer's vehicle should be carried out No matter how much skill or experience atechnician has, troubleshooting without confirming the problem symptoms will lead to important repairs being

overlooked and mistakes or delays

For example:

With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a

stationary vehicle or a vehicle with a warmed-up engine Vibration, heat or water penetration

(moisture) is difficult to reproduce The following symptom simulation tests are effective substitutes for the conditions and can be applied to a stationary vehicle Important points in the symptom

simulation test:

In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed First, narrow down the possible problem circuits according to the symptoms Then,

connect the tester and carry out the symptom simulation test, judging whether the circuit being

tested is defective or normal Also, confirm the problem symptoms at the same time Refer to

Problem Symptoms Table for each system to narrow down the possible causes.

To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.

DTCs are output PROBLEM INDICATED BYTROUBLESHOOT FOR

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VIBRATION METHOD: When a malfunction seems to occur as a result of vibration

*a Vibrate Slightly

*b Shake Slightly

PARTS OR SENSORSApply slight vibration with a finger to the part or sensor suspected to be the cause of the problem, andcheck whether the malfunction occurs

NOTICE:

Applying strong vibration to relays may open the relays

i.

CONNECTORSSlightly shake the connector vertically and horizontally

ii.

WIRE HARNESSSlightly shake the wire harness vertically and horizontally

Heat the component that is the possible cause of the malfunction with a hair dryer or similar device

Check if the malfunction occurs

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DIAGNOSTIC TROUBLE CODE CHART

Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the Diagnostic Trouble Code chart of

the appropriate section Use the chart to determine the trouble area and the proper inspection procedure A

description of each of the columns of the chart is shown in the table below

WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity

Link Indicates the page where the inspection procedurefor each circuit is to be found, or gives instruction

for checking and repairs

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PROBLEM SYMPTOMS TABLE

When no DTC is output but the problem still occurs, use the Problem Symptoms Table The suspected areas

(circuits or parts) for each problem symptom are shown in the table The suspected areas are listed in order of

probability A description of each of the table columns is shown in the following table

HINT:

In some cases, the problem is not detected by the diagnostic system even though a problem symptom occurs It

is possible that the problem occurs outside the detection range of the diagnostic system, or that the problem

occurs in a completely different system

PROBLEM SYMPTOMS TABLE

When no DTC is output but the problem still occurs, use the Problem Symptoms Table The suspected areas

(circuits or parts) for each problem symptom are shown in the table The suspected areas are listed in order of

probability A description of each of the table columns is shown in the following table

HINT:

In some cases, the problem is not detected by the diagnostic system even though a problem symptom occurs It

is possible that the problem occurs outside the detection range of the diagnostic system, or that the problem

occurs in a completely different system

Tiêu đề	Hilux 2015 2018 Manual General Information
Trường học	Toyota Motor Corporation
Chuyên ngành	Automotive Maintenance
Thể loại	manual
Năm xuất bản	2017
Thành phố	Toyota City

Định dạng
Số trang	502
Dung lượng	11,74 MB
File đính kèm	Hilux 2015-2018 Manual_Thong tin chung.zip (10 MB)