P Mfs
c Apply adhesive to 2 or 3 threads of the taper screw. Adhesive Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. d Install the taper screw plug. Install a new gasket and the oil strainer with the 2 bolts and 2 nuts. Torque 8 N m 80 kgf-cm, 69 in.lbf a Remove any old packing FIPG material and be careful not to drop any oil on the contact surfaces of the oil pan and cylinder block. Using a razor blade and gasket scraper, remove all the old packing FIPG material from the gasket...
Check Piston Stroke Of Overdrive Brake
a Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. Set part Afo. Component part No. b Measure the stroke applying and releasing the compressed air 392 785 kPa, 4 8 kgf crn2 or 57 114 psi as shown in the illustration. Piston stroke 1.40 1.70 mm 0.0551 0.0669 In. This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides...
Install Intake Pipe
Place a new gasket on the intake manifold. Connect the air hose and install the intake pipe. Press the clamp lock together with the pliers and press down the tip of the lock plate. Carefully let the lock spread apart. Take care not to let the pliers slip. Install the 4 seal washers and nuts. Torque 12 N-m 120 kgf-cm, 9 ft lbf
Foreword
This repair manual has been prepared to provide information covering general service repairs for the 1KZ- TE engine equipped on the TOYOTA HILUX. Please note that the publications below have also been prepared as relevant service manuals for the components and system in this engine.
Info Lxn
Check the check engine warning light. 1 The check engine warning light will light up when the ignition switch is turned ON and the engine is not running. If the check engine warning light does not light up, proceed to troubleshooting of the combination meter. 2 When the engine is started, the check engine warning light should go off. If the light remains on, the diagnosis system has detected a malfunction or abnormality in the system, b Check the DTC. 1 Turn the ignition switch ON.
Inspection Yoq
a Engine at normal operating temperature c All pipes and hoses of air induction system connected d All accessories switched OFF e All vacuum lines properly connected f ECD system wiring connectors fully plugged g Valve clearance set correctly h Injection timing set correctly
A Qkw
N-m kgf-cm, ft-lbf Specified torque N-m kgf-cm, ft-lbf Specified torque When removing the crankshaft pulley and timing gear as the timing belt is off and the valve interferes with the piston, never,turn the crankshaft to the right beyond the dead point above the No.4 cylinder. j 1. REMOVE TIMING BELT AND PULLEYS . 2. REMOVE DRIVE BELT, FAN AND WATER PUMP amp ' PULLEY See page CO-5
Inspection Procedure 1
Reference INSPECTION USING OSCILLOSCOPE . . During cranking or idling, check the waveform between terminals TDC and TDC- of the engine ECU connector. HINT -
Info Ufg
All conditions below are detected continuously for 8 sec. or more a Vehicle speed signal 0 km h 0 mph b Engine speed 1,800 - 3,200 rpm c Engine coolant temp. 60C 176F or more d Accelerator pedal opening angle 32 or more Combination meter ' lt 5- Open or short in vehicle speed sensor circuit
Install Turbo Water Pipe
a Place a new gasket on the turbocharger with the protrusion facing upward. NOTICE Be careful of the gasket installation direction. b Install the water pipe with the 2 nuts and bolt. Torque Nut 12 N-m 120 kgf-cm, 9 ft-lbf Bolt 8 N-m 80 kgf-cm, 69 in.lbf c Connect the 2 water bypass hoses to the turbo water pipe. 8. INSTALL EXHAUST MANIFOLD HEAT INSULATOR Install the heat insulator with the 4 bolts. 9. INSTALL TURBOCHARGER HEAT INSULATOR Install the heat insulator with the 4 bolts. 10. INSTALL...
Inspect Camshaft Journals
Using a micrometer, measure the journal diameter. Journal diameter 27.969 - 27.985 mm 1.1011 -1.1018 in. t j If the journal diameter is not as specified, check the oil clearance. 16. INSPECT CAMSHAFT BEARINGS Check the bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set.
P Dgg
sr 2 Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge. SST 09223-78010 3 Apply MP grease to the oil seal lip. A b If the timing gear cover is instatretfTOTftS eyffmter btock 1 Using a screwdriver, pry out the oil seal. NOTICE Be careful not to damage the injection pump drive gear. Tape the screwdriver tip.
Inspection Procedure Mza
If DTC 22, 24, 35 and 39, E2 sensor ground may be open. a Remove the glove compartment See page ED-25 . b Turn the ignition switch ON. CHECK Measure the voltage between terminals THA and E2 of the engine ECU connector. OK
Info Gik
VSV for No.1 Intake VSV for No.2 Intake Constrictor Control Constrictor Control Vacuum Hose Connector Connector No.2 Camshaft Timing Pulley No.2 Camshaft Timing Pulley Flange N-m kgf-cm, ft-Ibf Specified torque
Installation Nub
1. fiHECK PISTON PROTRUSION AND SELECT CYLINDER HEAD GASKET a Check the piston protrusions for each cylinder. 1 Clean the cylinder block with solvent. Y 2 Sent the piston of the cylinder to be measured to slightly before TDC. - 3 Place a dial indicator on the cylinder block, and set the dial indicator at 0 mm 0 in. . __________ HINT .-. st - T - jt ' Use a dial indicator measuring tip a shown in the illustration. f Make sure that the measuring tip is square to the cylinder block gasket surface...
Inspection Flz
The thermostat is numbered with the valve opening temperature. a Immerse the thermostat in water and gradually heat the water. b Check the valve opening temperature. Valve opening temperature 80 - 84 C 176 - 183 F If the valve opening temperature is not as specified, replace the thermostat. Valve lift 10 mm 0.39 in. or more at 95 'C 203 F If the valve lift is not as specified, replace the thermostat. d Check that the valve is fully closed when the thermostat is at low temperatures below 40 C...
Bd
lt 51e idfirCoHh ,e t6f_ Support Clip
Nspection Procedure
DTC 22, 24, 35 and 39 are output simultaneously, E2 sensor ground may be open. a Remove the glove compartment See page ED-25 . b Turn the ignition switch ON. CHECK Measure the voltage between terminals THF and E2 of the engine ECU connecter. OK
B Rcc
If the belt tension is not as specified, adjust it. HINT New belt refers to a belt which has been used less than 5 minutes on a running engine. Used belt refers to a belt which has been used on a running engine for 5 minutes or more. After installing a new belt, run the engine for about 5 minutes and recheck the deflection. VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES Check that the wiring is in good condition. Check that there is no abnormal noise form the alternator while...
Bq
b Check the lock plate height H after completing the caluk-ing. 7.40 - 7.80 mm 0.2913 - 0.3071 in. If not within the specified height, adjust the stopper bolt of the handle again and caulk again. a Install a new O-ring to the drain plug.
B Tyy
yji rfHyy lW h b Atn tfm p tf lf d Install new terminal 30 kit parts. 1 Temporarily install a new terminal insulator inside . 2 Temporarily install a new contact plate. 3 Temporarily install a new terminal bolt. 4 Temporarily install a new O-ring. 5 Temporarily install a new packing and new terminal insulator outside . Match the protrusion of the insulator with the indentation of the housing. 6 Temporarily install a new wave washer. 7 Temporarily install a new terminal nut. NOTICE Be careful to...
P Iui
g Install the alternator with the pivot be lock baft. 11 21 Nm 210 kgf-cm, 15 ft Ibf for Lock bo 62 N m 620 kgfcm, 45 ft lbf for Pivot boft t 2. INSTALL CAMSHAFT OIL SEAL RETAINER See page EM-34 j 3. INSTALL NO.1 CAMSHAFT TIMING PULLEY Seepage EM-18 4. INSTALL IDLER PULLEY AND TIMING BELT j See page EM-18 5. INSTALL WATER PUMP PULLEY, FAN AND DRIVE BELT Install the pump pulley, the fluid, fan and coupling assembly with the 4 nuts. When intalling the fluid coupling on the water purhp, must...
Inspect Intake And Exhaust Manifolds
Using precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage 0.40 mm 0.0157 in. If warpage is greater than maximum, replace the manifold. 21. INSPECT CYLINDER HEAD BOLTS ------ Using vernier calipers, measure the minimum outer diameter of the compressed thread at the measuring point. Standard outer diameter 11.8 -12.0 mm 0.465 - 0.472 in. Minimum outer diameter 11.6 mm 0.457 in. If the outer diameter is less than minimum, replace...
S Rpa
6. REMOVE FUEL TEMPERATURE SENSOR AND DISTRIBUTIVE HEAD PLUG NO.2 a Hold the distributive head plug, and using a 19 mm deep socket wrench, remove the fuel temperature sensor and O-ring. b Remove the distributive head plug and O-ring. c Bemove the strainer and wave washer. 7. REMOVE DISTRIBUTIVE HEAD PLUG NO.1 Using SST, remove the distributive head plug. SST 09260-54012 09262-54010
Info Rpt
2. INSPECT RADIATOR CAP NOTICE If the radiator cap has contaminations, always rinse it with water. Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. When performing steps a and b below, keep the tester at an angle of over 30 above the horizontal. a Using a radiator cap tester, slowly pump the tester and check that air is coming form the vacuum valve. Pump speed 1 push 3 seconds or more I Push the pump at a constant speed. I If air is not...
Info Nzi
HEAT METHOD When the problem seems to occur when the suspect area is heated. -eat the component that is the likely cause of the malfunction . a hairdryer or similar object. Check to see if the malfunction . xurs. Do not heat to more than 60 C 140 F . Temperature is limited not to damage the components. 2 Do not apply heat directly to parts in the ECU.
Adjust Injection Timing
Remove the cylinder block insulator. Loosen the bolt holding the injection pump to the injection Loosen the 2 nuts holding the injection pump to the timing gear case. Align the punching line and upper processing surface by slightly tilting the injection pump. Tighten the 2 nuts holding the injection pump to the timing gear case. Torque 21 N-m 210 kgf cm, 15 fWbf r Tighten the bolt holding the injection pump to the injection pump stay. Torque 32 Nm 330 kgf.cm, 24 ftlbf Reinstall the cylinder...
Inspect Camshaft Journal Oil Clearance
-Glean the bearing caps and camshaft journals. Place the camshaft on the cylinder head. Lay a strip of Plastlgage across each of the camshaft journals. Install the bearing caps. See page EM-64 Torque 18 N m 185 kgf cm, 13 ft-lbf Measure the Plastigage at its widest point. Standard oil clearance 0.025 - 0.062 mm 0.0010 - 0.0024 in. t Maximum oil clearance 0.10 mm 0.039 in. If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head...
Remove Piston Rings
a Cteing a piston ring expander, remove the 2 compression rings and oil ring. Arrange the rings in correct order only. blSCONMEfcT CONNECTING ROD FROM PISTON a Using a small screwdriver, pry off the snap ring form the piston. . b Gradually heat the piston to approx. 60 C 140 F . c Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. The piston pin are matched set. Arrange the pistons, pins, rings, connecting rods and bearings in correct...
Removal Fus
a Disconnect the 2 VSV connectors. b Disconnect the 2 vacuum hoses from the actuator. c Disconnect the vacuum hose from the 3-way from vacuum pump . d Remove the 4 nuts and seal washers. s e Disconnect the 2 PCV hoses. f Use pliers to pinch the ends of the clamp together until the lock plate engages the catch. Make sure the lock plate and catch are engaged securely. g Remove the intake pipe and gasket. h Remove the 2 nuts and accelerator cable bracket from the intake pipe. i Remove the 2 nuts...
Removal Uzj
1. DRAIN ENGINE COOLANT 2. REMOVE DRIVE BELTAS, FAN AND WATER PUUP PULLEY , a Stretch the belt tight arid loosen the 4 pump pulley set nuts. j f lt - b Loosen the pivot bolt and adjusting lock bolt. c Loosen the adjusting bolt, and remove the drive beft. d Remove the 4 nuts, fan and fluid coupling assembly and pulley. 3. REMOVE TIMING BELT AND IDLER PULLEY See page EM-13 4. REMOVE N0.1 CAMSHAFT TIMING PULLEY See page EM-13 5. REMOVE CAMSHAFT OIL SEAL RETAINER See page EM-24
H Jeb
ri nnrmiinirlt mirtn riniiTitinto amp dt - t ' xr a Read the pressure gauge just a the injection pressure 14,808-15,593 kPa 151 - 159 kgf cm2, 2,148 - 2,261 psi 14,320-15,100 kPa 146-154 kgf cm2, 2,076 - 2,190 psi Proper nozzle operation can be determined by a swishing sound. If the opening pressure is not as specified, disassemble the nozzle holder and change the adjusting shim on the top of the pressure spring. Adjusted opening pressure 14,220-15,200 kPa
1kzte Engine Compression In Psi
If there is lack of power, excessive oil consumption or poor fuel lt leiii eri economy, measure the compression pressure. Allow the engine to warm up to normal operating temperature. 2. DISCONNECT INJECTION PUMP SPILL CONTROL VALVE CONNECTOR gt 3. DISCONNECT GLOW PLUG WIRE FROM GLOW w PLUG CONNECTOR v el NOTICE v v In order not to short the glow plug wire, apply vinyl tape around the terminal. ' i 4. REMOVE INTAKE PIPE See page EM-44 3X9 ion 3i it 1i 5. , REMOVE INJECTION PIPES See page FU-18f...
Disassembly 1
1. Remove clutch cover and disc 4. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 5. REMOVE TIMING BELT AND PULLEYS 6. REMOVE CYLINDER HEAD j See page EM-44 7. REMOVE ALTERNATOR AND ALTERNATOR BRACKET See page CO-5 8. REMOVE WATER PUMP Swpage CO -5 9. REMOVE INJECTION PUMP See page FU-18 10. REMOVE OIL COOLER See page LU-21 11. REMOVE TIMING GEARS See page EM-24 12. TIMING GEAR CASE See page LU-7 13. REMOVE WATER INLET AND THERMOSTAT See page CO-11 14. REMOVE WATER TEMPERATURE SENSOR 15. REMOVE...
J Tqk
k Using SST, disconnect the injection pump from the timing gear case. SST 09960-50010 09951-05010, 09952-05010, I 09953-05020, 09954-05010 Remove the 2 nuts, injection pump and cylinder block insulator. j y m Remove the O-ring from the injection pump.
Inspect Idler Gear
a Using a cylinder gauge, measure the inside diameter of the idler gear. 4 Idler gear inside diameter 44.000 - 44.025 mm 1.7323 - 1.7333 in. S qirtr ' t ' b Using a micrometer, measure the diameter of the idler gear shaft. - 43.955 - 43.990 mm 1.7305 -1.7319 in. I c Subtract the idler gear shaft diameter measurement from the idler gear inside diameter measurement. Standard oil clearance 0.010 - 0.070 mm 0.0004 - 0.0028 In. Maximum oil clearance 0.20 mm 0.0079 in. If the clearance is greater...
1kz Idler Gear Removal
7. CHECK THRUST CLEARANCE OF IDLER GEAR Using-a dial indicator, measure the thrust clearance. Standard thrust clearance 0.06 - 0.11 mm 0.0024 - 0.0043 In. Maximum thrust clearance 0.30 mm 0.0118 in. If the thrust clearance is greater than maximum, replace the thrust plate. If necessary, replace the idler gear and or idler gear shaft. The matchmark on each gear laces the front of the en-t - gine. Take care not to damage the gear teeth when removing and installing the gears. Do not use parts that...
P Puy
b Check the drive belt deflection by pressing on the belt at the points indicated in the illustration with 98 N 10 kgf, 22 . t, Ibf of pressure, r. Drive belt deflection If necessary, adjust the drive belt deflection. Using a belt tehsion gai ge, measure the belt tension. Belt tension gauge
Remove Oil Strainer
Remove the 2 bolts, 2 nuts, oil strainer and gasket. 12. REMOVE OIL PUMP TIMING GEAR CASE a Before removing the 2 nuts holding the timing gear case to the injection pump, check if the injection pump period lines are aligned. If not, place new matchmarks for reinstallation. c Remove the 8 bolts and union bolt. d Using a plastic-faced hammer, lightly tap out the timing gear case.
Info Oyc 1
Open or short in throttle position sensor circuit for 0.05 sec. or more Open or short in throttle position sensor circuit Throttle position sensor Mien the connector for the throttle position sensor is disconnected, DTC 41 is not displayed. DTC 41 is dismayed only when there is an open or short in the VA signal circuit of the throttle position sensor. .tO-HU Hi . it- J WSA i j
Circuit Description Sjg
When the ignition switch turns ON, the engine ECU calculates the glow indicator lighting time heating corresponding to the coolant temperature at that time and turns ON the glow indicator light glow plug relay. As the ceramics is used for a glow plug material, the current control is not performed.
B Yvn
3. INSPECT ENGINE ECU See page DM5 a Remove the glow plug relay. Marking SUB GLW RLY b Inspect the glow plug relay continuity. 1 Using an ohmmeter, check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay. 2 Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay.
Circuit Description Ffx
The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the engine ECU. The engine ECU determines the vehicle speed based on the frequency of these pulse signals.
Sc
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools SST and special service materials SSM may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found in section PP Preparation in this manual. Medium Current Fuse and High Current Fuse Equal Amperage Rating
Reassembly 1
Thoroughly clean all parts to be assembled. S Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. lt X Replace all gaskets, O-rings and oil seals with new parts. 1. ASSEMBLE PISTON AND CONNECTING ROD a Install a new snap ring on one side of the piston pin hole. b Gradually heat the piston to 80 C 176 F . . c Coat the piston pin with engine oil. ' d Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. e Install...
Remove Valves
a Using SST, compress the valve spring and remove the 2 keepers. b Remove the spring retainer, valve spring, valve and spring seat. Arrange the valves, valve springs, spring seats and spring retainers in correct order. c Using needle-nose pliers, remove the oil seal. Using5ST, remove the 4 combination chambers. SST 09208-48010 Arrange the combustion chambers in correct order. 1. fcLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK a Turn the crankshaft, and bring each piston to the top dead...