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Toyota

Toyota Hilux Vigo Service Repair Manual 2005-2009

Toyota Hilux Vigo Service Repair Manual 2005-2009

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Vehicle data plateRef 104907
Brand
Toyota
Vehicle
Truck
Models covered
Hilux, Vigo
Years
2005, 2006, 2007, 2008, 2009
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ 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.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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