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Service Manuals
Service Manuals
As automobiles evolve, new systems and features
are incorporated in the new models
...

To inform the service personnel around the world of
the proper service procedures and new
technologies, TMC (TOYOTA Motor Corporation)
publishes various types of manuals
...

Repair manuals for the USA and Canada are published for every model, and for the automatic transmission
...

EWD (Electrical Wiring Diagram)
The EWD manuals include summaries of the wiring of the vehicles in diagrams, and is published for every model
...
It is published every year
...

SDS (Service Data Sheets)
Values (such as V- belt tension and valve clearance) that are frequently used during inspection and adjustment
are listed on a single sheet
...

Owner's Manuals
Written for the owners of Toyota vehicles, these manuals provide them with important information for ensuring the
proper operation of their vehicles
...

Others
To complement the aforementioned manuals, the following manuals are also published:
1
...
Fundamental Auto Body Repair Procedures
3
...
HFC134a Air-Conditioning Fundamentals and Repairs
5
...
Audio Components Service Manuals
7
...
Diagnosis Manuals
9
...
Service Bulletin
11
...

These parts undergo the strictest quality
inspections to ensure high quality and long service
life
...


(1/1)

Toyota Parts Numbers
To correctly identify the components of all vehicles,
a part number that consists of 10 or 12 digits of
alphanumeric characters is assigned to every part
...

* Published by Toyota's service parts administration
division
...

For example, a part number that starts with
81110 represents a part of a headlight
...

(-00)
The next 2 digits, which are included only when
needed, are used for classifying colors and
sizes
...
All part numbers can be looked up in
the parts catalogs
...
Refer to PARTS CATALOG GUIDE* for the
proper method for using the catalogs
...

Microfiche Parts Catalog
The Microfiche Parts Catalog comes in the form
of plastic sheets called "fiches"
...

Paper Parts Catalog
These catalog is published to the countries
excluding North America and Europe
...

-2-

(1/1)

Searching Parts Numbers
Information used for searching Parts Catalogs
To look up a telephone number in a telephone
directory, you will need to know beforehand the
name of the person or the address for the number
you are seeking
...

For example:
• Model code
• Body color code
• Trim code
• Transmission code
• Axle code
These pieces of vehicle information are indicated
on the nameplate or the certification regulation
label of the vehicle
...
Its contents vary according to the
destination of the vehicle
...
The repair manual shows the exact
location of the nameplate
...
A model code consists of
alphanumeric characters
...

Vehicles with the same model designation do not necessarily come with the same type of engine or total piston displacement
...

A frame number contains the basic model code and a serial number
...

Body Color Code
The exterior color of the vehicle is also represented by a code
...

Trim Code
The trim code represents the color of the vehicle interior
...

Transmission Code
The transmission code represents the type of transmission that is used in that particular vehicle
...

Axle Code
An axle code consists of alphanumeric characters that represents the following pieces of information:
-Diameter of the ring gear
-Gear ratio
-Number of pinions and presence of LSD (Limited Slip Differential)
Plant Name Code
The plant name code represents the name of the plant where the vehicle was manufactured
...

(2/4)

Numbers indicated on the vehicle
Frame number or VIN (Vehicle Identification
Number) is punched on the engine compartment or
chassis, etc
...
Refer to
the repair manuals because the punched locations
vary with the vehicle types
...

A VIN contains 17 digits consisting of WMI, VDS,
and VIS
...

The VIN is used in the following countries:
• The USA and Canada (including U
...
trust
territories)
• Europe (including French trust territories)
• Australia, NZ, Brazil, Hong Kong, Indonesia,
South Africa, etc
...


WMI World Manufacturer Identifier
VDS Vehicle Description Section
VIS Vehicle Indicator Section

Body type, Drive train etc
...


(4/4)

Vehicle Specification
Vehicle Specification
The vehicle specifications, which consist of vehicle
size, performance, and other pieces of information,
are included in the product brochure and NCF
(New Car Features) manuals, etc
...


(1/1)

-5-

Major Dimensions & Vehicle Weights
Major dimensions include these items as in the
diagram on the left
...
Luggage and occupants are
excluded
...

Interior Width
This is the maximum distance in the center of the interior
between the right and left doors
...


Gross vehicle weight
This is the weight of the vehicle to which the weight
of the riding capacity and the weight of the
designed maximum loading capacity have been
added
...

Front axle gross weight
This is the part of the gross vehicle weight that is
applied to the front axle
...
the rear axle
...


Rear axle gross weight
This is the part of the gross vehicle weight that is
applied to the rear axle
...

Ground Clearance
This is the distance from the ground surface to the lowest
portion of the vehicle in the gross vehicle weight condition
...

Front Overhang
This is the distance from the center of the front wheel axle to the
front end of the vehicle
...

Overall Length
This is the distance from the frontmost to the rearmost area of
the vehicle
...

Departure Angle
This is the angle that is formed by the road surface and a
hypothetical line (drawn between the bottom of the rear end of
the vehicle and the ground contact surface of the rear tire)
...
Maximum speed
This represents the vehicle's driving performance
...
The
measurement is indicated in km/h (mph) units
...
Fuel consumption rate
This represents the volume of fuel that the engine
consumes when the vehicle travels a given
distance
...
g
...
)
(2/4)

3
...


Distance of horizontal travel
Ascending height
Maximum grade
=

/

Example:
Where height (B = 20m), and distance (A = 100m),
20 / 100 = 0
...

HINT:

The vehicle may not be able to actually climb to the
maximum grade if the tires and the road surface
lack the proper amount of friction resistance
...
Minimum turning radius
This is the radius that is drawn between the center
of the rotation of the vehicle and the center of the
tire of the outermost wheel (or the outermost side
of the body), when the vehicle is turned slowly on a
paved road by turning the steering wheel all the
way to the right or left
...
Long-stroke engine
An engine in which the piston stroke is greater than
the cylinder bore
...
Square engine
An engine in which the cylinder bore and the piston
stroke are the same size
...
Short-stroke engine
An engine in which the piston stroke is smaller than
the cylinder bore
...

BDC (Bottom-Dead-Center)
The position of the piston in the cylinder when it
is at the lowest point
...
The total piston displacement is obtained by
multiplying the piston displacement of a cylinder by
the number of cylinders
...

Bore
Stroke
TDC (Top-Dead-Center)
BDC (Bottom-Dead-Center)
(2/5)

-8-

Compression ratio
This is the ratio in which the air-fuel mixture is
compressed by the piston
...

Compression ratio = (V1+V2)/V1
Combustion chamber volume
Cylinder volume
(Piston displacement)
TDC (Top-Dead-Center)
BDC (Bottom-Dead-Center)
(3/5)

Engine torque
The engine torque represents the power that
rotates the crankshaft
...
11355 kgf
1 kgf = 9
...
Although kW is
the international unit, the units of HP and PS are
also used
...
Because the axial torque
decreases due to decrease the intake efficiency
that occurs at high speeds, the power output peaks
at a certain level
...

HINT:

The following values describe the relationship
between kW to HP and PS
...
3596 PS
(1 PS = 0
...
3410 HP
(1 HP = 0
...


The value that represents the power output of
the engine
There is no direct correspondence among the
values of these standards
...

Net power output
This value is obtained from an engine that is
actually installed on a vehicle
...

(1/1)

REFERENCE:
Driving performance curve
This curve renders the performance of the vehicle
equipped with the engine into a graphical form
...

The driving power and the vehicle speed
The connection between the driving power at
each gear position and vehicle speed while the
accelerator is fully applied
...


(1/1)

-10-

Exercise
Question-1
Mark each of the following statements True or False:
No
...


2

The total piston displacement is obtained by multiplying the
j
k
l
m
j
k
l
m True n False
displacement of the combustion chamber by the number of cylinders
...


4

The total piston displacement of the engine is obtained by
j
k
l
m
j
k
l
m True n False
multiplying the displacement of a cylinder by the number of cylinders
...


j
k
l
m
j
k
l
m
n True n False

j
k
l
m
j
k
l
m
n True n False

j
k
l
m
j
k
l
m
n True n False

Question-2
Which one of the following statements is true about the nameplate of a vehicle?

j
k
l
m
n 1
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j
k
l
m
n 2
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j
k
l
m
n 3
...

j
k
l
m
n 4
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Question-3
Which one of the following statements is true about the wheelbase?

j
k
l
m
n 1
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j
k
l
m
n 2
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j
k
l
m
n 3
...

j
k
l
m
n 4
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Question-4
From the word group indicated below, select the words that correspond to numbers 1 through 5

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