Documente Academic
Documente Profesional
Documente Cultură
&
Pub . No . TTM101EN
FORE WOR D
Thi s Tra in ing Ma nual has been pr epared for tech nicia ns em ployed by Toyota overse as dist ributor s and
dealers. This manu al. Toyota & the To yota Technician, is Volume 1 of the th ree Trai nin g Ma nual
volumes w hich constitute Step 1 of th e program of skills w hich all Toyota New TEAM * technicians
should master. It should be used by t he inst ructor in con junct ion w ith th e accompanying Instr uct ion
Guide.
The cont ents of th e New TEAM Step 1 Training M anual are as foll ows:
Volume 1 -
Th is vo lume contains the genera l knowledge w hich is necessary for all t hose w ho work as Toyota
techni cians.
Volume 2 -
Fundamentals of Servicing
Thi s volu m e provides a genera l know ledge of th e automobile; it inclu des work safety pro cedures,
vehicle specificat ions, th e fundam entals of elect ricity , etc., as w ell as informati on conce rn ing the
basic constr ucti on and f unctions of automobiles, and simple servicing methods.
Vol ume 3 -
This volume is used to in stru ct th e tech nician on t he necessity of P.D.S. and Perio dic Mai ntena nce
and provid e t he methods used in t hese serv ice operations.
It is not enough j ust to " know" or " understand" -
For t hi s reason , t heory and pract ice have been combin ed in Vols. 2 and 3 of the Train in g Man ual. The
top of each page is ma rked w it h a ~ sym bol to in dicate tha t it is a Theory page or a
sym bol to
"T EAM ; TEAM stand s for 'TeChn ical Education for Au tomo tive M asl e, y"', whi ch is a, tr aining program divide d into ttue e steps according 10 the
te.:: hnic lans rechmcal level. ThIS progra m makes II possjbre for technIcia ns to receiv e Ihe apprcpna re train in g for their level In a svstemanc
manner so as to help them achieve l he skills and efficiency of skilled tech nicians in the shortes t possible time
TABLE OF CONTENTS
Page
OUTLIN E OF TOYOTA
HISTORY OF TOYOTA
2
4
.. ..... .. ,
5
6
1. Passenger Cars
11
12
14
OUTLINE OF TOYOTA -
History of Toyota
OUTLINE OF TOYOTA
HISTORY OF TOYOTA
1.
ESTABLISHMENT OF TOYOTA
The founder of Toyota Motor Corporation was Kiichiro Toyoda. Kiichiro's father, Sakichi Toyoda, was an
inventor of automatic looms, but as it was his belief that "this is the age of the automobile", he wanted to start
the production of automobiles. However, he was unable to see the industry develop in his lifetime, so Kiichiro
became the successor to his father's dream and began producing vehicles for the Japanese domestic market .
1931
Resolving that "the establishment of the automobile industry is our lifework", Kiichiro Toyoda
embarked on a course of research into automotive technologies.
1933
A research lab was built at the Toyoda Automatic Loom Works, and an automotive division was
established.
1935
Trial production of the model A 1 passenger car and model G1 truck was completed .
REFERENCE
A Type Engine Specifications
Number of Cylinders/Arrangement : 6/ln-line
Valve Type : O.HV.
1937
Toyota Motor Company, Ltd. (now Toyota Motor Corporation) was established.
1938
The first automobi le production plant in Japan (Toyota's present Honsha Plant) was built in Koromo
(now Toyota City). This was the foundation of Toyota Motor Corporation.
1950
Toyota Motor Company separated into two companies: TMC and TMS (Toyota Motor Sales)
1950
1965
1982
REFERENCE - --
___...
. 1886
1893
1898
1908
1923
Daimler-Benz (Germany)
1963
Engine
Passenger Cars
Model A 1 Phaeton
Others
Corona
Publica
D Type Engine
U Type Engine
A lternator Generator
Toyota 1000
(Publica Pickup)
Coaster
Cooler
P Type Engine
A utomat ic Transmission
1968
1969
1970
1971
1972
1973
Corolla
To y ota 2000GT
Carina , Celica
Hiace, Hilu x
Liteace
H Type Enqine
T Type Engine
EFI Engin e"
Tercel 2W D
1979
1980
Supra
Camry
A Type Engi ne
1987
G Type Engin e
Turbocharged Engine
S Type Engine
TCCS Engine ' 3
C and Y Type Engines
Multi-valve Engin e
W Type Engine
E Type Engine
Supercha rged Engine
N Type Engine
Twin Cam Engin e w ith
Scissors Gear
VZ Type Engine
Blizzard
1988
RZ Type Engin e
1981
1989
ABS ' 6
Autom atic Air Conditio ner
B Type Engine
Engi ne w ith EGR' 2 Emission
Control Device
Starl et
1978
1983
1984
1985
1986
CCS"
A ir Condition er
Ma cPherson Front Suspension
Power Steer ing, LSD ' ~
Energy Absorbing Steer ing
Column
M Type Engi ne
K Type Engine
Cressida
1974
1976
1977
1982
Others
Engine
Passenger Cars
Terc el4WD
MR2
Lexu s LS 4 0 0
Lexus ES 25 0
UZ Ty pe
PZ Ty pe
HZ Type
HD Ty pe
1990
Prev ia
TZ Type Engi ne
1991
Paseo
Lexus SC 30 0 /400
JZ Typ e Engine
199 2
Toyot a T 10 0
1993
Lex us GS 300
19 94
Toyot a RAV 4
EFI
EGR
. 3 TCCS
CCS
LSD
. 6 ABS
. 1
. 2
Engin e
Engine
Engin e
Engin e
Digita l M eter
ECPB
Piston w ith W ear-Resistant
FRM Ring ' 9
TEMS " o
EM AS , 1
TRC , 2
SRS ' 1 3 Airbag Syst em
FZ Typ e Engin e
KZ Ty pe Engi ne
M Z Ty pe Engine
. 1 ELR
ECT
. 9 FRM
. ,o TEMS
. 1 1 EM AS
. 1 2 TRC
" 3S RS
OUTLINE OF TOYOTA -
History of Toyota
Engine
Passeng er Cars
1995
Avalon
Hiace SBV
1996
Picnic
M eq a-Cru iser
RX30 0
Aven sis
1997
1998
Snaclo
1999
Tund ra
Yar is
IS200
Centu ry
Truck s an d Buses
M Z Type Engi ne
RZL Type
3S Type Engi ne
M Z Ty pe Engi ne
4A'7 A ' 3S'2C Type Engine
4A Ty pe Engine
VZ 'U Z Type Engine
1SZ
1G Type Engine
GZ Type Engi ne
Others
OUTLIN E OF TOYOTA -
1. GEN ERAL
Company Name
Date Established
Capitalization
No. of Em ployees
70,600
Products
Automobiles (Passenger Cars, Trucks, & Buses), Indu strial Vehicl es,
Auto Parts, Prefabricat ed Homes
(Past 15 Years)
--e==l
~
~
-~. _ -
_.
- 3.4
c---
3.7
4.0
3.6
-c--- -
4.2
4.0
--
4. 1
- - =.:..:..:..- - - -- - - - - -- - - - - -- - -- - - - - - - -- - - - - - - - - - -- - - --
3.9
--
--
-- - 3.6
"
C---
.... .. .. .. . . .. . .. .. . . . .... ..
~
3.5
~
--
--
.-
--
-.
--
--
- 3.2
.-
--
--
--
--
..
--
--
.-
--
.-
--
--
3.3
.
-
--2.0 - l - -
--I1.7- -- 1.8 --
--
--
--
1.9
l-
I-
1.8
1.8
- - 1.7
-
'-
1.7
-- l1.7
--I1.7---
--I-
1.5
--
--
1.5
3.4
.3.5
--
..
--
- -1.2
I-
1.3
-l -
..
..
1.5
o
1983
'84
'85
'86
'87
'88
'89
' 90
'91
' 92
' 93
'94
'95
'96
'97
Note: Production and export s exclude KD sets and overseas prod uction .
November 2006
2.
Established
Location
Honsha Plant
19 38
Motomachi Plant
19 59
I<amigo Plant
1965
Takaoka Plant
1966
Miyoshi Plant
19 68
Chassis parts
19 70
Myochi Plant
1973
Shimoyama Plant
19 7 5
1978
Tahar a Plant
19 79
Teiho Plant
1986
Hirose Plant
1989
1992
ToyotaMotor Hokkaido,lnc.
199 2
A uto part s
U.K. 1 - - .
Turk ey 1 - - ---,
Portuga l 1-4t
~
Pakistan 1
India 1
Bangladesh 1
Keny a 1
- -- - -t.
.J
.1r
A
_ _- - - - - -
L
,
-
Canada 2
Japan
r-;:==-
- - - Indonesia 1
New Zealand 1
Au stralia 1
Argentina 1
START OF SALES
1966
Corolla
100
200
300
I:
290
Camry
1982
134
Toyota RAV4
1994
121
Tercel
1978
84
Star let
1978
80
Lex us ES 300
1989
61
Lexus LS 400
1989
24
PICN IC
1996
21
,
,
9,907
293
I:
I ::
2,649
:
:
:
1,104
328
279
29
Celica
1970
18
,
,
Previa
1990
14
Lexus GS 300
1993
14
,,
,
,
,,
,
,,
:
:
:
:
Coro nal
Carina G
1958
11
Paseo
1991
Crown
1954
Lexus
SC 300/400
1991
Supra
1986
MR2
1984
,,
153
709
81
162
Hiluxl
4Ru nner
1968
287
Land Cruiser
1952
164
Hiace
1967
76
Dynal
Toyo ace
1957
27
1992
25
1971
10
Toyota
noo
Lit eace
1959
Stout
1953
Toyota Truck
(He avy-Duty)
1951
Coaster
200
100
,
,
,,
,
:
:
360
2,831
188
(Unit: 1,000 vehicles)
3,047
67
2. TRUCKS AND BUSES (Inc luding pas senger vehicles of the same name)
MODEL NAME
CUMULATIVE
TOTAL
2,167
I
I
400
300
400
CUMULATIVE
TOTAL
7,465
2,669
1,632
740
149
414
145
222
182
1.
Nissan
13,502
1 1 ,726 ~
Honda
,
,
11,306
,
,
,
,
Mitsubishi
1 ~69
Mazda
500
1,000
2,000
3,000
2,500
3,500
EXPORT SHIPMENTS
DOMESTIC SALES
2.
1,240
6,000
5,000
4,000
3,000
2,000
1,000
1990
1991
1992
REFERENCE - - - - - - - -- - --
1994
199 3
---::::=;:::::::::::::----
1996
2.
309
5,630
4,900
31,00 0
3.
No. of Distributors
No. of Dealers
No. of Service Shops
No. of Technicians
168
7,564
6,30 0
48,700
Jap an
Euro pe
North America
20 /330/2,900
4/1,430/11 ,700
Africa
49 /360/3 ,900
33 / 750/11,200
Lat in America
and Caribbean
4 0/ 24 0/ 3,000
Estab lished
Main Products/Activities
Nov. 1926
Mar. 1940
May 194 1
Toyota A ut o Body Co . Lt d .
A ug. 1945
J uly 1948
J une 194 9
DENSO CORPORATION
Dec. 1949
Toyoda Bo sho ku
Corpo rat io n
May 1950
A ug. 1953
Nov. 1960
Apr. 1946
J une 1949
May 194 2
M ar. 190 7
10
form of cars . For this reason, Toyota's basic policy can be expressed in the two words: "CUSTOMER FIRST" .
Under this policy or way of thinking, the customer is number one, the dealer/distributor is number two, and
the manufacturer is number three -
In other words, the benefits from a vehicle go first to the customer, then to the dealer /distributor, and finally to
the manufacturer. If this is aimed at, the result will be not just increased vehic le sales, but the development
and prosperity of Toyota as a whole -
but these can only be realized by gaining the trust and confidence of
the customer.
Furthermore, even after a vehicle is paid for, the sale is only half comp lete: the sale can be considered
complete only when the customer has actually used the vehicle and is fully satisfied with it.
Thus , the job of all Toyota dealer /distributors service departments and Toyota Motor Corporation (TMC) is to
make it possible for customers to use their vehicles with confidence and satisfaction. That is, you, as a Toyota
technician, have the important responsibi lity of raising the level of customer satisfaction through your
competent servicing and repairs .
Customer
Satisfaction
11
No.1
Quality
Product
TQS
Increased Customer
Visits to Workshop
Increased Repeat and
Referr al Vehicle Sales
Increased Sales of Parts
h>
Financial
Stability
and
Long-Term
Development
of Dealer/
Distr.
OHP 7
Your service departm ent, too, engages in TQS (Toyota Quality Service) activities in order to realize the abovementioned sales concept. " TQS activities" are activities designed to bind the dealer /distributor and TMC
togeth er in providing No. 1 Quality Product s and No. 1 After-Sales Service to obtain the "Best Customer
Satisfaction".
Increa sing your custom ers' satis faction will not only help your company prosper -
own job satisfaction. This is because, as we mentioned above, your customers ' satisfaction will ref lect onto
you r company, and as a result, you yourself will also benefit - for example, your working env ironment might
improve, you may receiv e better treatment (salary, promotions, etc.) from your company, and you could obtain
greater job security.
12
Production of Suitable
Vehicles
Dealer/Distributor
Branch
Customer
I
TMC
Distributor
I
I
I
I
I
I
I
I
ProductlTechnical
Information
ProductiTechnica I
Information
Product/Technical
Information
No. 1 After-Sa les Service means offering the best service in town -
exceeds that provided by your competitors, thus keeping his or her vehicle in the best condition at all times,
and making sure he or she can always use the vehicle with confidence.
Customer
Dealer/Distributor
Branch
I
I
I
I
I
Service
Guidance &
Assistance
Distributor
TMC
Guidance &
Assistance
* Caring Service
Customers have four expectations regarding service :
Cordial treatment
Accurate, reliab le servicing
Reasonable charges
Efficient. speedy servicing
In addition, many customers would like "something extra" -
expression in extra little services for customer convenience, such as oiling squeaky door hinges,
"professional advice" (tips on driving in the mountains, for example) given by the Service Advisor or other
workshop staff -
13
WHAT IS A TOYOTA TECHNIC IAN? - What Does Toyota Ask of You, a Toyota Technician?
1.
2.
Speedy,
Reliab le
Servicing
14
Minimum
Cost
WHAT IS A TOYOTA TECHN ICIAN ? - What Does Toyota Ask of You, a Toyota Technician?
15
W HAT IS A TOYOTA TECHNICIAN? - The 10 Pr incip les of Bette r Workmanship for Technicians
1.
PROFESSIONAL APPEARANCE
Wea r a clean uniform w it h your name on it.
A lways wear safety shoes.
2.
3.
4.
WORK SAFETY
Use too ls & other equipment (auto lift, jacks, grinde rs, etc.) correc t ly.
Be careful of fi re; do not smoke w hile wo rk ing.
5.
16
WHAT IS A TOYOTA TECHN ICIAN? - The 10 Principles of Bette r Workm ansh ip for Tech nicians
REFER ENCE-
Depending on th e conditions prevail ing in differe nt market s (countries), th e basic prin ciples (such as
methods of greet ing) to be obs erved may di ffer somew hat. If the di str ibu tor in your count ry has
established a diff erent version of these ten basic principles, please use th em .
6.
7.
8.
9.
17
@TOYOTA
~
(
OV ERSEAS SERVICE DIVISIO N
PRINT ED IN JAPAN
89 03 N50002
NAME