Table Of Contents - Toyota 1PZ Repair Manual

Table of Contents

Caution3
Introduction Contents5
How To Use This Manual6
Repair Procedures6
Identification Information8
Engine Serial Number8
General Repair Instructions8
Abbreviations Used In This Manual11
Engine Mechanical Contents12
Table Of Contents12
Description13
Troubleshooting15
Diesel Engine Diagnosis15
General15
Preliminary Checks15
Diesel Electrical System Diagnosis25
Pre-Heating System25
Fuel Cut Solenoid Valve27
Engine Tune-Up28
Inspection/Cleaning Of Air Filter28
Inspection Of Alternator Drive Belt29
Adjustment Of Valve Clearance30
Set No 1 Cylinder To Tdc/Compression30
Adjusting Shim Selection Using Chart (Intake)32
Adjusting Shim Selection Using Chart (Exhaust)33
Adjustment Of Injection Timing34
Install Sst And Dial Indicator34
Release Acsd Advance35
Adjust Injection Timing35
Remove Metal Plate36
Remove Sst And Dial Indicator37
Torque Union Nuts Of Injection Pipes37
Adjustment Of Idle Speed And Maximum Speed38
Initial Conditions38
Adjust Idle Speed38
Adjust Maximum Speed38
Adjustment Of Air Conditioner Idle-Up Setting Speed40
Adjust Air Conditioner Idle-Up Setting Speed40
Compression Check41
Check Cylinder Compression Pressure41
Timing Belt43
Components43
Removal Of Timing Belt44
Remove Timing Belt Cover44
Set No 1 Cylinder To Bdc44
Remove Timing Belt Idler Pulley45
Remove No 2 Camshaft Timing Pulley45
Remove Intake Pipe45
Remove Cylinder Head Cover46
Remove No 1 Camshaft Timing Pulley46
Inspection Of Timing Belt Components47
Inspect Idler Pulley48
Inspect Tension Spring48
Installation Of Timing Belt49
Instal No 1 Camshaft Timing Pulley49
Install Cylinder Head Cover49
Install Intake Pipe49
Instal No 2 Camshaft Timing Pulley50
Install Timing Belt Idler Pulley50
Check Valve Timing51
Install Timing Belt Cover52
Timing Gears53
Removal Of Timing Gears54
Remove Oil Pipe54
Remove Vacuum Pump54
Remove Crankshaft Pulley54
Remove Timing Gear Cover55
Check Thrust Clearance Of Idler Gear55
Remove Pump Drive Shaft Gear55
Remove Idler Gear56
Remove Injection Pump Drive Gear56
Remove Crankshaft Timing Gear56
Inspection Of Timing Gears57
Inspect Idler Gear57
Inspect Injection Pump Drive Gear Bearing57
Replace Injection Pump Drive Gear Bearing57
Check Backlash Of Timing Gears58
Replacement Of Crankshaft Front Oil Seal59
Replacement Of Injection Pump Drive Gear Oil Seal60
Installation Of Timing Gears61
Install Crankshaft Timing Gear61
Install Injection Pump Drive Gear61
Install Idler Gear61
Install Pump Drive Shaft Gear62
Install Timing Gear Cover62
Install No 1 Crankshaft Pulley63
Install Vacuum Pump64
Instal Oil Pipe64
Cylinder Head65
Removal Of Cylinder Head66
Remove Oil Dipstick And Oil Dipstick Guide66
Remove Intake Manifold66
Remove Nozzle Leakage Pipe66
Remove Injection Nozzles67
Remove Glow Plugs68
Remove Exhaust Manifold68
Separate Exhaust Manifold69
Remove Camshaft Oil Seal Retainer70
Remove Camshaft70
Remove Cylinder Head71
Disassembly Of Cylinder Head72
Remove Valves72
Remove Combustion Chambers73
Inspection, Cleaning And Repair Of Cylinder Head Components74
Clean Top Of Pistons And Top Of Block74
Remove Gasket Material74
Clean Combustion Chambers74
Inspect Cylinder Head For Flatness75
Inspect Cylinder Head For Cracks75
Clean Valves75
Inspect Valve Stems And Guide Bushings75
Replace Valve Guide Bushings76
Inspect And Grind Valves77
Inspect And Clean Valve Seats78
Inspect Valve Springs79
Inspect Camshafts And Bearings80
Inspect Valve Lifters And Lifter Bores81
Inspect Intake And Exhaust Manifold82
Inspect Cylinder Head Bolts82
Replacement Of Camshaft Oil Seal83
Assembly Of Cylinder Head84
Install Half Circular Plug84
Select Combustion Chamber Shim84
Install Combustion Chambers84
Install Valves85
Install Valve Lifters And Shims85
Installation Of Cylinder Head86
Check Piston Protrusion And Select Cylinder Head Gasket86
Install Cylinder Head88
Cylinder Block88
Install Camshaft89
Adjust Valve Clearance90
Install Camshaft Oil Seal Retainer90
Install Pulleys And Timing Belt90
Assembly Exhaust Manifolds90
Install Exhaust Manifold91
Install Glow Plug92
Install Injection Nozzles93
Install Nozzle Leakage Pipe93
Install Water Outlet94
Install Intake Manifold94
Install Oil Dipstick Guide And Oil Dipstick94
Install Injection Pipes94
Preparation For Disassembly96
Disassembly Of Cylinder Block97
Remove Rear Oil Seal Retainer97
Check Connecting Rod Thrust Clearance97
Remove Connecting Rod Caps And Check Oil Clearance97
Remove Piston And Connecting Rod Assemblies99
Check Crankshaft Thrust Clearance100
Remove Main Bearing Cap And Check Oil Clearance100
Remove Crankshaft103
Remove Check Valves And Oil Nozzles103
Inspection Of Cylinder Block104
Inspect Top Of Cylinder Block For Flatness104
Inspect Cylinder For Vertical Scratches104
Inspect Cylinder Bore Diameter104
Remove Cylinder Ridge105
Inspect Main Bearing Cap Bolts105
Disassembly Of Piston And Connecting Rod Assemblies106
Inspect Cylinder Block Orifice106
Remove Piston Rings106
Disconnect Connecting Rod From Piston106
Inspection And Repair Of Piston And Connecting Rod Assemblies108
Clean Piston108
Inspect Piston Diameter And Oil Clearance108
Inspect Clearance Between Wall Of Ring Groove And New Piston Ring109
Inspect Piston Ring End Cap109
Inspect Piston Pin Fit110
Inspect Connecting Rod110
Replace Connecting Rod Bushings111
Boring Of Cylinders114
Keep Oversized Pistons114
Calculate Amount To Bore Cylinder114
Bore And Hone Cylinders To Calculate Dimensions114
Inspection And Repair Of Crankshaft115
Inspect Crankshaft For Runout115
Inspect Main Journals And Crank Pins115
Grind And Hone Main Journals And/Or Crank Pins115
Replacement Of Crankshaft Oil Seal116
Assembly Of Piston And Connecting Rod Assemblies117
Install Piston Rings117
Install Bearings118
Assembly Of Cylinder Block119
Install Oil Nozzles And Check Valves119
Install Main Bearings119
Install Thrust Washers120
Install Main Bearing Cap120
Install Piston And Connecting Rod Assemblies122
Install Connecting Rod Caps122
Install Rear Oil Seal Retainer123
Post Assembly124
Turbocharger Contents125
Operation Of Turbocharger127
Waste Gate Valve127
Precautions128
Turbocharger Electrical System Diagnosis (Hzj80131
On-Vehicle Inspection Of Turbocharger132
Inspect Intake Air System132
Inspect Exhaust System132
Check Turbocharging Pressure132
Removal Of Turbocharger134
Remove Exhaust Manifold Heater Insulator134
Remove Turbo Heat Insulator134
Remove Turbocharger Stay134
Remove Turbo Oil Pipe135
Remove Turbocharger And Exhaust Manifold Assembly135
Separate Turbocharger And Exhaust Manifold135
Remove No 2 Turbo Heat Insulator135
Inspection Of Turbocharger136
Inspect Impeller Wheel Rotation136
Inspect Axial Play Of Impeller Wheel136
Inspect Radial Play Of Turbine Shaft136
Installation Of Turbocharger137
Inspect Actuator Operation137
Install Turbine Outlet Elbow137
Install No 1 Turbo Water Pipe137
Assemble Turbocharger And Exhaust Manifold138
Install Turbocharger And Exhaust Manifold Assembly138
Install Turbo Oil Pipe138
Install Turbocharger Stay138
Install Turbocharger Heat Insulator139
Install Exhaust Manifold Heat Insulator139
Fuel System Contents140
Injection Pump142
Operation142
Replacement Of Fuel Filter143
Drain Fuel From Fuel Filter143
Fuel Heater System145
System Circuit145
Inspection Of Components146
Fuel Heater146
Vacuum Switch146
Fuel Heater Relay147
Removal Of Injection Nozzles148
Remove Injection Pipes148
Injection Nozzles (1Pz And 1 Hz148
Test Of Injection Nozzles149
Remove Nozzleleakage Pipe149
Injection Pressure Test149
Leakage Test150
Spray Pattern Test150
Adjusting Shim Thickness150
Disassembly Of Injection Nozzles151
Cleaning And Inspection Of Injection Nozzles151
Inspect Nozzle Assembly152
Assembly Of Injection Nozzles153
Installation Of Injection Nozzles153
Injection Nozzles (1Hd-T153
Disconnect Injection Pipes155
Assembly And Adjustment Of Injection Nozzle159
Adjust Pre-Lift159
Check No 2 Opening Pressure161
Adjust No 1 Opening Pressure163
Removal Of Injection Pump166
Disassembly Of Injection Pump172
Remove Two Fuel Pipes172
Remove Idle-Up Lever172
Remove Thermo Wax172
Remove Pcs Actuator173
Remove Fuel Cut Solenoid173
Remove Adjusting Lever174
Remove Governor Cover174
Remove Governor Adjusting Lever Shaft From Governor Cover175
Disassembly High Altitude Compensator175
Disassemble Boost Compensator177
Remove Governor Shaft And Flyweight Holder179
Remove Injection Pump Stay179
Remove Distributive Head Plug179
Remove Delivery Valve Holders180
Remove Distributive Head180
Remove Pump Plunger181
Remove Governor Link181
Remove Face Camplate And Coupling181
Remove Roller Ring And Drive Shaft182
Remove Timer183
Remove Fuel Feed Pump184
Remove Regulator Valve184
Remove Fuel Inlet Hollow Screw184
Inspection Of Injection Pump Components185
Inspect Delivery Valves185
Inspect Pump Plunger, Spill Ring And Distributive Head186
Inspect Plunger Springs For Squareness186
Inspect Spring Length186
Inspect Roller Ring And Rollers187
Inspect Fuel Cut Solenoid187
Inspect Pickup Sensor187
Replace Oil Seal187
Assembly Of Injection Pump188
Install Fuel Inlet Hollow Screw188
Install Regulator Valve188
Install Fuel Feed Pump188
Install Drive Shaft189
Install Timer Piston190
Install Roller Ring190
Adjust Plunger Spring Shim192
Plunger Spring Shim Selection Chart For 1 Pz And 1 Hz192
Plunger Spring Shim Selection Chart For 1 Hd-T192
Plunger Adjusting Shim Selection Chart194
Install Face Cam Plate195
Install Governor Link195
Install Pump Plunger195
Install Distributive Head196
Install Delivery Valve Holders197
Install Governor Shaft And Flyweight Holder197
Check Flyweight Holder Thrust Clearance197
Adjust Protrusion Of Governor Shaft198
Assemble High Altitude Compensator198
Assemble Boost Compensator199
Install Adjusting Lever Shaft To Governor Shaft200
Install Governor Cover200
Install Adjusting Lever200
Adjust Plunger Pre-Stroke202
Install Distributive Head Plug203
Install Fuel Cut Solenoid206
Install No 1 Pcs Lever206
Install Pcs Actuator207
Install Thermo Wax207
Install Idle-Up Lever208
Perform Air Tight Test208
Adjustment Of Injection Pump209
Pretest Check And Preparation209
Preset Full Load Injection Volume214
Preset Maximum Speed215
Adjust Pump Inner Pressure215
Check Overflow Volume216
Release Cold Starting System For Next Inspections216
Adjust Timer216
Check Air Tightness Of Boost Compensator217
Adjust Full Load Injection Volume217
Check Injection Volume220
Adjust Full Load Minimum Injection Volume223
Adjust Boost Compensator Characteristic223
Inspect Boost Compensator Characteristic Tendency224
Check Hysteresis224
Adjust Load Sensing Timer225
Adjust Cold Starting System229
Adjust Fast Idle230
Post Adjustment Check230
Seal Parts231
Install Two Fuel Pipes231
Installation Of Injection Pump232
Power Control System234
On-Vehicle Inspection234
Inspect Power Control System234
Inspection Of Power Control System Components234
Inspect Shift Position Switch235
Cooling System Components236
Radiator238
Radiator Cap238
Reservoir Tank238
Thermostat238
Check And Replacement Of Engine Coolant239
Check Engine Coolant Level At Reservoir Tank239
Check Engine Coolant Quality239
Replace Engine Coolant239
Water Pump241
Removal Of Water Pump242
Inspect Of Water Pump243
Installation Of Water Pump243
Inspect Fluid Coupling243
Install Water Pump Pulley, Fan And Drive Belt244
Removal Of Thermostat245
Inspection Of Thermostat245
Installation Of Thermostat246
Place Thermostat In Cylinder Block246
Install Water Inlet To Cylinder Block246
Cleaning Of Radiator247
Inspection Of Radiator247
Inspect Radiator Cap247
Inspect Cooling System For Leaks247
Lubrication System Contents248
Oil Pump250
Oil Pressure Regulator250
Oil Filter250
Oil Pressure Check252
Check Engine Oil Quality252
Check Engine Oil Level252
Replacement Of Engine Oil And Oil Filter253
Drain Engine Oil253
Replace Oil Filter253
Fill With Engine Oil254
Oilpump255
Removal Of Oil Pump256
Remove Oil Pan256
Disassembly Of Oil Pump257
Inspection Of Oil Pump258
Inspect Relief Valve258
Inspect Drive And Driven Rotors258
Assembly Of Oil Pump259
Install Relief Valve259
Installation Of Oil Pump259
Pour Engine Oil Into Oil Pump260
Install Oil Strainer261
Install Oil Pan261
Oil Cooler, Relief Valve And Check Valve262
Removal Of Oil Cooler, Relief Valve And Check Valve263
Inspection Of Oil Cooler, Relief Valve And Check Valve264
Installation Of Oil Cooler, Relief Valve And Check Valve265
Install Engine Drain Cock265
Install Check Valve265
Assemble Oil Cooler And Oil Cooler Cover265
Install Oil Cooler And Oil Cooler Cover Assembly266
Install Oil Dipstick Guide And Dipstick266
Oil Nozzles And Check Valves267
Removal Of Oil Nozzles And Check Valves267
Inspection Of Oil Nozzles And Check Valves268
Installation Of Oil Nozzles And Check Valves268
Starting System Contents269
Super Glow Type (Europe And Australia270
Inspection Of Pre-Heating System271
Timer Characteristic Diagram271
Inspect Preheating Timer Circuit273
No. 1 Glow Plug Relay273
Inspect Relay Continuity273
No.2 Glow Plug Relay274
Inspect Relay Operation274
Glow Plug275
Glow Plug Resistor275
Water Temperature Sensor276
Inspection Of Preheating System277
Inspect Lighting Time Of Glow Indicator Light277
Fixed Delay Type (Hzj80 And Hdj80) Ex. (Europe And Australia277
Pre-Heating Timer278
Fixed Delay Type (Pzj, Hzj75, Hzb And Hdb) Ex. (Europe And Australia279
Starting System Circuit281
Starter283
Disassembly Of Starter283
Remove Field Frame And Armature283
Remove Starter Housing, Clutch Assembly And Gears283
Remove Steel Ball284
Remove Brush Holder284
Inspection And Repair Of Starter285
Armature Coil285
Commutator285
Inspect Commutator For Open Circuit285
Field Coil (Field Frame)286
Brushes286
Brush Springs286
Inspect Undercut Depth286
Brush Holder287
Clutch And Gears287
Inspect Gear Teeth287
Inspect Clutch Pinion Gear287
Bearings289
Assembly Of Starter290
Magnetic Switch290
Perform Pull/Hold-In Coil Open Circuit Test290
Place Armature Into Field Frame290
Insert Steel Ball Into Clutch Shaft Hole291
Install Gear, Clutch Assembly And Starter Housing291
Install Field Frame And Armature Assembly292
Performance Test Of Starter293
Perform Pull/Hold-In Test293
Inspect Clutch Pinion Gear Return293
Perform No-Load Performance Test293
Starter Relay (Pzj, Hzj And Hdj)294
Inspection Of Starter Relay294
Starter Relay (Hzb And Hdb)295
Inspection Of Voltage Converter Timer296
Voltage Converter Timer (Hzj80 And Hdj80) (W/ 24 V Starter)296
Inspection Of Voltage Converter Relay297
Voltage Converter Relay (Hzj80And Hdj80) (W/24 V Starter)297
Inspection Of 24 V Hold Warning Relay298
Hold Warning Relay (Hzj80And Hdj80) (W/ 24 V Starter)298
Charging System Contents299
Charging System Circuit301
Inspect Battery Specific Gravity And Electrolyte Level303
Check Battery Terminals, Fusible Links And Fuses303
Inspect Drive Belts303
Check Alternator Wiring And Listen For Abnormal Noises304
Inspect Discharge Warning Light Circuit304
Inspect Charging Circuit Without Load304
Inspect Charging Circuit With Load305
Alternator306
Disassembly Of Alternator307
Remove Rear End Cover307
Remove Brush Holder And Ic Regulator307
Remove Rectifier Holder307
Remove Pulley308
Remove Rectifier End Frime308
Inspection And Repair Of Alternator310
Rotor310
Stator (Drive End Frame)310
Rectifiers (Rectifier Holder)311
Assembly Of Alternator314
Install Rotor To Drive End Frame314
Install Rectifier End Frame314
Install Pulley315
Install Rectifier Holder315
Install Ic Regulator And Brush Holder316
Install Rear End Cover317
Service Specifications Contents318
Engine Mechanical319
Torque Specifications324
Turbocharger System325
Fuel System326
Injection Pump Adjustment330
Lever Angle333
Adjusting333
1Hd-T Plus333
Injection333
Item334
1Hd-T336
(Europe) Plus336
Plus 21 - 3336
Pump Rpm Measuring Strokes336
Cooling System338
Lubrication System338
Starting System339
Charging System339
Standard Bolt Torque Specifications340
How To Determine Bolt Strangth341
Sst And Ssm343
Sst (Special Service Tools)344
Ssm (Special Service Materials)348