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    James Swift Sr
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    like VW idiot book but Toyota Pickups

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    like VW idiot book but Toyota Pickups

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    © All Rights Reserved
    Download as PDF or read online from Scribd
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    467 views389 pages

    Toyota Pickup Idiot Book

    Uploaded by

    James Swift Sr
    like VW idiot book but Toyota Pickups

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 389
    ee STEP) STEP PROCEDURES Joti COMPLEAT IDIOT Oy Zaz LNRRXOWENS HOW TO KEEP YOUR TOYOTA PICKUP —— ALIVE —— STEP-BY-STEP PROCEDURES FOR THE COMPLEAT IDIOT FOR 1975- 1987/2 & 4WD BY LARRY OWENS ILLUSTRATED BY JOE LEAHY — JOHN MUIR PUBLICATIONS — Production Credits: Cover: Peter Aschwanden Ilustrations: Joe Leahy Design and Production: Jim Wood Editor: Richard Harris ‘Typography: Copygraphics, Santa Fe NM ‘Typeface: Times Roman Printed on Recycled Paper Copyright © 1988 by John Muir Publications Al Rights Reserved Published by: John Muir Publications P.O, Box 613 Santa Fe, NM 87504 Printed in the U.S.A. Library of Congress Catalogue No. 87-043130 ISBN 0-912528-89-3 First edition. Second printing PLEASE NOTE: ‘The repair and maintenance procedures in this book are based on the training, personal experiences and research of the author, and on recommendations of responsible automotive professionals. If you fol- low all the directions specifically, you should be able to complete the procedures in this book successfully and safely. Please understand that the recommendations and warnings herein cannot cover all conceivable ways in which service procedures may be done, or every possible hazard and risk involved. The author, illus- trator and publisher are not responsible for any adverse consequences that may occur in connection with the procedures explained in this book. Please do not use the book unless you are willing to assume the risk of adverse consequences. We urge you to consult with a qualified mechanic before using any proce- dure where there is any question as to its completeness or appropriateness. ‘We especially advise you to heed all WARNINGS and CAUTIONS, to use all recommended safety precautions called for throughout the book—and to use common sense. Thanks. ACKNOWLEDGMENTS Although my name is on the cover, there are several other people who deserve an equal share ofthe credit for this manual. Without them the project would have floundered many times over. So with great pleasure I now get to thank them publicly for their efforts. ‘Thanks to all the people at John Muir Publications for their support throughout the project. Especially Ken Luboff and Steven Cary for backing the project, Richard Harris for the difficult task of translating my writing into English, and Jim Wood for book design, layout and paste up. T can't thank Joe Leahy enough for the great illustrations. Joe's pictures really are worth thousands of words. And thanks to Peter Aschwanden for the cover design. ‘Thanks to Mike Michels, Jim Pond and Scott Goldenberg at Toyota Motor Sales, U.S.A. Inc., who offered friendly, enthusiastic support for the project. Special thanks to three top notch Toyota mechanics at Joe Redford’s Toyota in Goleta, California, Niko Norton, Dave Harris and Alan Pratini for the valuable technical assistance and suggestions about how to-do things easier and/or better. Others who helped with the project are: Sol Morrison, Paul Miller, Peter and Jonathan Porinsh, Alec and Cindy Chambers, David Norrie, John Alper, Kevin Robinson and Billy J. Trucker. This book is dedicated to my wife Camille (Mimi) and my son Oscar (Oz). Thanks for keeping me going when the going got tough, and when it seemed like it would never end. TABLE OF CONTENTS INTRODUCTION CHAPTER 1 HOW TO USE THIS BOOK.........000000000000000 000s eeeeeeeeeeeeeeeeeee! 9 CHAPTER 2 ORIENTATION, SAFETY AND DRIVING TIPS .......00000000eeeeeeeeeeeee 13 CHAPTER3 TOOLS, PARTS AND BOOKS .......0000506266000000000eeeeeeeeeeeeeeeeee 33 CHAPTER 4 TROUBLESHOOTING ......0006000000000000cceeeeeeeeeeeeeeeeeeeeeeeee! 41 CHAPTERS MAINTENANCE, LUBRICATION AND TUNE-UP CHAPTER 6 COOLING AND HEATING SYSTEMS .......000006600000000eeeeeeeeeeeee 133 CHAPTER7 BRAKES..........000000000000655 cece cess eeeetteteeeeeteeeeeeeneee 147 CHAPTER8 ELECTRICAL SYSTEM .....000000000000cceeeceeeeceeeeeseeeeeeeeseees 195 CHAPTER 9 FUEL SYSTEM ......0.6.06060000000eeeeee ceceeeeeeeseeeeeeeeeeeeeeee 241 CHAPTER 10 EXHAUST AND EMISSION ‘ONTROL SYSTEMS . CHAPTER I CLUTCH, TRANSMISSION, DIFFERENTIAL, DRIVESHAFTS. AND REAR AXLE CHAPTER 12. SUSPENSION, STEERING AND FRONT AXLES . CHAPTER 13 ENGINE REPAIR .... 353 CHAPTER 14 MODIFYING YOUR TOYOTA . 363 CHAPTER 15 MECHANIC’S TIPS, SECRETS, ODDS 'NENDS 373 INDEX . 383 INTRODUCTION Contrary to popular belief, modern cars and trucks are not to0 complicated for the average owner 10 maintain, often at a savings of $100-1000 per year! ‘The basic things that professional and amateur mechanics have dealt with since cars were invented haven't really changed that much—except that alot of things have gotten casier. For example, some of the most com- ‘mon sources of trouble, ike breaker points inthe distributor and carburetor adjustments, have been eliminated on later models. Changing the oil and filter is just as messy now as it was when Henry Ford did it on his first car, but even this bothersome chore doesn't have to be done as often as it did in the old days, thanks to higher quality oils and engine materials. And it’s much easier to replace the pads on disc brakes than it is to replace brake shoes. Your truck has disc brakes up front where most brake wear occurs, so maintaining the brakes is casier now than in the old days. ‘What I'm getting at is that in most cases it's easier now to do the maintenance on your truck than it ever was. Yes, i’s true, Cars and trucks builtin the last few years have computers and other complicated gadgets that are beyond the home mechanic's means to deal with. But there’s no need to mess with these systems unless they start causing problems, which is very rarely. All those wires, hoses and mysterious looking gizmos under the hood just make things look a lot mote complicated than they really are. ‘So whats left to do? Basically, simple things like replacing the spark plugs (a task very similar to replac- ing a light bulb), replacing other parts periodically (ike the air, oil and fuel filters which are a piece of cake to replace), and doing a few other simple things like keeping the tires inflated properly and rotating them regularly. How To Keep Your Toyota Pickup Alive was written for people with little or no mechanical experience. ‘Normal people like you who, with a litle friendly direction, can do most of the work on their truck, I've tried to write ito you'll feel as if my friendly hand is on your shoulder as you go through the procedures. Using this ‘manual you can do the things that you would otherwise pay someone else a wad of money to do. T'll warn you up front if procedure requires special tools or expertise. ‘The heart of this book is a detailed lubrication, maintenance and tune-up chapter. In this chapter engine tune-ups, the maintenance ofall other vital systems such as brakes, cooling, suspension and steering systems, as well as checking the condition of almost all other vital parts on the truck like tires, wiper blades, lights, and so on are arranged in a logical maintenance schedule based on recommendations by the Toyota factory as well ‘as my own experience. This book includes maintenance, diagnosis and repair instructions for all 1975-87 gasoline powered Toyota pickups, 4 Runners and Cab and Chassis models. Due to special tools, safety factors, and/or complexity, in- structions for the following models and systems are not covered: Landcruisers, diesel engines, air condition- ing and power steering. Also, there are peculiarities on some Cab and Chassis models that have campers, flat beds or utility beds that are not covered. ‘Toyota trucks are renowned for their toughness, dependability and ease of maintenance. But, like almost everything else, they need to be fondled occasionally to stay in tip-top shape. With a minimum amount of at- tention they will stay looking good and running great almost indefinitely Professional mechanics, machinists and parts store personne are almost always willing to help inexperienced mechanics who get stuck with catastrophes like a broken bolt or crossed wire. In fact, they generally seem to be impressed by people who want to maintain their own vehicles. Be sure to reward those who help you with a cold six-pack, a dozen donuts or something—you never know when you'll need their help again. If you are unsure of your mechanical abilities, read Chapter I: How To Use This Book, then do the Vital (yet simple) chapters and procedures listed at the end of that chapter, to slowly wade into the book. As you build up confidence, gradually go deeper and deeper into Chapter 5. Soon you'll be changing the oil and filter, massag- ing away your truck's aches and pains, and eventually you'll be doing thorough, competent tune-ups and repairs ‘Also, you'll be replacing worn parts before they fail completely, which might have left you on the side of the road with a roast in the oven, the kids stranded at school, a hungry date waiting to be picked up, ad infinitum, ‘Write to me at John Muir Publications, P.O. Box 613, Santa Fe, New Mexico 87504, to let me know how it goes. I'm always open to suggestions for easier or better ways to do things, interesting stories, pictures of my readers with their machines, compliments and complaints. ‘Thanks, Chas, Ouore Larry Owens CHAPTER 1 HOW TO USE THIS BOOK ‘To get your money's worth from this book, you gotta read it. Skipping paragraphs, sentences, and some- times even skipping a word can defeat hours of otherwise meticulous attention to instructions. When helping. ‘Volkswagen and Subaru owners who got stuck using the How To Keep Your Volkswagen Alive and How To Keep Your Subaru Alive books, and when testing this book on inexperienced mechanics, the most common problem ‘was that people were skipping part of the instructions. The information was there, they just weren't using it ‘To make this book really work for you, please read Chapter 2: Orientation, Safety, and Driving Tips before getting your nose and hands greasy. Orientation will define some very important terms so you can correctly follow the instructions, “Right side” and “left side” sound simple and concrete, but they are actually relative to where you're standing when reading the instructions. The Safety part of Chapter 2 will tell you how todo things safely. A trip to the emergency room could quickly wipe out the money you were trying to save by doing the ‘work yourself. I want you to come through the procedures with nary a scratch, let alone major damage (to your body or your ego). Driving Tips will give you some pointers on how to drive to minimize wear and tear on your Toy. Nobody knows it ll! There are times when you'll need to ask questions of the pros. The people atthe Toyota caler will help you when they have time. [also urge you to seck out advice ata friendly, well-equipped indepen-

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