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

1999 TOYOTA MOTOR CORPORATION A ll r ight s r es er v ed. This CD may not be repro- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing; Jun. 11, 199901--990611--00--2 FOREWORD This REPAIR MANUAL has been prepared to provide information covering general service repairs for the 1KZ-TE ENGINE equipped on the TOYOTA HILUX. Applicable models: KZN165 series Please note that the publications below have also been prepared as relevant service manuals for the components and system in this engine. Manual Name Pub. No. S HILUX Electrical Wiring Diagram EWD307F All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non--specialized or uncertified technicians perform repair or service only using this manual or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer’s vehicle. In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow the instruction shown below. S Must read this manual thoroughly. It is especially important to have good understanding all the contents written in the PRECAUTION of ”IN” section. S The service method written in this manual is very effective to perform repair and service. When performing the operations following the procedures using this manual, be sure to use tools specified and recommended. If using non--specified or recommended tools and service method, be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer’s vehicle before starting the operation. S If part replacement is necessary, must replace the part with the same part number or equivalent part. Do not replace it with inferior quality. S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is important to warn of all the possible hazardous consequences that might result from failure to follow these instructions. BACK TO ENGINE INDEX VIEW THE MAIN INDEX RM710E-D Pages From Manual CAUTION TOYOTA MOTOR CORPORATION 1KZ-TE TO MODEL INDEX

INTRODUCTION PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS ENGINE MECHANICAL TURBOCHARGER EMISSION CONTROL ELECTRONIC CONTROL DIESEL ENGINE FUEL COOLING LUBRICATION STARTING CHARGING ALPHABETICAL INDEX BACK TO MAIN FOREWORD & To Engine Index ENGINE 1KZ-TE: HILUX Pages From Manual 1KZ-TE MAIN INDEX June 2000 TO MODEL INDEX

INTRODUCTION HOW TO USE THIS MANUAL IN-- 1 ............. GENERAL INFORMATION IN-- 1 .................. IDENTIFICATION INFORMATION IN--3 .......... ENGINE SERIAL NUMBER IN--3 ................. REPAIR INSTRUCTIONS IN--4 ................. GENERAL INFORMATION IN--4 .................. FOR ALL OF VEHICLES IN--8 .................. PRECAUTION IN--8 ............................. HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN--9 ......... GENERAL INFORMATION IN--9 .................. HOW TO PROCEED WITH TROUBLESHOOTING IN-- 10 .............. HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE IN--20 .......... TERMS IN--25 ................................. ABBREVIATIONS USED IN THIS MANUAL IN--25 .... BACK TO MAIN INDEX Pages From Manual TO MODEL INDEX 1KZ-TE

IN04V--04 B07996 B08237 N∙m (kgf∙cm, ft∙lbf) : Specified torque z Non--reusable part z Crankshaft Front Oil Seal z Gasket Relief Valve Spring Plug 49 (500, 36) Driven Rotor -- INTRODUCTION HOW TO USE THIS MANUAL IN--1 HOW TO USE THIS MANUAL GENERAL INFORMATION 1. INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page. 2. PRECAUTION At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN--9. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe- cial Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: CLICK HERE TO VIEW CHAPTER INDEX Pages From Manual CONTINUED TO MODEL INDEX 1KZ-TE

Illustration: what to do and where 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Task heading : what to do SST 09350--30020 (09350--06120) Set part No. Component part No. Detailed text : how to do task (b) Piston stroke: 1.40 — 1.70 mm (0.0551 — 0.0669 in.) Specification Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. Measure the stroke applying and releasing the compressed air (392 — 785 kPa, 4 — 8 kgf/cm 2 or 57 — 114 psi) as shown in the illustration. IN--2 -- INTRODUCTION HOW TO USE THIS MANUAL The procedures are presented in a step--by--step format: S The illustration shows what to do and where to do it. S The task heading tells what to do. S The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: 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 detailed information. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick ref- erence. 8. CAUTIONS, NOTICES, HINTS: S CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. S NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. S HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. 9. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N∙m (310 kgf∙cm, 22 ft∙lbf) CLICK HERE TO VIEW CHAPTER INDEX Pages From Manual TO MODEL INDEX 1KZ-TE

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

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