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Toyota ISO Adapter Wiring Diagram

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Filed Under (Toyota Manuals) by admin on 19-05-2011

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1988-1996 TOYOTA PICK-UP LOWER CONTROL ARMS INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 26-03-2012

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1) Park your truck on flat level surface. Chock the rear wheels. Loosen front lug nuts. Raise the front with a floo jack. Support the frame with jack stands. Remove front wheels. NOTE : ALWAYS USE JACK STANDS – NEVER RELY ON JACKS ONLY!! 2) Starting on the drivers side, locate the height adjusting bolt at the rear of the torsion bar. Measure and record the length of the threads exposed between the end of the adjusting bolt and jam nuts (Fig. A). Now make a mark at the front of the torsion bar, where it goes into the bracket bolted the lower control arm. Mark bath the bar and the bracket (Fig. B). This will index the bar into the correct position when installing. Fig. A Fig. B Note : Step #2 assumes torsion bars are in the factory position. 3) Loosen the height adjusting bolts until there is no longer any load on the torsion bars. 4) Remove the 2 bolts that hold the tensioncompression rod and sway bar end link bolts. 5) Now remove the two bolts on each arm that holds the torsion bar receiver to the back of the control arm. Slide the torsion bar and receiver back from the control arm. There is a wide spline on the torsion bar corresponding to the double width tooth on the torsion bar receiver. The receiver will not slide back onto the bar if the splines are not aligned properly. 6) Loosen and remove the 3 nuts and bolts that hold each ball joint to the lower control arms. 7) Remove the pivot bolts holding the lower control arm to the frame and remove control arm from truck. 8) Unbolt and remove original bump stops from factory arms and bolt them to you new DJM control arm. 9) Drill out the small hole on the end of the torsion bar receiver to 7/16″on both sides. This is to accept the 7/16″ x 5- 1/2″ bolt supplied. 10) Compare the new DJM control arms with the factory ones. Carefull note the diameter of the factory ball joint mounting holes. You will find either three 10mm hole used on most earlier models or larger 13mm holes on late models. If you factory arms have the 10mm holes continue to step # 10. If factory holes are 13mm it will be necessary to enlarge the holes with a 1/2″ drill bit(Fig. C). Fig. C 11) Mount the DJM control arms to the truck. Make sure the steering stops are facing the front of the truck. Insert the pivot bolts and install the washers and nuts. DO NOT TIGHTEN YET . 12) Bolt on the tensioncompression rods to the lower control arms. It mat be necessary to loosen the large nuts that hole the tensioncompression rods to the frame in order to rotate the rods to the proper angle to align bolts into control arms.

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Dodge Ram 1500 4wd Installation Instructions

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Filed Under (Dodge Manuals) by admin on 25-12-2011

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Step 1: (A) Position truck on a flat surface and lift vehicle by the frame so that the front wheels are off the ground using a floor jack and jack stands or a (2) two post lift if available. Next locate the torsion key at the rear of the torsion bar under the cab of the truck. (Insert A) Note: Prior to lifting the vehicle it is recommended that you measure the stock height of the vehicle so that you have a base line to gauge when you are adjusting the height of the vehicle. Measuring the vehicle from the bottom of the wheel to the lip of the fender as in (Insert B) is recommended. (B) Step 2: Remove the torsion key adjusting bolt completely. Using a ReadyLift® Torsion Bar Unloading Tool Part # 66-7822A, and the bracket supplied in the kit as shown in (Insert C) Compress the key so that you can remove the threaded part of the torsion adjuster. Releasing the tension on the unloading tool will now release the tension on the torsion bar. Slide torsion bar forward allowing the torsion key to be removed. As in (Insert D) Insert C Insert D Installation Instructions 02-05 Dodge Ram 1500 4wd (cont.) Step 3: Install the Forged torsion key and slide torsion bar back into position as in (Insert E) IMPORTANT! Make sure Torsion Bar is extended at least ¼inch through the Torsion Key. Apply pressure with Torsion Bar Unloading Tool to the torsion key, and create enough space to reinsert the torsion key keeper that the adjusting bolt threads into. Insert E Step 4: Reinstall the adjusting bolt, and adjust it so ¼” of bolt threads extend beyond torsion key keeper. IMPORTANT! – Each ¼” of adjustment on the bolt equals 1″ at the wheel. It is best to check ride height after this initial setting and adjust as needed. Step 5: Repeat steps 1 through 3 on the Passenger Side of the vehicle. Follow each step closely making sure to double check the torque on all fasteners. Measure the distance between the tires and fenders to make sure both sides of the truck are even. Step 6: Wheel Alignment; a Certified Alignment Technician that is experienced with lifted vehicles is recommended to perform the alignment. *It is recommended that you have your vehicle’s alignment checked whenever installing new tires. *It is also recommended that you adjust your headlights whenever your vehicle’s ride height is altered.

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TOYOTA LANDCRUISER INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 10-11-2011

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INSTALLATION INSTRUCTIONS 1. Park the vehicle on a level surface. Check the vehicle height from side to side and front to back. This is done by measuring from the ground up to the fender using the hub as a centering point. 2. Apply a thin coat of grease to the polyurethane bushings and insert into each eye of the new front springs. Now apply a thin coat of grease on outside of bushings. This will help you to insert the bushing into the spring mount. 3. Raise the front of the vehicle and support securely with jack stands under the frame behind the front springs, and block the rear wheels. Remove the tires, shocks, u-bolts, and loosen the sway bar bolts. (Caution: the front axle will now be free to move, so support securely on floor jack.) 4. With a floor jack supporting the axle, unbolt each end of leaf springs and remove from both sides. (If new shackle bushings were purchased, grease and install them in the frame at this time.) Install new front springs, part # 8041. When installing the front springs that the fat part of the shim on the bottom of the spring pack should be pointing toward the rear of the vehicle. Notice the tie bolt in the front leaf springs is not in the center of the leaf spring, but there is a long end and short end. Install the springs with the short end towards the rear, and long end towards the front bumper. Do not tighten spring eyebolts at this time. 92756702 64-80 TOYOTA LANDCRUISER INSTALLATION
INSTRUCTION SHEET Technical Assistance – (731) 285-9000 Page 2 5. Using the floor jack, lower the front axle down to the leaf springs. Be sure the tie bolts align and fit into the tie bolt holes in the front axle housing. Install and tighten new u-bolts. Torque u-bolts to 75-90 ft.lbs. 6. Install new shocks and tires then lower the vehicle to the ground. Tighten spring eyebolts at this time. NOTE: The drag link that goes along side of the frame from the gear box to the bell crank may require slight bending for clearance of the new shock. Bending this drag link will not affect it, but do not kink the bar. 7. Raise the rear of the vehicle. Support securely with jack stands and block the front wheels. Remove the tires, shocks, and u-bolts. (CAUTION: the rear axle will be free to move, so support securely on a floor jack. 8. Apply a thin coat of grease to the polyurethane bushings and insert into each eye of the new rear springs. Now apply a thin coat of grease on outside of bushings. This will help you to insert the bushing into the spring mount. 9. With a floor jack supporting the rear axle, unbolt each end of the rear leaf spring and remove from both sides. (If new shackle bushings were purchased, grease and install them in the frame at this time.) Install new springs, part # 8042. When installing the rear springs the fat part of the shim on the bottom of the spring pack should be pointing toward the front of the vehicle. Notice the tie bolt in the rear leaf springs is not in the center of the leaf springs, but there is a long end and a short end. Install the springs with the short end towards the front and longer end towards the rear bumper. Do not tighten spring eyebolts at this time. 10. Using a floor jack, lower the rear axle down to the leaf springs. Be sure tie bolts align and fit into the tie bolt holes in the axle housing. Install and tighten new u-bolts, shocks and tires then lower vehicle to the ground. Torque u-bolts to 75-90 ft.lbs. Tighten spring eyebolts at this time.

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2003-2007 Dodge (DR/DH/D1/DC) Ram Truck Front EndShimmy On 4×4 Vehicles When Traveling Over Rough Surfaces In The Road

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Filed Under (Dodge Manuals) by admin on 17-04-2014

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REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle . Tire Size FRONT Tire Pressure LT235/80R17EorLT245/70R17E 448 Kpa (65 psi) LT265/70R17EorLT285/70R17E 414 Kpa (60 psi) 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. Tire Size REAR Tire Pressure LT235/80R17EorLT245/70R17E Refer to the Tire Inflation Chart brochure in the Owners Manual or to the placards located either on the face of the driver’sdoor or on the driver’sside”B”pillar. LT265/70R17EorLT285/70R17E Refer to the Tire Inflation Chart brochure in the Owners Manual or to the placards located either on the face of the driver’sdoor or on the driver’sside”B”pillar. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dustcovers are not worn. a. Attempt to rotate the dustcover by hand. b. If the dustcover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) fora tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications.

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Installation of the Smitty 5-speed Toyota Kit

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Filed Under (Toyota Manuals) by admin on 25-10-2011

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Toyota pilot bearing: Toyota uses a ball pilot bearing which is a very accurate fit on the end of the pilot shaft. I had to sand my pilot shaft down slightly with wet/dry paper to get the bearing to be other than a force fit. You need a sliding fit for installation of the trans in the car. Pilot Tool adjustment: I believe it is necessary, or desirable at least, to tighten up the accuracy of the supplied plastic pilot tool to make sure the nose of the first-motion shaft will slide into the Toyota pilot bearing during installation of the trans. I wrapped the pilot tool with enough electrical tape so it was a perfect fit on both the pilot bearing and the clutch disc splines. 1 layer of tape around the contour of the splines did the trick. Smitty supplies an aluminum ring which holds the Toyota pilot bearing into the Healey flywheel. I used a vise to press the bearing into the ring, and a large 1-5/16 socket as a tool to hammer this into the recess in the flywheel. This was easy if you’re careful. Your lead hammer makes a dandy driver for this. Toyota Trans install: The shop manuals warn against tilting the engine into the radiator. Mine has the 6- bladed fan about 1/2″ back from the radiator and during this process it never came close to the radiator. If you have the block between the valve cover and the firewall, minor or no jacking of the engine should be necessary in order to get the Toyota trans in place. Position your trans jack or floor jack in the middle of the hole and place the Toyota trans on top of it. Lower enough to get the bell housing through the opening, then raise it back up to where the bolt holes align. Observe parallelism between the bell housing and engine flange. I believe the limiting factor here is the alignment of the Toyota pilot shaft with the pilot bearing–I believe this is at least as accurate as anything to do with the dowel bolts.

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2011- Present Chevy and GMC HD Truck Torsion Key Lift With Shock Extenders

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Filed Under (Chevy Manuals) by admin on 21-12-2011

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Lifting a vehicle does cause the center of gravity to rise and rollover may become easier, always avoid situations where a rollover may occur and always wear seat belts. Larger tires will cause braking performance to decrease. Mixing of brands and lift components is not recommended. 1. Park vehicle on level ground and take before measurements to use for reference when adjusting the height on the new keys. LF___ RF___ LR___ RR___ 2. Block the rear wheels and jack up the front of the vehicle and support with jack stands on the frame so the front wheels are off the ground. 3. Remove the front tire and wheel assemblies using 22mm socket. 4. Measure the torsion key adjuster bolts for reference points for later reinstallation. Left Side____ Right Side____ (Figure1) Figure1 Figure2 5. Remove the adjuster bolts from the torsion key keeper using 21mm socket and save for later reinstallation. (Figure 2) 6. Using the torsion key unload tool (figure3) or a ball joint press can also be used, (figure4) carefully unload the torsion key and remove the keeper.
Figure3 Figure4 7. Remove the keys from the torsion bars. Sometimes the keys rust weld to the bar the use of an air hammer and striking the back of the bar thru an access hole in the back of the torsion bar cross member. This usually breaks the bars free from the keys. 8. Install new keys onto the bars in the same location as the old ones were located on the bar. 9. Now that the suspension is unloaded the shock extenders will need to be installed. 10. Remove the lower shock bolt and nut using 21mm socket and 21mm wrench and save for reinstallation. Push the shock up out of the way and install shock extender. Use stock bolt to mount the extender to the control arm shock mount. (Figures 5 & 6)

Burien Toyota 5SFE Turbo Installation Instructions

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Filed Under (Toyota Manuals) by admin on 17-06-2011

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The following parts are not required, but you may want to have on hand: 9 Fresh Toyota engine coolant 9 New engine oil (preferably synthetic) and new Toyota oil filter 9 New parts to perform a tune-up (spark plugs, distributor cap & rotor). If you do replace your plugs, you may want to use a colder plug to reduce the chance of detonation. 9 New Ignition wires, if your current wires are old 9 New Toyota fuel filter (since you’re replacing the expensive injectors) 9 Shorter oil filter union from Toyota (See step #11) 9 Tie-wraps to secure vacuum lines (See step #27) 9 Shielded audio cable (See step #26.b) 9 For automatic transmissions, consider replacing the transmission fluid with a good synthetic brand and installing an ATF cooler. Burien Toyota 5S-FE Turbocharger Installation Manual Page 2 of 20Kit Contents ¾ Toyomoto exhaust manifold ¾ Garrett TB0344 turbo (Exhaust manifold and turbo charger come attached) ¾ Intermediate pipe (‘S’ shaped pipe with blow off valve attached) ¾ Down pipe (‘J’ shaped pipe with 90° bend and exhaust flange, also has mount for oxygen sensor) ¾ Turbo intake pipe (Usually attached to turbo) ¾ 90º elbow with valve cover breather hose attached (Elbow used to mount air filter) ¾ K&N air filter ¾ HKS Racing Blow-off/Pop-off valve ¾ (4) 360cc Toyota Injectors ¾ Toyota Oil pan ¾ Toyota MAP Sensor ¾ All necessary hoses, clamps, nuts, bolts, fittings, studs, gaskets and such required to install the system.

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3406E Truck Engine Installation OR Removal Of The Speed/ Timing Sensor

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Filed Under (More Manuals) by admin on 22-06-2012

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1. Disconnect the speed/timing connector “P9/J9″ (2) . Inspect the connector for the following conditions. * Corrosion * Bent pins * Missing pins * Damaged sockets * Mismating * Broken wires 2. Remove the Speed/timing sensor (1) from the front gear cover. 3. Examine the plastic end of the sensor for signs of wear or contaminants such as metal filings. The plastic end of the speed/timing sensor should have no contaminants and should show no wear (greater than 0.051 mm (0.0020 inch) from the face) . 4. Use a screwdriver to carefully pry the plastic sensor end to the fully extended position (approximately 4.775 mm (0.1880 inch) beyond the metal housing of the sensor). 5. Gently push in on the plastic end of the sensor. The plastic end should be firm. The plastic end should resist movement in the retract direction. If there is no resistance replace the sensor 6. Remove the two bolts (3) and remove the cover (5) from the flywheel housing. This hole is used for engine turning. 7. Put one bolt (3) in the timing bolt location (4) . The timing bolt location is approximately 127 mm to 152 mm (5 inch to 6 inch) above the hole in the flywheel housing for engine turning. I 8. Use 9S-9082 Engine Turning Tool (6) and a 1/2 inch drive ratchet wrench to turn the engine flywheel in the direction of normal engine rotation. The normal engine rotation is in a counterclockwise direction when viewed from the flywheel end. Turn the engine flywheel until the timing bolt engages with the threaded hole in the flywheel. Note: Visually check the location of the tooth on the wheel on which the speed/timing sensor is to be positioned. The end of the sensor must be in alignment with a tooth on the wheel and not in alignment with the valley of the wheel. Note: The No. 1 piston must be at either top center of the compression stroke or at top center of the exhaust stroke. 9. Inspect the speed/timing sensor before installation. Use steps 3 through step 6 to inspect the sensor. 10. If the sensor end is not fully extended, use a screwdriver to carefully pry the plastic sensor end to the fully EXTENDED position approximately 4.775 mm (0.1880 inch) beyond the metal housing of the sensor.

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TOYOTA LANDCRUISER BRAKE CONVERSIONS SERVICE MANUAL

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Filed Under (Toyota Manuals) by admin on 19-05-2011

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Transport Inspectors: Provides sufficient guidance to ensure familiarity with approved brake system modifications to stated Toyota Landcruiser models. Approved Inspection Stations (AIS): Provides sufficient guidance to ensure familiarity with approved brake system modifications to stated Toyota Landcruiser models for the issue of a Safety Certificate. Approved Persons: Provides sufficient guidance to ensure familiarity with approved brake system modifications to stated Toyota Landcruiser models so as to ensure consistent certification of vehicles. Vehicle owner: Provides guidance on vehicle compliance requirements. Applies to Installation of Safe Effect Integrated Braking System (SIBS) to Series 70, 75, 78, 79, 80 and 100 Series Toyota Landcruiser motor vehicles. Installation of the Corefleet Offroad Braking (Rear) (COBR) system to Series 78 and 79 Series Toyota Landcruiser motor vehicles. Objective To ensure that braking modifications carried out to the above mentioned Toyota Landcruiser vehicles are to the approved and certified standard. Background Modification approval has been issued to two applicants regarding braking modifications to a range of Toyota Landcruiser vehicles. These vehicles are commonly used in the mining and exploration industry. The standard manufacturer supplied braking systems have been considered of very high maintenance characteristics due to the nature of vehicle operations (for example, underground mining activities, harsh operating conditions). An additional model of vehicle has recently been approved and the list of approved models of vehicles amended. These vehicles are also commonly registered for use on public roads. To ensure the braking systems of these vehicles remain in a serviceable condition to prescribed standards and maintain extended service life, modified braking systems have been developed to address the harsh operating conditions that are experienced in the underground mining and exploration industries

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