1. Introduction to Your Manual
This comprehensive Haynes Service and Repair Manual provides detailed, step-by-step instructions for the maintenance, servicing, and repair of Toyota Yaris models manufactured between 1999 and 2005, specifically those equipped with petrol engines. The manual is designed to assist both novice and experienced mechanics in performing various tasks, from routine checks to complete engine overhauls.
Image 1.1: Front cover of the Toyota Yaris Haynes Service and Repair Manual, indicating coverage for 1999-2005 petrol models.
1.1. About This Manual
Every Haynes manual is based on a complete strip-down and rebuild of the vehicle in our own workshop. This hands-on approach ensures that all procedures are thoroughly tested and clearly explained. The manual includes:
- Step-by-step guides to maintenance and repair.
- Hundreds of photographs and illustrations for visual guidance.
- Spanner ratings to indicate job difficulty.
- Helpful tips and shortcuts from experienced mechanics.
- Tool tips for using common tools and avoiding special equipment.
Image 1.2: An example page detailing the features found within the manual, including spanner ratings for job difficulty.
Image 1.3: A page illustrating the manual's focus on DIY-friendly techniques, using common tools and clear instructions.
2. Safety Precautions
Always prioritize safety when working on your vehicle. Before beginning any procedure, ensure you have read and understood all relevant safety warnings and instructions. Wear appropriate personal protective equipment (PPE) such as gloves and eye protection. Disconnect the battery when working on electrical systems, and ensure the vehicle is securely supported on jack stands before working underneath it. Refer to the 'Safety First!' section within the manual for comprehensive safety guidelines.
3. Routine Checks and Roadside Assistance
Regular checks and knowing how to handle common roadside issues are crucial for maintaining your Toyota Yaris. This section covers essential procedures to keep your vehicle in optimal condition and address minor problems.
3.1. Roadside Repairs
- Jump starting
- Wheel changing
- Identifying leaks
- Towing
3.2. Weekly Checks
- Underbonnet check points
- Engine oil level
- Coolant level
- Brake and clutch fluid level
- Screen washer fluid level
- Power steering fluid level
- Wiper blades
- Tyre condition and pressure
- Battery
- Electrical systems
3.3. Lubricants and Fluids
Information on recommended lubricants and fluid types for various vehicle systems.
3.4. Tyre Pressures
Guidelines for correct tyre pressures to ensure safety and optimal vehicle performance.
4. Scheduled Maintenance
Adhering to the manufacturer's recommended maintenance schedule is vital for the longevity and reliability of your Toyota Yaris. This section details routine servicing tasks and procedures.
4.1. Routine Maintenance and Servicing
This subsection outlines the periodic maintenance tasks required for your vehicle, including oil changes, filter replacements, and general inspections.
Image 4.1: An example page detailing procedures for the 20,000-mile service interval, including fluid changes and inspections.
4.2. Maintenance Procedures
Detailed, step-by-step instructions for performing various maintenance tasks, ensuring correct execution and optimal results.
5. Repair Procedures
This section provides comprehensive repair instructions for major vehicle systems, guiding you through complex tasks with clear explanations and illustrations.
5.1. Engine and Associated Systems
- Engine in-car repair procedures
- Engine removal and overhaul procedures
- Cooling, heating and air conditioning systems
- Fuel system
- Emission control and exhaust systems
- Starting and charging systems
- Ignition system
5.2. Transmission
- Clutch
- Manual transmission
- Automatic transmission
- Driveshafts
5.3. Brakes and Suspension
- Braking system
- Suspension and steering
Image 5.1: A detailed page illustrating the repair and maintenance procedures for the suspension and steering components.
5.4. Body Equipment
- Bodywork and fittings
- Body electrical system
Image 5.2: An example page demonstrating the removal and installation of various bodywork and interior fittings.
5.5. Wiring Diagrams
Detailed wiring diagrams are included to assist in diagnosing and repairing electrical faults.
6. Troubleshooting
This section provides guidance on identifying and resolving common vehicle problems. It includes a fault finder to help pinpoint specific issues and offers step-by-step diagnostic procedures.
7. Technical Specifications
This section provides critical technical data and specifications for your Toyota Yaris, essential for accurate maintenance and repair.
7.1. Capacities
- Engine oil (including oil filter): 3.2 litres (All models)
- Cooling system (approximate): 4.7 litres (All models)
- Manual transmission: 1.4 litres (1.0 litre engine models), 1.9 litres (1.3 litre engine models)
- Automatic transmission: 5.5 litres (From dry), 2.1 litres (Drain and refill)
- Fuel tank: 45.0 litres (All models)
7.2. Cooling System
Antifreeze mixture: 50% antifreeze. Protection down to -37°C. Refer to antifreeze manufacturer for latest recommendations.
7.3. Auxiliary Drivebelt
Deflection (tension check):
- Models with manual steering: New belt: 4.5 to 5.5 mm, Used belt: 6.0 to 6.5 mm
- Models with electric power steering: New belt: 4.5 to 5.5 mm, Used belt: 6.0 to 6.5 mm
- Models with hydraulic power steering: New belt: 8.5 to 9.5 mm, Used belt: 11.5 to 12.5 mm
Note: Models with hydraulic power steering will have a fluid reservoir - refer to 'Weekly checks'.
7.4. Ignition System
Spark plugs:
- 1.0 litre engine models: Up to June 2001: NGK BKR5EYA or Denso K16R-U (Gap: 0.8 mm)
- July 2001 onwards: Bosch FR7DPP (Gap: 0.9 to 1.0 mm), Denso K20R-U11 (Gap: 1.0 to 1.1 mm)
- 1.3 litre 2SZ-FE engine models: Denso K16R-U (Gap: 0.8 mm)
- 1.3 litre 2NZ-FE engine models: NGK BKR5EYA or Denso K16R-U11 (Gap: 1.1 mm)
*The spark plug gap quoted is that recommended by Toyota for their specified plugs listed above. If spark plugs of any other type are to be fitted, refer to their manufacturer's recommendations.
Note: Refer to Chapter 2A for engine code information.
7.5. Brakes
Friction material minimum thickness:
- Front brake pads: 1.0 mm
- Rear brake shoes: 1.0 mm
7.6. Tyre Pressures
Refer to 'Weekly checks' on page 0•18 for detailed tyre pressure information.
Image 7.1: A page from the manual detailing various servicing specifications, including fluid capacities, drivebelt deflection, and spark plug gaps.
8. Additional Reference Information
This section contains supplementary information to aid in understanding and working with your Toyota Yaris.
- Dimensions and weights
- Conversion factors
- Buying spare parts
- Vehicle identification
- General repair procedures
- Jacking and vehicle support
- Disconnecting the battery
- Tools and working facilities
- MOT test checks
- Glossary of technical terms
9. Support and Contact Information
For further assistance or inquiries regarding this manual, please refer to the publisher's official website or contact their customer support. Ensure you have the manual's ISBN (1785213245 or 978-1785213243) available for reference.