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Table Of Contents - Toyota 1KZ-TE Repair Manual

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Repair manual (341 pages)

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Supplemental repair manual (118 pages)

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Repair manual (284 pages)

Table Of Contents

Table of Contents

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Table of Contents

Check Piston Stroke Of Overdrive Brake6

Identification Information7

Engine Serial Number7

Repair Instructions8

Basic Repair Hint8

If Vehicle Is Equipped With Mobile Communication System12

For Using Hand-Held Tester12

How To Troubleshoot Ecu Controlled Systems13

How To Proceed With Troubleshooting14

Customer Problem Analysis15

Symptom Confirmation And Diagnostic Trouble Code Check16

Symptom Simulation18

Water Sprinkling Method19

Diagnostic Trouble Code Chart20

Problem Symptoms Table21

Circuit Inspection22

Wiring Diagram22

Inspection Procedure23

How To Use The Diagnostic Chart And Inspection24

Connector Connection And Terminal Inspection24

Continuity Check (Open Circuit Check)25

Resistance Check/Short Circuit Check25

Visual Check And Contact Pressure Check25

Connector Handling26

Check Open Circuit26

Check Short Circuit27

Check And Replace Ecu28

Abbreviations29

Engine Mechanical Special Service Tools32

Engine Mechanical Recommended Tools36

Engine Mechanical Equipment37

Engine Mechanical Special Service Materials38

Turbocharging Special Service Tools39

Turbocharging Recommended Tools40

Turbocharging Equipment41

Electronic Control Diesel Special Service Tools42

Electronic Control Diesel Recommended Tools43

Electronic Control Diesel Equipment44

Engine Fuel Special Service Tools45

Engine Fuel Recommended Tools47

Engine Fuel Equipment48

Cooling Special Service Tools49

Cooling Equipment50

Coolant Special Service Materials52

Lubricant Special Service Materials54

Starting Special Service Tools55

Starting Recommended Tools56

Starting Equipment57

Charging Special Service Tools58

Charging Recommended Tools59

Charging Equipment60

Service Specifications61

Standard Bolt62

How To Determine Bolt Strength62

Specified Torque For Standard Bolts63

How To Determine Nute Strength64

Engine Mechanical Service Data65

Engine Mechanical Torque Specification69

Turbocharging Service Data70

Turbocharging Torque Specification71

Electronic Control Diesel Service Data72

Electronic Control Diesel Torque Specification73

Engine Fuel Service Data74

Engine Fuel Torque Specification75

Cooling Service Data76

Cooling Torque Specification77

Lubrication Service Data78

Lubrication Torque Specification79

Starting Service Data80

Starting Torque Specification81

Charging Service Data82

Charging Torque Specification83

Customer Problem Analysis Check86

Diagnosis System87

Diagnosis Inspection (Normal Mode)88

Fail-Safe Chart91

Check For Intermittent Problems91

Basic Inspection92

Reference Value Of Engine Ecu Data94

Engine Diagnostic Trouble Code Chart96

Engine Parts Location98

Terminals Of Ecu99

Engine Problem Symptoms Table101

Engine Speed Sensor Circuit Malfunction (Tdc Or G1 Circuit)103

Engine Circuit Inspection103

Engine Circuit Description103

Engine Wiring Diagram103

Engine Inspection Procedure104

Engine Speed Sensor Circuit Malfunction (Ne Circuit)105

Timing Control System Malfunction106

Water Temp. Sensor Circuit Malfunction109

Intake Air Temp. Sensor Circuit Malfunction112

Injection Pump Correction System Malfunction115

Turbo Pressure Sensor Circuit Malfunction117

Fuel Temp. Sensor Circuit Malfunction120

Throttle Position Sensor Circuit Malfunction123

Vehicle Speed Sensor Signal Circuit Malfunction125

Starter Signal Circuit Malfunction127

First Gear Position Switch Circuit Malfunction129

Back Up Power Source Circuit131

Engine Ecu Power Source Circuit133

Te1, Te2 Terminal Circuit137

Pre-Heating Control Circuit139

Spill Control Valve Relay Circuit144

Air Filter Inspection149

Compression Inspection150

Valve Clearance Inspection152

Adjusting Shim Selection Using Chart154

Injection Timing Inspection156

Adjust Injection Timing156

Idle Speed And Maximum Speed Inspection157

Intake Construction Control Inspection158

Connect Vacuum Gauges158

Inspect Hot Engine Condition159

Remove Vacuum Gauges159

Timing Belt Components160

Timing Belt Removal161

Remove Timing Belt Cover161

Set No.4 Cylinder To Tdc/Compression161

If Re-Using Timing Belt, Mark Timing Belt161

Remove Timing Belt Idler Pulley162

Remove Timing Belt162

Remove Intake Pipe162

Remove Cylinder Head Cover163

Remove No.1 Camshaft Timing Pulley163

Inspect Timing Belt164

Inspect Idler Pulley164

Inspect Timing Belt Tensioner165

Timing Belt Installation166

Install No.1 Camshaft Timing Pulley166

Install Cylinder Head Cover166

Install Intake Pipe166

Install No.2 Camshaft Timing Pulley167

Install Timing Belt167

Install Timing Belt Idler Pulley167

Set Timing Belt Tensioner168

Install Timing Belt Tensioner168

Check Valve Timing168

Install Timing Belt Cover169

Timing Gear Components170

Timing Gear Removal172

Remove Camshaft Oil Seal Retainer172

Remove Vacuum Pump172

Remove Crankshaft Pulley172

Remove Timing Gear Cover173

Check Thrust Clearance Of Idler Gear174

Remove Timing Gears174

Disassembly Idler Gear175

Timing Gear Inspection177

Inspect Idler Gear177

Inspect Injection Pump Drive Gear Bearing177

Check Backlash Of Timing Gears178

Timing Gear Replacement179

Replace Crankshaft Front Oil Seal179

Replace Injection Pump Drive Gear Oil Seal180

Replace Injection Pump Drive Gear Bearing180

Timing Gear Installation182

Assemble Idler Gear182

Install Timing Gear183

Install Timing Gear Cover186

Check Injection Pump Drive Shaft Thrust Clearance187

Install Crankshaft Pulley187

Install Vacuum Pump187

Cylinder Head Components189

Cylinder Head Removal192

Drain Engine Coolant192

Remove Water Outlet192

Remove Intake Manifold193

Remove Nozzle Leakage Pipe193

Remove Injection Nozzles193

Cylinder Head Disassembly197

Cylinder Head Inspection199

Clean Top Surfaces Of Pistons And Cylinder Block199

Remove Gasket Material199

Clean Combustion Chambers199

Clean Cylinder Head200

Inspect For Flatness200

Inspect For Cracks200

Clean Valves200

Inspect Valve Stems And Guide Bushings201

Inspect And Grind Valves201

Inspect And Clean Valve Seats202

Inspect Valve Springs203

Inspect Camshaft For Runout204

Inspect Cam Lobes204

Inspect Camshaft Journals204

Inspect Camshaft Bearings204

Inspect Camshaft Journal Oil Clearance205

Inspect Camshaft Thrust Clearance205

Inspect Valve Lifters And Lifter Bores205

Inspect Intake And Exhaust Manifolds206

Inspect Cylinder Head Bolts206

Cylinder Head Replacement207

Replace Valve Guide Bushings207

Replace Camshaft Oil Seal208

Cylinder Head Reassembly209

Select Combination Chamber Shim209

Install Combustion Chambers210

Install Valves210

Install Valve Lifters And Shims211

Install Semi Circular Plug211

Install Heater Water Inlet Pipe211

Install Front Engine Hanger211

Cylinder Head Installation212

Check Piston Protrusion And Select Cylinder Head Gasket212

Place Cylinder Head On Cylinder Block213

Install Cylinder Head Bolts214

Install Camshaft214

Install Camshaft Oil Seal Retainer215

Cylinder Block Components220

Cylinder Block Disassembly223

Remove Piston Rings230

Disconnect Connecting Rod From Piston230

Cylinder Block Inspection231

Cylinder Block Replacement239

Replace Oversized (O/S) Pistons239

Cylinder Block Reassembly242

Turbocharging249

Turbocharging Troubleshooting250

Turbocharging Maintenance Precaution251

Turbocharger On-Vehicle Inspection252

Inspect Intake Air System252

Inspect Exhaust System252

Turbocharger Components253

Turbocharger Removal255

Turbocharger Disassembly256

Turbocharger Inspection259

Clean Compressor Housing260

Turbocharger Reassembly261

Turbocharger Installation265

Emission Control System267

Positive Crankcase Ventilation (Pcv) System Inspection268

Electronic Control Diesel269

Ecd System Precaution270

Throttle Body On-Vehicle Inspection272

Inspect Throttle Body Operation272

Throttle Body Components273

Throttle Body Removal274

Throttle Body Inspection275

Throttle Body Installation276

Timing Control Valve Inspection277

Spill Control Valve Inspection278

Ecd Main Relay Inspection279

Spill Control Valve Relay Components280

Spill Control Valve Relay Inspection281

Vsv For Intake Constructor Control Components282

Vsv For Intake Constructor Control Inspection283

Water Temperature Sensor Inspection284

Fuel Temperature Sensor Inspection285

Intake Air Temperature Sensor Inspection286

Turbo Pressure Sensor Inspection287

Engine Speed Sensor Inspection289

Crankshaft Position Sensor Inspection290

First Gear Position Switch Inspection291

First Gear Position Switch Replacement292

Injection Pump Correction Resistor Inspection293

Engine Ecu Components294

Engine Ecu Inspection295

Fuel Filter Replacement297

Injection Nozzle Components299

Injection Nozzle Removal301

Injection Nozzle Disassembly303

Injection Nozzle Inspection304

Injection Nozzle Reassembly306

Injection Nozzle Test307

Injection Pressure Test307

Leakage Test308

Spray Pattern Test308

Injection Nozzle Installation309

Injection Pump On-Vehicle Inspection311

Injection Pump Components312

Injection Pump Removal314

Injection Pump Disassembly316

Injection Pump Inspection318

Injection Pump Reassembly319

Injection Pump Installation321

Coolant Inspection324

Coolant Replacement325

Fill Engine Coolant325

Water Pump Components326

Water Pump Removal328

Water Pump Inspection330

Water Pump Installation331

Install Water Pump Assembly331

Thermostat Components333

Thermostat Removal334

Thermostat Inspection335

Thermostat Installation336

Radiator On-Vehicle Cleaning337

Radiator On-Vehicle Inspection338

Remove Radiator Cap338

Inspect Radiator Cap338

Inspect Cooling System For Leaks338

Radiator Components339

Radiator Disassembly340

Radiator Reassembly341

Caulk Lock Plate342

Oil And Filter Inspection345

Oil And Filter Replacement346

Oil Pump Components348

Oil Pump Disassembly353

Oil Pump Inspection354

Oil Pump Reassembly355

Oil Pump Installation356

Oil Cooler Components360

Oil Cooler Removal362

Oil Cooler Inspection364

Oil Cooler Installation365

Oil Nozzle Components367

Oil Nozzle Removal368

Oil Nozzle Inspection369

Oil Nozzle Installation370

Pre-Heating System Components372

Pre-Heating System Inspection373

Pre-Heating System Replacement375

Replace Glow Plugs375

Starter Disassembly378

Starter Inspection380

Starter Replacement383

Starter Reassembly387

Starter Relay Inspection391

Charging System393

Charging System On-Vehicle Inspection394

Alternator Disassembly398

Alternator Inspection400

Alternator Replacement402

Alternator Reassembly404

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Troubleshooting