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Toyota Hilux Vigo Service Repair Manual 2005-2009

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🏷️ Basic Information Identification Make: Toyota Model: Hilux Vigo Model Generation: AN10/AN20 Series (Second Generation) Production Years Covered: 2005, 2006, 2007, 2008, 2009 Codes Chassis Codes: AN10, AN20 👋 Introduction Market Position Target Audience: Do-it-yourselfers and experienced mechanics Competitive Analysis Value Proposition: Inexpensive way to keep vehicle working properly, saving money on repairs Key Features Comprehensiveness: Covers every single detail, essential for repair, maintenance, rebuilding, refurbishing, restoration Accuracy: Factory-written, detailed illustrations, diagrams, wiring schematics, specifications Accessibility: Instant download, searchable, bookmarked, compatible with multiple devices 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair for Toyota Hilux Vigo All Models Included: Yes All Engines Included: Yes Page Count Total Pages: 3000+ Manual Type Type: Service and Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Overhaul, rebuilding, performance tuning, timing belt, serpentine belt routing, firing orders Engine Management: Trouble codes, computer diagnostics, diagnostic trouble tree charts, engine performance diagnostics Fuel System: Fuel injection, fuel pump, fuel filter, fuel tank service Cooling System: Radiator, water pump, thermostat, coolant capacities Lubrication System: Oil pump, oil filter, oil capacities, lubrication procedures Exhaust System: Muffler, catalytic converter, exhaust manifold service Transmission Manual: Removal, installation, in-car servicing, rebuild procedures, specifications Transmission Automatic: Removal, installation, in-car servicing, rebuild procedures, specifications, fluid capacities Drivetrain: Driveshaft, differential, axle service, U-joint and CV-joint service procedures Suspension Front: Components, alignment procedures, specifications, strut/shock replacement Suspension Rear: Components, leaf spring service, shock absorber replacement Steering: Power steering system, steering column, tie rods, steering rack/box service Brakes Front: Disc brake service, pad/rotor replacement, caliper service, specifications Brakes Rear: Drum brake service, shoe replacement, wheel cylinder service, specifications Brake Control Systems: ABS, EBD (if equipped), brake booster, master cylinder service Electrical System Power: Battery, charging system (alternator, starter), wiring harness repair Electrical System Lighting: Headlights, taillights, interior lighting, bulb replacement Electrical System Accessories: Power windows, power locks, wipers, horn, audio system service Climate Control: Air conditioning service, refrigerant capacities, heater core, blower motor service Body Exterior: Body panels, doors, bumpers, glass, sunroof service Body Interior: Seats, dashboard, trim panels, headliner service Safety Systems: Airbag system service, seatbelt maintenance Procedures Included Maintenance: Factory maintenance schedules and charts, fluid changes, filter replacements, lubrication Diagnostics: Troubleshooting and diagnostics, computer diagnostic codes, vacuum diagrams, diagnostic trouble trees Repair: Step-by-step instructions for all major repair procedures, component replacement Rebuilding: Engine overhaul and rebuilding, transmission rebuilding, brake system rebuilding Refurbishing: Procedures for restoring components and the vehicle Restoration: Guidance for comprehensive vehicle restoration projects Electrical Repair: Wiring diagrams for complete electrical system troubleshooting and repair Alignment: Front end alignment procedures and specifications Timing Belt: Timing belt replacement procedures and specifications Driving Concerns: Troubleshooting common driving issues and concerns Technical Depth Depth: Complete disassembly and reassembly, advanced diagnostics, factory-level repair procedures Illustrations: Hundreds of detailed illustrations and diagrams Specifications: Detailed specifications on every model and component covered, complete torque specifications 📊 Manual Specifications File Format Compatibility: All Versions of Windows & Mac, Linux OS, iPhone, iPad, Android Requirements: Adobe PDF Reader & WinZip Print Quality Readability: High-resolution, searchable, bookmarked for easy navigation Usability: Printable pages, zoomable for detailed views Binding Type Type: Digital Download (PDF) Paper Type Not Applicable: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options: Multiple diesel and petrol engines covered (specifics vary by market and sub-model, e.g., 2KD-FTV 2.5L Diesel, 1KD-FTV 3.0L Diesel, 2TR-FE 2.7L Petrol, 5L-E 3.0L Diesel). Performance Power And Torque: Detailed specifications for each engine variant will be found within the manual, including horsepower and torque figures. Fuel System Injection Type: Common Rail Direct Injection (for diesel variants), EFI (for petrol variants). Manual covers system diagnostics and repair. Maintenance Timing Belt Type: Timing belt (on some petrol engines) or timing chain (on diesel engines). Manual provides replacement procedures for belts and maintenance for chains. Emissions Emission Control: Information on emission control systems and troubleshooting will be included. 🔧 Transmission Standard Manual Transmission: 5-speed manual transmission commonly available. Optional Automatic Transmission: 4-speed automatic transmission often available as an option. Features Drivetrain Options: Available in 2WD (RWD) and 4WD configurations. Manual covers both systems. Specifications Fluid Type Atf: Specific Automatic Transmission Fluid (ATF) type required for automatic transmissions. Consult manual for exact Toyota specification (e.g., Toyota ATF Type T-IV or equivalent). Fluid Type Mtf: Specific Manual Transmission Fluid (MTF) type required for manual transmissions. Consult manual for exact Toyota specification (e.g., Toyota MTF or equivalent). 📐 Dimensions Exterior Body Styles: Single Cab, Extended/Space Cab, Double Cab, Chassis Cab. Wheelbase: Varies by body style and configuration. Typical ranges from approximately 3085 mm to 3420 mm. Weights Curb Weight: Varies significantly based on configuration (cab type, engine, drivetrain). Expect ranges from ~1600 kg to ~2000 kg+. Cargo Payload Capacity: Varies by model and configuration, typically designed for substantial payload capacity. 🛡️ Safety Features Ratings Crash Test Ratings: Ratings...
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Toyota Hilux Vigo Service Repair Manual 2005-2009
🏷️ Basic Information
Identification
Make:
Toyota
Model:
Hilux Vigo
Model Generation:
AN10/AN20 Series (Second Generation)
Production Years Covered:
2005, 2006, 2007, 2008, 2009
Codes
Chassis Codes:
AN10, AN20
👋 Introduction
Market Position
Target Audience:
Do-it-yourselfers and experienced mechanics
Competitive Analysis
Value Proposition:
Inexpensive way to keep vehicle working properly, saving money on repairs
Key Features
Comprehensiveness:
Covers every single detail, essential for repair, maintenance, rebuilding, refurbishing, restoration
Accuracy:
Factory-written, detailed illustrations, diagrams, wiring schematics, specifications
Accessibility:
Instant download, searchable, bookmarked, compatible with multiple devices
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service and Repair for Toyota Hilux Vigo
All Models Included:
Yes
All Engines Included:
Yes
Page Count
Total Pages:
3000+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Overhaul, rebuilding, performance tuning, timing belt, serpentine belt routing, firing orders
Engine Management:
Trouble codes, computer diagnostics, diagnostic trouble tree charts, engine performance diagnostics
Fuel System:
Fuel injection, fuel pump, fuel filter, fuel tank service
Cooling System:
Radiator, water pump, thermostat, coolant capacities
Lubrication System:
Oil pump, oil filter, oil capacities, lubrication procedures
Exhaust System:
Muffler, catalytic converter, exhaust manifold service
Transmission Manual:
Removal, installation, in-car servicing, rebuild procedures, specifications
Transmission Automatic:
Removal, installation, in-car servicing, rebuild procedures, specifications, fluid capacities
Drivetrain:
Driveshaft, differential, axle service, U-joint and CV-joint service procedures
Suspension Front:
Components, alignment procedures, specifications, strut/shock replacement
Suspension Rear:
Components, leaf spring service, shock absorber replacement
Steering:
Power steering system, steering column, tie rods, steering rack/box service
Brakes Front:
Disc brake service, pad/rotor replacement, caliper service, specifications
Brakes Rear:
Drum brake service, shoe replacement, wheel cylinder service, specifications
Brake Control Systems:
ABS, EBD (if equipped), brake booster, master cylinder service
Electrical System Power:
Battery, charging system (alternator, starter), wiring harness repair
Electrical System Lighting:
Headlights, taillights, interior lighting, bulb replacement
Electrical System Accessories:
Power windows, power locks, wipers, horn, audio system service
Climate Control:
Air conditioning service, refrigerant capacities, heater core, blower motor service
Body Exterior:
Body panels, doors, bumpers, glass, sunroof service
Body Interior:
Seats, dashboard, trim panels, headliner service
Safety Systems:
Airbag system service, seatbelt maintenance
Procedures Included
Maintenance:
Factory maintenance schedules and charts, fluid changes, filter replacements, lubrication
Diagnostics:
Troubleshooting and diagnostics, computer diagnostic codes, vacuum diagrams, diagnostic trouble trees
Repair:
Step-by-step instructions for all major repair procedures, component replacement
Rebuilding:
Engine overhaul and rebuilding, transmission rebuilding, brake system rebuilding
Refurbishing:
Procedures for restoring components and the vehicle
Restoration:
Guidance for comprehensive vehicle restoration projects
Electrical Repair:
Wiring diagrams for complete electrical system troubleshooting and repair
Alignment:
Front end alignment procedures and specifications
Timing Belt:
Timing belt replacement procedures and specifications
Driving Concerns:
Troubleshooting common driving issues and concerns
Technical Depth
Depth:
Complete disassembly and reassembly, advanced diagnostics, factory-level repair procedures
Illustrations:
Hundreds of detailed illustrations and diagrams
Specifications:
Detailed specifications on every model and component covered, complete torque specifications
📊 Manual Specifications
File Format
Compatibility:
All Versions of Windows & Mac, Linux OS, iPhone, iPad, Android
Requirements:
Adobe PDF Reader & WinZip
Print Quality
Readability:
High-resolution, searchable, bookmarked for easy navigation
Usability:
Printable pages, zoomable for detailed views
Binding Type
Type:
Digital Download (PDF)
Paper Type
Not Applicable:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Options:
Multiple diesel and petrol engines covered (specifics vary by market and sub-model, e.g., 2KD-FTV 2.5L Diesel, 1KD-FTV 3.0L Diesel, 2TR-FE 2.7L Petrol, 5L-E 3.0L Diesel).
Performance
Power And Torque:
Detailed specifications for each engine variant will be found within the manual, including horsepower and torque figures.
Fuel System
Injection Type:
Common Rail Direct Injection (for diesel variants), EFI (for petrol variants). Manual covers system diagnostics and repair.
Maintenance
Timing Belt Type:
Timing belt (on some petrol engines) or timing chain (on diesel engines). Manual provides replacement procedures for belts and maintenance for chains.
Emissions
Emission Control:
Information on emission control systems and troubleshooting will be included.
🔧 Transmission
Standard
Manual Transmission:
5-speed manual transmission commonly available.
Optional
Automatic Transmission:
4-speed automatic transmission often available as an option.
Features
Drivetrain Options:
Available in 2WD (RWD) and 4WD configurations. Manual covers both systems.
Specifications
Fluid Type Atf:
Specific Automatic Transmission Fluid (ATF) type required for automatic transmissions. Consult manual for exact Toyota specification (e.g., Toyota ATF Type T-IV or equivalent).
Fluid Type Mtf:
Specific Manual Transmission Fluid (MTF) type required for manual transmissions. Consult manual for exact Toyota specification (e.g., Toyota MTF or equivalent).
📐 Dimensions
Exterior
Body Styles:
Single Cab, Extended/Space Cab, Double Cab, Chassis Cab.
Wheelbase:
Varies by body style and configuration. Typical ranges from approximately 3085 mm to 3420 mm.
Weights
Curb Weight:
Varies significantly based on configuration (cab type, engine, drivetrain). Expect ranges from ~1600 kg to ~2000 kg+.
Cargo
Payload Capacity:
Varies by model and configuration, typically designed for substantial payload capacity.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Ratings vary by region and specific testing body. Generally designed to meet regional safety standards.
Active Features
Braking Systems:
ABS, EBD (Electronic Brakeforce Distribution) may be available depending on trim and market. Manual details their operation and service.
Passive Features
Airbags:
Front airbags for driver and passenger typically standard or optional. Manual covers system diagnostics and replacement.
💡 Technology Features
Infotainment
Audio System:
Factory audio systems typically included AM/FM radio, CD player, and basic speaker setups. Higher trims may have more advanced units. Manual covers head unit and speaker troubleshooting.
Driver Assistance
ABS Ebd:
Availability of Anti-lock Braking System (ABS) and Electronic Brakeforce Distribution (EBD) varied by market and trim level. Manual explains system operation.
Connectivity
Wiring Schematics:
Comprehensive wiring diagrams for all electrical systems, crucial for diagnosing and repairing any aftermarket or factory electronic issues.
🔧 Maintenance
Service Intervals
Oil Change:
Typical interval of 5,000 km or 6 months for engine oil and filter change, but refer to manual for specific engine and operating conditions.
Transmission Service:
Automatic transmission fluid and filter typically recommended every 40,000-80,000 km. Manual transmission fluid checks/changes at longer intervals. Consult manual for exact recommendations.
Timing Belt Replacement:
If equipped with a timing belt, replacement is critical, typically around 90,000-150,000 km. Manual provides precise interval.
Fluid Specifications
Engine Oil:
Viscosity grade will vary based on engine type and climate (e.g., 5W-30, 10W-30, 15W-40 for diesel). Manual lists specific API/ACEA classifications and Toyota specifications.
Coolant:
Toyota Super Long Life Coolant (SLLC) or equivalent. Manual specifies capacity and type.
Known Issues
Diesel Engines:
Potential for injector issues, turbocharger wear, and glow plug failures depending on mileage and maintenance history. Manual provides diagnostic procedures.
Suspension And Steering:
Wear on ball joints, tie rod ends, and bushings can occur with heavy use or off-road driving. Manual offers inspection and replacement guides.
📚 Vehicle History
Brand Heritage
Toyota Trucks:
Toyota has a long-standing reputation for durable and reliable pickup trucks globally with the Hilux nameplate dating back to 1968.
Model Evolution
Hilux Vigo:
The 'Vigo' designation was primarily used for the second generation Hilux (AN10/AN20), a significant update introducing modern styling and technology. It served as a bridge to the later Hilux Revo.
Production
Manufacturing Locations:
Primarily manufactured in Thailand, with exports to many global markets.
🏆 Awards & Recognition
Recognitions
General Reputation:
The Hilux line is globally recognized for its durability, reliability, and ruggedness, often performing well in critical reviews for pickup trucks.
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