BASIC REPAIR HINT

HINTS ON OPERATIONS

Fig 1: Precaution For - About Basic Repair Hint

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REPAIR INSTRUCTION PRECAUTION CHART

1	Attire	Always wear a clean uniform. Hat and safety shoes must be worn.
2	Vehicle protection	Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation.
3	Safe operation	When working with 2 or more persons, be sure to check safety for one another. When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. When jacking up the vehicle, be sure to support the specified location with a safety stand. When lifting up the vehicle, use appropriate safety equipment.
4	Preparation of tools and measuring gauge	Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement.
5	Removal and installation, disassembly and assembly operations	Diagnose with a thorough understanding of proper procedures and of the reported problem. Before removing the parts, check the general condition of the assembly and for deformation and damage. When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check.
6	Removed parts	Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts. For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual. Retain the removed parts for customer inspection, if requested.

JACKING UP AND SUPPORTING VEHICLE
1. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.
PRECOATED PARTS
1. Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.
2. If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.
3. When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part.
4. Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.
  
  Fig 2: Identifying Seal Lock Adhesive Bolts (Precoated Parts)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
GASKETS
1. When necessary, use a sealer on gaskets to prevent leaks.
BOLTS, NUTS AND SCREWS
1. Carefully follow all the specifications for tightening torques. Always use a torque wrench.

FUSES

When inspecting a fuse, check that the wire of the fuse is not broken.
When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating.

Fig 3: Inspecting Fuses
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

FUSE SYMBOL CHART

Illustration	Symbol	Part Name	Abbreviation
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSE	FUSE
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	MEDIUM CURRENT FUSE	M-FUSE
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	HIGH CURRENT FUSE	H-FUSE
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSIBLE LINK	FL
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	CIRCUIT BREAKER	CB

CLIPS

The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.

HINT:

If clips are damaged during a procedure, always replace the damaged clip with a new clip.

SHAPE (EXAMPLE), ILLUSTRATION, PROCEDURES CHART

Shape (Example)	Illustration	Procedures
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove clips with clip remover or pliers.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove the clips with clip remover or screwdriver.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove clips with wide scraper to prevent panel damage.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove clips by pushing center pin through and prying out the shell.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove clips by unscrewing the center pin and prying out the shell.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Remove clips by prying out the pin and then prying out the shell.

CLAWS

The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.

HINT:

If claws are damaged during a procedure, always replace the damaged claws with new caps or covers.

SHAPE (EXAMPLE) ILLUSTRATION PROCEDURES CHART

Shape (Example)	Illustration	Procedures
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, detach the claws and remove the cap or covers.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, detach the claws and remove the cap or covers.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, detach the claws and remove the cap or covers.

REMOVAL AND INSTALLATION OF VACUUM HOSES
1. To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage.
  
  Fig 4: Detaching Claws And Remove Cap Or Covers Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
3. After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.
4. When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, it may leak air. Use a step down adapter if necessary.
  
  Fig 5: Identifying Vacuum Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL

Fig 6: Identifying Torque Wrench With Extension Tool

Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench.

Formula:

T' = L2 / (L1 + L2) * T

FORMULA CHART

T'	Reading of torque wrench {Nm (kgfcm, ft.*lbf)}
T	Torque {Nm (kgfcm, ft.*lbf)}
L1	Length of SST or extension tool {cm (in.)}
L2	Length of torque wrench {cm (in.)}

Fig 7: Identifying Length Of Torque Wrench With Length Of SST

Safety Warning

Repair Instruction: Precaution

Use the Manual With the Right Hardware

When to See a Mechanic

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