Toyota 3.0L (1KZ-T/1KZ-TE) Turbo Diesel Engine OEM Service & Repair Manual

EG-244 LUBRICATIONSYSTEM DESCRIPTION Afullypressurized,fullyfilteredlubricationsystemhasbeenadoptedforthisengine . OPERATION ENGINE - LUBRICATIONSYSTEM EG 140-02 EG14S-0S  P11699 r VACUUMPUMP VALVELIFTERS& ____~ VALVESTEMS IDLERGEAR --- PISTON&CYLINDERS CAMS i r -- OILNOZZLE CONNECTINGRODS } CAMSHAFTJOURNALS CHECKVALVE --- CRANKSHAFT CYLINDERHEAD -- --7 F i MAINOILHOLE RELIEFVALVE OILFILTER  ~ r- i BALANCESHAFT I ---------------- RELIEFVALVE OILCOOLER i TURBOCHARGER ~CHECK VALVE i RELIEFVALVE OILPUMP j OILSTRAINER OILPAN

ENGINE - LUBRICATIONSYSTEM EG-245 Apressurefeedinglubricationsystemhasbeenadoptedtosupplyoiltothemovingpartsofthis engine .Thelubricationsystemconsistsofanoilpan,oilpump,oilfilterandotherexternalparts OILPUMP Theoilpumppumpsupoilfromtheoilpanandsendsitunderpressuretothevariouspartsofthe engine .Anoilstrainerismountedinfrontoftheinlettotheoilpumptoremoveimpurities .The oilpumpitselfisatrochoidtypepump,whichusesadriverotorandadriveninsidethepump body .Whenthedriverotorrotates,thedrivenrotorrotatesinthesamedirection .Theaxisofthe driverotorshaftisdifferentfromthecenterofthedrivenrotor,sowhenbothrotorsrotate,the spacebetweenthe2rotorschanges .Oilisdrawninwhenthespacewidensandisdischarged whenthespacebecomesnarrow . OILPRESSUREREGULATOR(RELIEFVALVE) Athighenginespeeds,theengineoilsuppliedbytheoilpumpexceedsthecapacityoftheengine toutilizeit .Forthatreason,theoilpressureregulatorwor stopreventanoversupplyofoil . Duringnormaloilsupply,acoilspringandvalve eepthebypassclosed,butwhentoomuchoil isbeingfed,thepressurebecomesextremelyhigh,overpoweringtheforceofthespringand openingthevalve .Thisallowstheexcessoiltoflowthroughthevalveandreturntotheoilpan . OILFILTER Theoilfilterisafullflowtypefilterwithareliefvalvebuiltintothepaperfilterelement .Particles ofmetalfromwear,airbornedirt,carbonandotherimpuritiescangetintotheoilduringuseand couldcauseacceleratedwearorseizingifallowedtocirculatethroughtheengine .Theoilfilter, integratedintotheoilline,removestheseimpuritiesastheoilpassesthroughit .Thefilteris mountedoutsidetheenginetosimplifyreplacementofthefilterelement .Areliefvalveisalso includedaheadofthefilterelementtorelievethehighoilpressureincasethefilterelement becomescloggedwithimpurities .Thereliefvalveopenswhentheoilpressureoverpowersthe forceofthespring .Oilpassingthroughthereliefvalvebypassestheoilfilterandflowsdirectly intothemainoilholeintheengine .

EG-246 PREPARATION SST(SPECIALSERVICETOOLS) RECOMMENDEDTOOLS EQUIPMENT Oilpressuregauge Precisionstraightedge Torquewrench LUBRICANT SSM(SPECIALSERVICEMATERIALS) ENGINE - LUBRICATIONSYSTEM EG14U-06 EGI4V-02 EG14W-O6 EGI4X-07 EG14V-04 08826 - 00080 Sealpac ingorequivalent Oilpan 08833 - 00080 Adhesive1344, Oilpressuresendergauge THREEBOND1344, LOCTITE242orequivalent Item Capacity Classification Engineoil APIgradeCDorbetter Dryfill Drainandrefill w/Oilfilterchange w/oOilfilterchange 8.5liters(9 .0USqts,7 .5Imp .qts) 8.0liters(8.5USqts,7 .0Imp .qts) 7 .3liters(7 .7USqts,6 .4Imp.qts) 09200-00010 EngineAdjustKit ---~,Q 09905-00013 SnapRingPliers 09032-00100 OilPanSealCutter 09228-10001 OilFilterWrench

ENGINE - LUBRICATIONSYSTEM OILPRESSURECHECK EG-247 EG35A-01 1 . CHECKENGINEOILQUALITY Chec theoilfordeterioration,entryofwater,dis- coloringorthinning . Ifthequalityisvisiblypoor,replacetheoil . Oilgrade : APIgradeCDorbetter Recommendedviscosity : Refertoillustration 2 . CHECKENGINEOILLEVEL Theoillevelshouldbebetweenthe"L"and"F"mar s onthedipstic . Iflow,chec forlea ageandaddoilupto"F"mar . 3 . REMOVEOILPRESSURESENDERGAUGE 4 . INSTALLOILPRESSUREGAUGE 5 . WARMUPENGINE Allowtheenginetowarmuptonormaloperating temperature . 6 . CHECKOILPRESSURE Oilpressure : Atidle 29 Pa(0 .3 gf/cm 2 , 4 .3psi)ormore At3,000rpm 250 - 600 Pa(2 .5 - 6 .1 gf/cm 2, 18 - 42psi) 7 . REMOVEOILPRESSUREGAUGE 8 . REINSTALLOILPRESSURESENDERGAUGE (a) Applyadhesiveto2or3threadsoftheoilpressure sendergauge . Adhesive : PartNo . 08833-00080, THREEBOND 1344, LOCTITE242orequivalent (b) Installtheoilpressuresendergauge . 9 . STARTENGINE,ANDCHECKFOROILLEAKS RecommendedViscosity(SAE) : Pl - i 15W-40 20W40 20W50 10W40 tOW50 I 1OW30 5W-30 30 20 i , °C-29  - 18  -7  4  16 27  38 °F--20  0  20  40  60 80  100 TEMPERATURERANGEANTICIPATEDBEFORENEXT OILCHANGE 03174

ENGINE - LUBRICATIONSYSTEM OILANDFILTERREPLACEMENT EG177-03 CAUTION : •  Prolongedandrepeatedcontactwithmineraloilwill resultintheremovalofnaturalfatsfromthes in, leadingtodryness,irritationanddermatitis .Inaddi- tion,usedengineoilcontainspotentiallyharmful contaminantswhichmaycauses incancer . •  Careshouldbeta en,therefore,whenchanging engineoiltominimizethefrequencyandlengthof timeyours inisexposedtousedengineoil .Protec- tiveclothingandglovesthatcannotbepenetrated byoilshouldbeworn .Thes inshouldbethorought- hlywashedwithsoapandwater,orusewater-less handcleaner,toremoveanyusedengineoil .Donot usegasoline,thinners,orsolvents . •  Inordertopreservetheenvironment,usedoiland usedoilfiltermustbedisposedofonlyatdesignated disposalsites . 1 . DRAINENGINEOIL (a) Removetheoilfillercap . (b) Removetheoildrainplug,anddraintheoilintoa container . 2 . REPLACEOILFILTER (a) UsingSST,removetheoilfilter . SST09228-10001 HINT :Putacontainerunderthedrainhose . (b) Cleantheoilfiltercontactsurfaceontheoilfilter mounting .

ENGINE - LUBRICATIONSYSTEM EG-249 (c) Lubricatethefilterrubbergas etwithcleanengine oil . (d) Tightentheoilfilterbyhanduntiltherubbergas et contactstheseatofthefiltermounting . (e) UsingSST,giveitanadditional3/4turntoseatthe filter . SST09228-10001 3 . FILLWITHENGINEOIL (a) Cleanandinstalltheoildrainplugwithanewgas et . Torque :34N .m(350 gf .cm,25ft .lbf) (b) Fillwithnewengineoil . Oilgrade :(Seestep1OilPressureChec ) Capacity : Drainandrefill w/Oilfilterchange 8 .0liters(8 .5USqts,7 .0Imp .qts) w/oOilfilterchange 7 .3liters(7 .7USqts,6 .4Imp .qts) Dryfill 8 .5liters(9 .0USqts,7 .5Imp .qts) (c)  Reinstalltheoilfillercap . 4 . STARTENGINEANDCHECKFOROILLEAKS 5 . RECHECKENGINEOILLEVEL

EG-250 ENGINE - LUBRICATIONSYSTEM OILPUMP COMPONENTSFORREMOVALAND INSTALLATION EG176-07 11 (210, 15) 16(160.12) N .m ( gf cm, ft lbf) •  Non-reusablepart 13(130,9) : Specifiedtorque 34(350,25) P12377

ENGINE - LUBRICATIONSYSTEM OILPUMPREMOVAL (SeeComponentsforRemovalandInstallation) HINT :Whenrepairingtheoilpump,theoilpanand strainershouldberemovedandcleaned . 1 . DRAINENGINECOOLANT 2 . DRAINENGINEOIL 3 . REMOVEDRIVEBELT,FANANDWATERPUMP PULLEY(Seestep2onpageEG-235) 4 . REMOVETIMINGBELT (SeepageEG-32) 5 . REMOVETIMINGGEARS (SeepageEG-41) 6 . REMOVEALTERNATORADJUSTINGBAR (a) Removetheloc bolt . (b) Removetheboltandadjustingbar . 7 . REMOVEALTERNATORANDALTERNATOR BRACKET (Seestep6onpageEG-235) 8 . REMOVEWATERPUMP (Seestep6onpageEG-235) 9 . REMOVEOILLEVELSENSOR (a) Disconncttheoillevelsensorconnector . (b) Removethe4boltsandoillevelsensor . 10 .REMOVEOILPAN (a) Removethe22boltsand2nuts . (b) InsertthebladeofSSTbetweenthecylinderbloc andoilpan,andcutoffappliedsealerandremovethe oilpan . SST09032-00100 NOTICE : •  DonotuseSSTfortheoilpumpbodysideandrear oilsealretainer . •  Becarefulnottodamagetheoilpanflange . EG-251 EG35B-01

EG-252 ENGINE - LUBRICATIONSYSTEM 11 .REMOVEOILSTRAINER Removethe2bolts,2nuts,oilstrainerandgas et . 12 .REMOVEOILPUMP(TIMINGGEARCASE) (a) Beforeremovingthe2nutsholdingthetiminggear casetotheinjectionpump,chec iftheinjection pumpperiodlinesarealigned . Ifnot,placenewmatchmar sforreinstallation . (b)Removethe2nuts . (c) Removethe8boltsandunionbolt . (d)Usingaplastic-facedhammer,lightlytapoutthe timinggearcase . (e) Removethe30-rings .

ENGINE - LUBRICATIONSYSTEM OILPUMPDISASSEMBLY (SeeComponentsforRemovalandInstallation) 1 . REMOVEDRIVENROTOR 2 . REMOVERELIEFVALVE Removetheplug,gas et,springandreliefvalve . OILPUMPINSPECTION 1 . INSPECTRELIEFVALVE Coatthevalvewithengineoilandchec thatitfalls smoothlyintothevalveholebyitsownweight . Ifitdoesn't,replacethereliefvalve .Ifnecessary, replacetheoilpumpassembly . 2 . INSPECTDRIVEANDDRIVENROTORS A . Inspectrotorbodyclearance Usingathic nessgauge,measuretheclearancebetweenthedrivenrotorandbody . Standardbodyclearance : 0 .100 - 0 .170mm(0 .0039 - 0 .0067in .) Maximumbodyclearance : 0 .20mm(0 .0079in .) Ifthebodyclearanceisgreaterthanmaximum,replacetherotorsasaset .Ifnecessary,replacetheoil pumpassembly . B . Inspectrotortipclearance Usingathic nessgauge,measuretheclearancebetweenthedriveanddrivenrotortips . Standardtipclearance : 0 .060 - 0 .160mm(0 .0024 - 0 .0063in .) Maximumtipclearance : 0 .21mm(0 .0083in .) Ifthetipclearanceisgreaterthanmaximum,replace therotorsasaset . EG-253 EG166-07 EG17A-07

Toyota 3.0L (1KZ-T/1KZ-TE) Turbo Diesel Engine OEM Service & Repair Manual

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