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Toyota Hilux Vigo INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 06-11-2011

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INSTALLATION Assemble the Top Bracket to the air spring using the 3/8 UNF Flange Locknut. Screw in the elbow air fittings to the top of the airsprings. The use of thread sealant is recommended here. Using 3/8 UNC x 3/4″ Counter sunk bolts, attach the bottom brackets to the airsprings as shown, ensuring the brackets are orientated as shown. Tighten the bolts. (See torque figures below). Align the Top and Bottom bracket as shown in the photograph, ensuring that the flanges of the Upper Brackets are running in line with the flanges of the Lower Bracket. Bottom Right Top Right
3 Raise the rear of the vehicle and drop the back axle to allow as much space to work with as possible. Do not over stretch and brake lines or cables. Loosen the U-bolts on the leaf springs and remove the bump stops Compress the air spring assembly and hold it compressed using an Inflation valve as shown. Place the assembly between the chassis and leaf spring. Ensure that the air spring assembly is facing inboard (towards the centre of the vehicle). Slip the U-bolts over the Lower Brackets as shown. Attach the Upper Brackets to the chassis using the M8 Bolts with washers and Nyloc nuts. Tighten the Upper Brackets until the bracket has pulled in to rest against the upper part of the chassis on both sides.

TOYOTA 4RUNNER OLD MAN EMU SUSPENSION SYSTEMS

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Filed Under (Toyota Manuals) by admin on 05-11-2011

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FS REAR LEAF SPRING PRE 1990 & IFS REAR COILS SPRING 1990-95 FRONT STOCk/LIGHT LOAD TORSION N/A 1 3030031 NITROCHARGER SHOCk 2 N98 IFS REAR COIL SPRING MODELS 1990-95 REAR MEDIuM LOAD (0LBS TO GVW) SPRING 1.5″ 1 2900 NITROCHARGER SHOCk 2 N72F HEAVy LOAD (330LBS CONSTANT LOAD) SPRING 1.5″ 1 2901 NITROCHARGER SHOCk 2 N72F IFS REAR LEAF SPRING MODELS PRE 1990 REAR MEDIuM LOAD (0LBS TO GVW) SPRING 2.0″ 2 CS009R3 NITROCHARGER SHOCk 2 *N85/N92 HEAVy CONSTANT (440LBS TO GVW) SPRING 2.25″ 2 CS010R3 NITROCHARGER SHOCk 2 N85 REQ’D FOR INSTALLATION (LEAF SPRING- MODELS ONLy) REAR LEAF SPRING BuSHING kIT 2 OMESB6 u BOLTS 4 OMEu532 STEERING DAMPER 1 OMESD33 BuSHING SLEEVE 2 181469 OPTIONALGREASABLE SHACkLE kIT 1 OMEGS3 REAR EXTRA LEAF D5XL 1 2 3 4 a djust Front torsion bar For additional height aFter installing rear springs . s et ride height to 1/3 upper bump stop clearance and 2/3 lower bump stop clearance . i nstall oe caster wedges From oe spring pack onto ome springs . e nsure wedges are Fitted as per original position . c ompare original spring pack height to ome spring pack to determine whether omeu53 or omeu53b u bolts are required . e xtra leaF can be Fitted For heaVier constant load carrying ability .

Toyota IFS Ball Joint Spacer Installation

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Filed Under (Toyota Manuals) by admin on 04-11-2011

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Ball Joint Spacer Installation Put the spacer in place, NOTCH FACING DOWNWARD and, using a floor jack to control arm height, align the ball joint and install the hardware. The notch acts as a weep hole to let any water that gets in from above drain out to prevent the ball joint from rusting out. Tighten ball joint hardware to 25 ft.lb. or 35 N.m. Note: Apply this torque to the allen head bolt and the Grade 10.9 nut only, then install the 2nd nylon lock nut and tighten it down snugly in order to lock the first nut in place. No need to toque the nylon lock nut to 25 ft.lb. value, it may strip. If you wish, you can spray the exposed head and threads of the bolts with some paint, as the black oxide coated hardware may tend to rust over time. Extend the shock to see if it needs shimming. (it likely will) Place the appropriate number of washers to ensure the shock does not limit down travel. Tighten shock hardware. Repeat for other side. Re-install the wheels. If the end of the upper control arm is too close to the tire at this point, there are several options: You can try and grind off part of the outer lip of the control arm (area at the left edge of the red circle in the photo above) You can add a 1/4″ wheel spacer to move the wheel/tire away from the suspension. You can swap to a narrower tire, for example changing from a 33×12.50 to a 33×10.50 tire will move the inner edge of the tire away from the control arm since it’ll have less sidewall bulge on the same wheel. You can swap to a wheel with less back side spacing, for example going from a 4.75″ to a 4.5″ backspaced wheel will move the inner edge of the wheel and tire 1/4″ away from the control arm (stock wheels are ~4.75″ backspacing). Put the vehicle back on the ground. For low profile bump stops only: Shim them approx. 1/2″ with some washers or use stock bump stops. Failure to do so could result in damage to CV joints, shocks, or other components

1963-1983 TOYOTA FAST TRAC TOP INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 28-10-2011

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Step 1. Windshield Slot. Center Windshield slot (Item 1) from side to side on top of windshield frame. Mark and drill 1/8″ holes using windshield slot as a template. Secure with #10 x 1/2″ sheet metal screws (Item 2) through windshield slot, fender washer (Item 3) and into windshield frame. See figure 2. Step 2. Horizontal Rod Bracket. Place holes in horizontal rod bracket (Item 4) over holes on inside corner of windshield frame. Secure with M6 x 12MM bolt (Item 5) through #12 flat washers (Item 6), horizontal rod bracket and into threaded holed in windshield frame. See figure 3. Figure 3 Step 3. Vertical Rod Bracket. Locate holes for vertical rod bracket (Item 7) by placing on top of door post and aligning with top edges of door post. Mark and drill 5/32″ holes using vertical rod bracket as a template. Secure with #14 x 1/2″ sheet metal screws (Item 8) through vertical rod bracket and into drilled holes. See figure 4. Step 4. Belt Rails And Corner Plate. Place belt rail (Item 10) up against rise in body behind the door opening. Secure belt rail to top of body with M6 x 1 x 35 MM hex head bolt (Item 9) through #12 flat washer (Item 6), belt rail 5/8″ spacer tube (Item 11) and into existing threaded hole on body. Butt rear corner plate (Item 12) to end of belt rail. Place a M6 x 1 x 35MM hex head bolt through #12 flat washer, corner plate, 5/8″ spacer tube and into existing hole closest to the tailgate. Do not tighten at this time. Using the corner plate as a template mark and drill 5/32″ holes for remaining mounting holes in corner plate making sure that corner plate is parallel with body and in line with belt rail. Secure with #14 x 1 “sheet metal screws (Item 13). Tighten all fasteners, except the bolt closest to tailgate, at this time. See figure 5. Drill 1/8″ holes in corner plate using tailgate clip (Item 14) as a template making sure that tailgate clip is parallel with corner plate. Secure tailgate clip to corner plate with #10 x 1/2 sheet metal screws (Item 2) and M6 x 35MM hex head bolt through slot in tailgate clip. Place footman loop (Item 15) at a 45 degree angle on top of corner plate. Using footman loop as a template mark and drill 1/8″ holes in the corner plate. Secure footman loop to top of corner plate with #8 x 1/2 “oval head sheet metal screws (Item 16). See figure 5. Step 5. Bow Mount Mark a line on top of belt rail 17 1/4″ from rear of door post. Place the end of bow mount (Item 17) on this fine flush with the inside edge of belt rail. Using outside set of holes in bow mount as a template, drill 5/32″ holes in belt rail. Secure bow mount to body using #14 x 1/2″ sheet metal screws (Item 8) through holes in bow mount. Repeat for the other side. See figure 6.

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2007-2010 Toyota Tundra SuperRail Mounting Kit Installation Instructions

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Filed Under (Toyota Manuals) by admin on 18-06-2011

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FOR KING PIN BOXES THAT ARE SHORTER FRONT TO BACK : 1. Place the Capture Plate over the king pin, with the guide wedge towards the rear of the trailer (wedge facing down), and measure the distance from the front and rear of the king pin box to the respective edges of the Capture Plate (to the bend of the Capture Plate in the front). Referring to Figure 5, suing the supplied extension plates, fasten plates to the front and back row of holes using the 1/4″ bolts and lock nuts provided. CAUTION : The provided extension plates are universal and must be trimmed to fit your specific application. When extensions are installed, the capture plate adapter (#3317) should be flush against eh bottom of the trailer’s king pin plate. 2. While the trailer plate is in position under the king pin box, clamp these plates to both the front and rear of the Capture Plate. Remove the Capture Plate and drill matching holes in the two support plates with a 1/4″ bit using the Capture Plate as a guide. 3. Fasten the two support plates to the Capture Plate with the 1/4″ Bolts {K7} and Lock Nuts {K8} provided. 4. Replace the Capture Plate on the king pin box, check for square alignment and weld the extension plates to the king pin box. 5. Attach the Knee Braces {K2,3 & 4} to the king pin box and the Capture Plate. Braces {K2} may have to be welded on if the interior of the king pin box is not accessible. 6. See Figure 5 below for diagram and special notes.

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2002 Ford Explorer/ Mountaineer Silicone Brake Caliper Grease and Dielectric Compound Workshop Manual

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Filed Under (Ford Manuals) by admin on 01-06-2011

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Removal CAUTION: Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage may occur. 1. Remove the engine front cover (6019). For additional information, refer to Engine Front Cover in this section. 2. NOTE: Procedure is for either RH or LH ignition coil (12029); LH ignition coil is shown. Disconnect the ignition coil electrical connector and remove the retaining bolt. 3. Tilt the coil away from the fuel injection supply manifold. 4. Remove the ignition coil. 5. NOTE: Remove any foreign material from the spark plug wells with compressed air before removing the spark plugs. Remove the spark plugs. 6. Position the lobe of the camshaft up. 7. Install the special tool between the valve spring coils to prevent valve stem seal damage. 8. NOTE: The roller followers are positional. Mark the followers for installation in their original locations. NOTE: The last three roller followers must be removed with special service tool 303-581. Use the special tool to compress the valve springs and remove the camshaft roller followers. 9. Remove the crankshaft sensor ring from the crankshaft.

2000 Saturn SL2 L4-1.9L DOHC VIN 7 Body/ Electrical Service Manual

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Filed Under (Kia Motors Manuals) by admin on 31-05-2011

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1. Disconnect negative battery cable. 2. Remove lock cylinder bezel from steering column shroud by carefully prying with a thin bladed screwdriver. 3. Remove shroud fasteners and remove steering column upper and lower shroud panels. 4. Insert key into ignition lock cylinder and rotate to RUN position If ignition lock cylinder can be rotated to RUN position, continue to step 30. ^If ignition lock cylinder cannot be rotated to RUN position, continue with next step. 5. Using a light hammer and brass drift, tap lightly on the top side of the ignition housing assembly at the location indicated in the illustration, while trying to turn the ignition key. ^If the ignition key turns, proceed to step 30. ^If the ignition key does not turn replace the ignition module/passlock sensor by continuing with next step. 6. Disable SIR system. Refer to “Disabling Frontal Inflators” procedure in the 2000/2001 S-Series Body Electrical Volume II Service Manual

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1993 Mitsubishi 3000GT V6-2972cc 3.0L DOHC Timing Belt: Service and Repair Manual

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Filed Under (Mitsubishi Manuals) by admin on 23-01-2011

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.Removal of crankshaft pulley. Using special tools remove the crankshaft pulley from the crankshaft. CAUTION: -Use only the specified special tools, or a damaged pulley damper could result. 10.Removal of engine support bracket. Remove the engine support bracket in the numbered sequence shown in the illustration. Spraying lubricant, slowly remove the bolt (reamer bolt) indicated by the arrow. CAUTION: -Keep in mind that the reamer bolt is sometimes heat seized on the engine support bracket. 12.Removal of timing belt. (a)Align the timing marks.
1993 Mitsubishi 3000GT V6-2972cc 3.0L DOHC 8.80 Page 3 (b)Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction it it is to be reused. (c)Loosen the center bolt on the tensioner pulley to remove the timing belt. CAUTION: -Water or oil on the belt shorten its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water. These parts should not be washed. Replace parts if seriously contaminated. If there is oil or water on each part check the front case oil seals, camshaft oil seal and water pump for leaks. 1993 Mitsubishi 3000GT V6-2972cc 3.0L DOHC 13.Installation of auto tensioner. (a)If the auto tensioner rod is in its fully extended position, reset it as follows:1993 Mitsubishi 3000GT V6-2972cc 3.0L DOHC 8.80 Page 5 1)Keep the auto tensioner level and, in that position. clamp it in the vise with soft jaws. 2)Push in the rod little by little with the vise until the set hole (A) in the rod is aligned with that (B) in the cylinder. CAUTION: -Push in the rod slowly to prevent the push rod from being damaged. 3)Insert a wire [1.4 mm (0.055 in.) in diameter] into the set holes. 4)Unclamp the auto tensioner from the vise. (b)Install the auto tensioner. CAUTION: -Leave the wire installed in the auto tensioner. 12.Installation of timing belt. (a)Align the timing marks on the respective sprockets. In case of the camshaft sprockets in the front bank, proceed as follows: 1)Install the crankshaft pulley. Shift the timing mark on the crankshaft sprocket by three teeth to lower the piston in No. 1 cylinder slightly from the top dead center on compression stroke. CAUTION: -Turning the camshaft sprocket with the piston in No.1 cylinder located at TDC on compression stroke may cause the valves to interfere with the piston

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Toyota Avalon, Camry, Camry Hybrid, Corolla, Highlander, Highlander CABIN AIR FILTER IDENTIFICATION / INSTALLATION MANUALHybrid, Matrix, Prius, RAV4, Sequoia, Tundra, Venza, Yaris

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Filed Under (Toyota Manuals) by admin on 20-04-2012

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1. Open passenger side door. 2. Open glove compartment. 3. Remove screw holding damper rod in place on right side of glove compartment. 4. Detach damper rod from glove compartment. 5. Push in on left and right sides of glove compartment to release glove compartment. Filter Housing Cover 6. Flip down glove compartment. 7. Remove filter housing cover. Filter Housing Cover 8. Replace filter and reassemble

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2007-2010 TOYOTA DOUBLE CAB (SMALLER DOORS) SIDE BAR PART INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 17-04-2012

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1. Begin installation by working on driver side of the vehicle. 2. Remove plastic plugs on rocker panel to locate mounting holes for brackets. Attach and secure Front, Center, and Rear Mount Bracket to existing holes using 8MM bolts, 8MM flat washers, and 8MM lock washers. For each outer hole and hand tighten. 4. Attach Side Tube to Front, Center and Rear Brackets using 3/8″ x 1″ bolts, 3/8″ SAE flat washers. Hand tighten. Adjust Side Tube so that it is level and centered, and tighten all bolts to complete the driver-side assembly. 5. Repeat process for driver side of vehicle to complete installation. Passenger side brackets Rear show directly below