MAINTENANCE AND GENERAL SERVICE Course 031 Technician Handbook (EN)

MAINTENANCE AND GENERAL SERVICE Course 031 Technician Handbook © 2012 Toyota Motor Sales, U.S.A., Inc. TOYOTA Technical Training All rights reserved. This book may not be reproduced or copied, in whole or in part by any means, without the written permission of Toyota Motor Sales, U.S.A., Inc. Revision Date: October 1, 2012

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Table of Contents 031 Maintenance and General Service Maintenance and General Course Menu ........................................................................................ 3 Service Section 1: Introduction to Toyota Training Section 1 Topics/Learning Objectives ................................................... 5 The Toyota Way ..................................................................................... 6 Your Role in Continuous Improvement .................................................. 7 Dealership Product Report (DPR) ..................................................... 7 Technical Assistance System (TAS) ..................................................

8 Submitting Corrections to TIS ............................................................ 9 Submitting Techstream Feedback ................................................... 10 The Role of Training ............................................................................ 11 Skill-level Requirements .................................................................. 11 Training Products ................................................................................. 12 Instructor-led Classes ...................................................................... 12 Web Training Modules .....................................................................

12 Quick Training and Reference Guides ............................................. 13 Toyota Tech Magazine .................................................................... 13 Course Map of Technician Training ..................................................... 14 Managing Your Training ...................................................................... 15 Section 2: Section 2 Topics/Learning Objectives ................................................ 17 Work Mix .............................................................................................. 18 Customer’s Viewpoint ..........................................................................

19 Multipoint Inspection Form .................................................................. 20 Toyota Maintenance Overview Section 3: Shop Safety Section 3 Topics/Learning Objectives ............................................... 21 Jack and Lifting Precautions ............................................................... 22 Using a Jack ................................................................................... 22 Using a Lift ...................................................................................... 23 Exhaust Ventilation .............................................................................

24 Hazardous Materials ........................................................................... 25 Safety Equipment ............................................................................... 26 Supplemental Restraint Systems ........................................................ 27 Hybrid Vehicles ................................................................................... 28 High Voltage Hybrid Vehicle Systems ............................................ 29 Hybrid Battery Warning Label ......................................................... 30 Other High Voltage Systems .............................................................. 31 Section 4:

Tools and Equipment Section 4 Topics/Learning Objectives ............................................... 33 Special Service Tools ......................................................................... 34 Where to Find SSTs ............................................................................ 35 Special Service Tools Web Site .......................................................... 36 SST Master Index ............................................................................... 37 Technical Training i

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Table of Contents 031 Maintenance and General Service Vehicle Preparation Section 5: Section 5 Topics/Learning Objectives ............................................... 39 Service Contract ................................................................................. 40 Verify RO Information ......................................................................... 41 Multipoint Inspection Form (MPI) ........................................................ 42 ј Time ............................................................................................ 42 Air Suspension Check ........................................................................

43 Bulb Check .......................................................................................... 43 Vehicle Protection ............................................................................... 44 Section 6: Vehicle Service Section 6 Topics/Learning Objectives ................................................ 47 Scheduled Maintenance ..................................................................... 48 Information Scheduled Maintenance Guide Website ......................................... 49 Maintenance Procedures .................................................................... 50 Accessory Installation Procedures ......................................................

51 Vehicle Information Labels ................................................................. 52 VIN Decoder ................................................................................... 53 Tire Information Label ......................................................................... 54 Vehicle Emissions Label ..................................................................... 55 Vehicle Inquiry .................................................................................... 56 Health Check ...................................................................................... 57 Customizable Settings ........................................................................

58 Section 7: Inspection, Adjustment and Section 7 Topics/Learning Objectives ............................................... 61 MPI Quick Reference and Training Guides ........................................ 62 Hands-on Shop Activity ...................................................................... 63 Service Section 8: ASM Section 8 Topics/Learning Objectives ................................................ 65 Overview ............................................................................................. 66 Categorizing Findings .........................................................................

67 Maintenance/Service Recommendations ........................................... 68 ASM Consultation ............................................................................... 71 Vehicle Delivery .................................................................................. 71 Consultation and Vehicle Delivery Indicator Lights ............................................................................... 71 Initialization ..................................................................................... 71 Customer Settings ..........................................................................

71 Final Inspection and Delivery .......................................................... 72 Appendix Appendix ........................................................................................... A-1 Multipoint Inspection Form (MPI) ...................................................... A-3 MPI Quick Training Guide ................................................................. A-5 Tire Inspection and Service Quick Training Guide ......................... A-11 Brakes Inspection Quick Training Guide ........................................ A-25 ii Technical Training

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Technician Handbook 031 Maintenance and General Service This page is intentionally blank. 2 Technical Training

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