Toyota 1KZ-TE Manuals

Manuals and User Guides for Toyota 1KZ-TE. We have 4 Toyota 1KZ-TE manuals available for free PDF download: Repair Manual, Supplemental Repair Manual

Toyota 1KZ-TE Repair Manual (408 pages)

Brand: Toyota | Category: Engine | Size: 14.88 MB

Introduction
4
Check Piston Stroke of Overdrive Brake
6
Identification Information
7
Engine Serial Number
7
Repair Instructions
8
Basic Repair Hint
8
If Vehicle Is Equipped with Mobile Communication System
12
For Using Hand-Held Tester
12
How to Troubleshoot ECU Controlled Systems
13
How to Proceed with Troubleshooting
14
Customer Problem Analysis
15
Symptom Confirmation and Diagnostic Trouble Code Check
16
Symptom Simulation
18
Heat Method
19
Water Sprinkling Method
19
Diagnostic Trouble Code Chart
20
Problem Symptoms Table
21
Circuit Inspection
22
Wiring Diagram
22
Inspection Procedure
23
How to Use the Diagnostic Chart and Inspection
24
Connector Connection and Terminal Inspection
24
Continuity Check (Open Circuit Check)
25
Resistance Check/Short Circuit Check
25
Visual Check and Contact Pressure Check
25
Connector Handling
26
Check Open Circuit
26
Check Short Circuit
27
Check and Replace ECU
28
Terms
29
Abbreviations
29
Preparation
31
Engine Mechanical Special Service Tools
32
Engine Mechanical Recommended Tools
36
Engine Mechanical Equipment
37
Engine Mechanical Special Service Materials
38
Turbocharging Special Service Tools
39
Turbocharging Recommended Tools
40
Turbocharging Equipment
41
Electronic Control Diesel Special Service Tools
42
Electronic Control Diesel Recommended Tools
43
Electronic Control Diesel Equipment
44
Engine Fuel Special Service Tools
45
Engine Fuel Recommended Tools
47
Engine Fuel Equipment
48
Cooling Special Service Tools
49
Cooling Equipment
50
Coolant
51
Coolant Special Service Materials
52
Lubricant
53
Lubricant Special Service Materials
54
Starting Special Service Tools
55
Starting Recommended Tools
56
Starting Equipment
57
Charging Special Service Tools
58
Charging Recommended Tools
59
Charging Equipment
60
Service Specifications
61
Standard Bolt
62
How to Determine Bolt Strength
62
Specified Torque for Standard Bolts
63
How to Determine Nute Strength
64
Engine Mechanical Service Data
65
Engine Mechanical Torque Specification
69
Turbocharging Service Data
70
Turbocharging Torque Specification
71
Electronic Control Diesel Service Data
72
Electronic Control Diesel Torque Specification
73
Engine Fuel Service Data
74
Engine Fuel Torque Specification
75
Cooling Service Data
76
Cooling Torque Specification
77
Lubrication Service Data
78
Lubrication Torque Specification
79
Starting Service Data
80
Starting Torque Specification
81
Charging Service Data
82
Charging Torque Specification
83
Diagnostics
84
Engine
85
Customer Problem Analysis Check
86
Pre-Check
87
Diagnosis System
87
Diagnosis Inspection (Normal Mode)
88
Fail-Safe Chart
91
Check for Intermittent Problems
91
Basic Inspection
92
Reference Value of Engine ECU Data
94
Engine Diagnostic Trouble Code Chart
96
Engine Parts Location
98
Terminals of ECU
99
Engine Problem Symptoms Table
101
Engine Speed Sensor Circuit Malfunction (TDC or G1 Circuit)
103
Engine Circuit Inspection
103
Engine Circuit Description
103
Engine Wiring Diagram
103
Engine Inspection Procedure
104
Engine Speed Sensor Circuit Malfunction (NE Circuit)
105
Timing Control System Malfunction
106
Water Temp. Sensor Circuit Malfunction
109
Intake Air Temp. Sensor Circuit Malfunction
112
Injection Pump Correction System Malfunction
115
Turbo Pressure Sensor Circuit Malfunction
117
Fuel Temp. Sensor Circuit Malfunction
120
Throttle Position Sensor Circuit Malfunction
123
Vehicle Speed Sensor Signal Circuit Malfunction
125
Starter Signal Circuit Malfunction
127
First Gear Position Switch Circuit Malfunction
129
Back up Power Source Circuit
131
Engine ECU Power Source Circuit
133
TE1, TE2 Terminal Circuit
137
Pre-Heating Control Circuit
139
Spill Control Valve Relay Circuit
144
Air Filter Inspection
149
Compression Inspection
150
Valve Clearance Inspection
152
Adjusting Shim Selection Using Chart
154
Injection Timing Inspection
156
Adjust Injection Timing
156
Idle Speed and Maximum Speed Inspection
157
Intake Construction Control Inspection
158
Connect Vacuum Gauges
158
Inspect Hot Engine Condition
159
Remove Vacuum Gauges
159
Timing Belt Components
160
Timing Belt Removal
161
Remove Timing Belt Cover
161
Set No.4 Cylinder to Tdc/Compression
161
If Re-Using Timing Belt, Mark Timing Belt
161
Remove Timing Belt Idler Pulley
162
Remove Timing Belt
162
Remove Intake Pipe
162
Remove Cylinder Head Cover
163
Remove No.1 Camshaft Timing Pulley
163
Inspect Timing Belt
164
Inspect Idler Pulley
164
Inspect Timing Belt Tensioner
165
Timing Belt Installation
166
Install No.1 Camshaft Timing Pulley
166
Install Cylinder Head Cover
166
Install Intake Pipe
166
Install No.2 Camshaft Timing Pulley
167
Install Timing Belt
167
Install Timing Belt Idler Pulley
167
Set Timing Belt Tensioner
168
Install Timing Belt Tensioner
168
Check Valve Timing
168
Install Timing Belt Cover
169
Timing Gear Components
170
Timing Gear Removal
172
Remove Camshaft Oil Seal Retainer
172
Remove Vacuum Pump
172
Remove Crankshaft Pulley
172
Remove Timing Gear Cover
173
Check Thrust Clearance of Idler Gear
174
Remove Timing Gears
174
Disassembly Idler Gear
175
Timing Gear Inspection
177
Inspect Idler Gear
177
Inspect Injection Pump Drive Gear Bearing
177
Check Backlash of Timing Gears
178
Timing Gear Replacement
179
Replace Crankshaft Front Oil Seal
179
Replace Injection Pump Drive Gear Oil Seal
180
Replace Injection Pump Drive Gear Bearing
180
Timing Gear Installation
182
Assemble Idler Gear
182
Install Timing Gear
183
Install Timing Gear Cover
186
Check Injection Pump Drive Shaft Thrust Clearance
187
Install Crankshaft Pulley
187
Install Vacuum Pump
187
Cylinder Head Components
189
Cylinder Head Removal
192
Drain Engine Coolant
192
Remove Water Outlet
192
Remove Intake Manifold
193
Remove Nozzle Leakage Pipe
193
Remove Injection Nozzles
193
Cylinder Head Disassembly
197
Cylinder Head Inspection
199
Clean Top Surfaces of Pistons and Cylinder Block
199
Remove Gasket Material
199
Clean Combustion Chambers
199
Clean Cylinder Head
200
Inspect for Flatness
200
Inspect for Cracks
200
Clean Valves
200
Inspect Valve Stems and Guide Bushings
201
Inspect and Grind Valves
201
Inspect and Clean Valve Seats
202
Inspect Valve Springs
203
Inspect Camshaft for Runout
204
Inspect Cam Lobes
204
Inspect Camshaft Journals
204
Inspect Camshaft Bearings
204
Inspect Camshaft Journal Oil Clearance
205
Inspect Camshaft Thrust Clearance
205
Inspect Valve Lifters and Lifter Bores
205
Inspect Intake and Exhaust Manifolds
206
Inspect Cylinder Head Bolts
206
Cylinder Head Replacement
207
Replace Valve Guide Bushings
207
Replace Camshaft Oil Seal
208
Cylinder Head Reassembly
209
Select Combination Chamber Shim
209
Install Combustion Chambers
210
Install Valves
210
Install Valve Lifters and Shims
211
Install Semi Circular Plug
211
Install Heater Water Inlet Pipe
211
Install Front Engine Hanger
211
Cylinder Head Installation
212
Check Piston Protrusion and Select Cylinder Head Gasket
212
Place Cylinder Head on Cylinder Block
213
Install Cylinder Head Bolts
214
Install Camshaft
214
Install Camshaft Oil Seal Retainer
215
Cylinder Block Components
220
Cylinder Block Disassembly
223
Remove Piston Rings
230
Disconnect Connecting Rod from Piston
230
Cylinder Block Inspection
231
Cylinder Block Replacement
239
Replace Oversized (O/S) Pistons
239
Cylinder Block Reassembly
242
Turbocharging
249
Turbocharging Troubleshooting
250
Turbocharging Maintenance Precaution
251
Turbocharger On-Vehicle Inspection
252
Inspect Intake Air System
252
Inspect Exhaust System
252
Turbocharger Components
253
Turbocharger Removal
255
Turbocharger Disassembly
256
Turbocharger Inspection
259
Clean Compressor Housing
260
Turbocharger Reassembly
261
Turbocharger Installation
265
Emission Control System
267
Positive Crankcase Ventilation (PCV) System Inspection
268
Electronic Control Diesel
269
ECD System Precaution
270
Throttle Body On-Vehicle Inspection
272
Inspect Throttle Body Operation
272
Throttle Body Components
273
Throttle Body Removal
274
Throttle Body Inspection
275
Throttle Body Installation
276
Timing Control Valve Inspection
277
Spill Control Valve Inspection
278
ECD Main Relay Inspection
279
Spill Control Valve Relay Components
280
Spill Control Valve Relay Inspection
281
VSV for Intake Constructor Control Components
282
VSV for Intake Constructor Control Inspection
283
Water Temperature Sensor Inspection
284
Fuel Temperature Sensor Inspection
285
Intake Air Temperature Sensor Inspection
286
Turbo Pressure Sensor Inspection
287
Engine Speed Sensor Inspection
289
Crankshaft Position Sensor Inspection
290
First Gear Position Switch Inspection
291
First Gear Position Switch Replacement
292
Injection Pump Correction Resistor Inspection
293
Engine ECU Components
294
Engine ECU Inspection
295
Engine Fuel
296
Fuel Filter Replacement
297
Injection Nozzle Components
299
Injection Nozzle Removal
301
Injection Nozzle Disassembly
303
Injection Nozzle Inspection
304
Injection Nozzle Reassembly
306
Injection Nozzle Test
307
Injection Pressure Test
307
Leakage Test
308
Spray Pattern Test
308
Injection Nozzle Installation
309
Injection Pump On-Vehicle Inspection
311
Injection Pump Components
312
Injection Pump Removal
314
Injection Pump Disassembly
316
Injection Pump Inspection
318
Injection Pump Reassembly
319
Injection Pump Installation
321
Cooling
323
Coolant Inspection
324
Coolant Replacement
325
Fill Engine Coolant
325
Water Pump Components
326
Water Pump Removal
328
Water Pump Inspection
330
Water Pump Installation
331
Install Water Pump Assembly
331
Thermostat Components
333
Thermostat Removal
334
Thermostat Inspection
335
Thermostat Installation
336
Radiator On-Vehicle Cleaning
337
Radiator On-Vehicle Inspection
338
Remove Radiator Cap
338
Inspect Radiator Cap
338
Inspect Cooling System for Leaks
338
Radiator Components
339
Radiator Disassembly
340
Radiator Reassembly
341
Caulk Lock Plate
342
Lubrication
344
Oil and Filter Inspection
345
Oil and Filter Replacement
346
Oil Pump Components
348
Oil Pump Disassembly
353
Oil Pump Inspection
354
Oil Pump Reassembly
355
Oil Pump Installation
356
Oil Cooler Components
360
Oil Cooler Removal
362
Oil Cooler Inspection
364
Oil Cooler Installation
365
Oil Nozzle Components
367
Oil Nozzle Removal
368
Oil Nozzle Inspection
369
Oil Nozzle Installation
370
Starting
371
Pre-Heating System Components
372
Pre-Heating System Inspection
373
Pre-Heating System Replacement
375
Replace Glow Plugs
375
Starter Disassembly
378
Starter Inspection
380
Starter Replacement
383
Starter Reassembly
387
Test
390
Starter Relay Inspection
391
Charging
392
Charging System
393
Charging System On-Vehicle Inspection
394
Alternator Disassembly
398
Alternator Inspection
400
Alternator Replacement
402
Alternator Reassembly
404
Index
406

Toyota 1KZ-TE Repair Manual (341 pages)

Fo Toyota Hilux KZN165 Series

Brand: Toyota | Category: Engine | Size: 11.05 MB

Alphabetical Index
2
Engine Mechanical
2
In04V
4
Repair Procedures
4
Check Piston Stroke of Overdrive Brake
5
Specifications
5
The Procedures Are Presented in a Step--By--Step Format
5
Engine Serial Number
6
Identification Information
6
Repair Instructions
7
- Example
  10
- For All of Vehicles
  11
- If Vehicle Is Equipped with Mobile Communication System
  11
- How to Troubleshoot ECU Controlled Systems
  12
- Symptom Confirmation and Diagnostic Trouble Code Check in
  13
- How to Proceed with Troubleshooting
  14
- Customer Problem Analysis
  15
- Erence
  15
- Symptom Confirmation and Diagnostic Trouble Code Check
  16
- Example
  18
- Symptom Simulation
  18
- Diagnostic Trouble Code Chart
  20
- Example
  20
- Problem Symptoms Table
  21
- Circuit Inspection
  22
- Erence
  22
- Connector Connection and Terminal Inspection
  24
- How to Use the Diagnostic Chart and Inspection
  24
- Continuity Check
  25
- Resistance Check
  25
- Visual Check and Contact Pressure Check
  25
- Check Open Circuit
  26
- Connector Handling
  26
- Check Hot Circuit
  27
- Check and Replace ECU
  28
- Example
  28
- Abbreviations
  29
- Terms
  29
- Preparation
  31
- Engine Mechanical
  32
- SST (Special Service Tools)
  32
- Recommended Tools
  36
- Equipment
  37
- SSM (Special Service Materials)
  38
- Turbocharging
  39
- Electronic Control Diesel
  42
- Engine Fuel
  45
- Cooling
  49
- Lubrication
  53
- Starting
  58
- Charging
  61
- Service Specifications
  64
- How to Determine Bolt Strength
  65
- Standard Bolt
  65
- Specified Torque for Standard Bolts
  66
- Example
  67
- How to Determine Nut Strength
  67
- Erence
  68
- Service Data
  68
- Erence
  70
- Erence
  71
- Torque Specification
  72
- Service Data
  73
- Torque Specification
  74
- Cooling Service Data
  79
- Lubrication Service Data
  81
- Starting Service Data
  83
- Charging Service Data
  85
- Erence
  85
- Diagnostics
  87
- Air Filter Inspection
  89
- Paper Filter Type
  89
- Compression Inspection
  90
- Erence
  90
- Adjust Valve Clearance
  92
- Check Valve Clearance
  92
- Valve Clearance Inspection
  92
- Reinstall Cylinder Head Cover
  93
- Adjusting Shim Selection Using Chart
  94
- Example
  94
- Example
  95
- Injection Timing Inspection
  96
- Idle Speed and Maximum Speed Inspection
  97
- Initial Conditions
  97
- Inspect Idle Speed
  97
- Inspect Maximum Speed
  97
- Connect Vacuum Gauges
  98
- Inspect Cold Engine Condition
  98
- Intake Constructor Control Inspection
  98
- Inspect Hot Engine Condition
  99
- Remove Vacuum Gauges
  99
- Timing Belt Components
  101
- Inspect Idler Pulley
  105
- Inspect Timing Belt
  105
- Inspect Timing Belt Tensioner
  106
- Timing Belt Installation
  107
- Timing Gear Components
  112
- Timing Gear Removal
  114
- Inspect Idler Gear
  119
- Inspect Injection Pump Drive Gear Bearing
  119
- Timing Gear Inspection
  119
- Timing Gear Replacement
  121
- Assemble Idler Gear
  124
- Timing Gear Installation
  124
- Install Timing Gear Cover
  128
- Erence
  129
- Cylinder Head
  131
- Cylinder Head Components
  134
- Cylinder Head Removal
  137
- Remove Intake Pipe
  137
- Cylinder Head Inspection
  144
- Remove Gasket Material
  144
- Clean Cylinder Head
  145
- Clean Valves
  145
- Inspect for Cracks
  145
- Inspect for Flatness
  145
- Inspect and Grind Valves
  146
- Inspect Valve Stems and Guide Bushings
  146
- Inspect and Clean Valve Seats
  147
- Inspect Valve Springs
  148
- Inspect Cam Lobes
  149
- Inspect Camshaft Bearings
  149
- Inspect Camshaft Journals
  149
- Inspect Camshaft Journal Oil Clearance
  150
- Inspect Camshaft Thrust Clearance
  150
- Inspect Valve Lifters and Lifter Bores
  150
- Inspect Cylinder Head Bolts
  151
- Inspect Intake and Exhaust Manifolds
  151
- Cylinder Head Replacement
  152
- Cylinder Head Reassembly
  154
- Erence
  154
- Cylinder Head Installation
  157
- Install Cylinder Head Bolts
  159
- Install No.1 Camshaft Timing Pulley
  161
- Install Timing Belt Idler Pulley
  161
- Install Cylinder Head Cover
  162
- Install Timing Belt Cover
  162
- Install Timing Belt Tensioner
  162
- Cylinder Block
  165
- Cylinder Block Components
  167
- Cylinder Block Disassembly
  170
- Example
  173
- Example
  175
- Disconnect Connecting Rod from Piston
  177
- Remove Piston Rings
  177
- Piston Diameter
  180
- Cylinder Block Replacement
  186
- Cylinder Block Reassembly
  189
- Install Cylinder Block Orifice
  190
- Erence
  208
- Vsv for Intake Constrictor Control
  219
- Water Temperature Sensor Inspection
  220
- Fuel Filter Replacement
  222
- Injection Nozzle
  224
- Injection Nozzle Components
  225
- Injection Nozzle Disassembly
  229
- Injection Nozzle Inspection
  230
- Injection Pump
  237
- Injection Pump
  238
- Injection Pump Components
  239
- Injection Pump Removal
  241
- Injection Pump Disassembly
  243
- Injection Pump Inspection
  245
- Injection Pump Reassembly
  246
- Install Timing Control Valv E
  247
- Injection Pump Installation
  248
- Erence
  249
- Coolant Inspection
  251
- Coolant Replacement
  252
- Drain Engine Coolant
  252
- Fill Engine Coolant
  252
- Water Pump
  253
- Water Pump Components
  254
- Water Pump Removal
  256
- Inspect Fluid Coupling
  258
- Inspect Water Pump
  258
- Water Pump Inspection
  258
- Install Water Pump Assembly
  259
- Thermostat Components
  261
- Remove Water Inlet and Thermostat
  262
- Thermostat Removal
  262
- Thermostat Inspection
  263
- Install Water Inlet to Cylinder Block
  264
- Place Thermostat in Cylinder Block
  264
- Thermostat Installation
  264
- Radiator
  265
- Radiator Cleaning
  266
- Inspect Cooling System for Leaks
  267
- Inspect Radiator Cap
  267
- Radiator On-Vehicle Inspection
  267
- Remove Radiator Cap
  267
- Radiator Components
  268
- Assemble SST
  269
- Radiator Disassembly
  269
- Inspect Lock Plate for Damage
  270
- Radiator Reassembly
  270
- Check Engine Oil Level
  274
- Check Engine Oil Quality
  274
- Check Oil Pressure
  274
- Oil and Filter Inspection
  274
- Oil and Filter Replacement
  275
- Oil Pump
  277
- Oil Pump Components
  278
- Oil Pump Removal
  281
- Remove Oil Level Sensor
  281
- Remove Oil Pan
  281
- Remove Oil Pump (Timing Gear Case)
  282
- Remove Oil Strainer
  282
- Oil Pump Disassembly
  283
- Inspect Drive and Driven Rotors
  284
- Inspect Relief Valve
  284
- Oil Pump Inspection
  284
- Install Relief Valve
  285
- Oil Pump Reassembly
  285
- Oil Pump Installation
  286
- Install Oil Level Sensor
  289
- Oil Cooler
  290
- Oil Cooler Components
  291
- Oil Cooler Removal
  293
- Remove Oil Dipstick and Guide
  293
- Separate Oil Cooler and Oil Cooler Cover
  293
- Inspect Oil Cooler
  295
- Oil Cooler Inspection
  295
- Assembly Oil Cooler and Oil Cooler Cover
  296
- Oil Cooler Installation
  296
- Inspect Check Valves
  300
- Inspect Oil Nozzles
  300
- Pre-Heating System Components
  303
- Inspect after Glow Time
  304
- Inspect Lighting Time of Glow Indicator Light
  304
- Pre-Heating System Inspection
  304
- Inspect Water Temperature Sensor
  305
- Pre-Heating System Replacement
  306
- Starter
  308
- Starter Components
  309
- Starter Disassembly
  310
- Inspect Armature Coil
  312
- Inspect Commutator
  312
- Starter Inspection
  312
- Inspect Brushes
  313
- Inspect Field Frame
  313
- Inspect Bearings
  314
- Inspect Clutch and Gears
  314
- Inspect Magnetic Switch
  314
- Starter Replacement
  315
- Starter Reassembly
  319
- Install Field Frame and Armature Assembly
  320
- Inspect Clutch Pinion Gear Return
  322
- Perform Hold - in Test
  322
- Starter Test
  322
- Inspect Starter Relay
  323
- Starter Relay Inspection
  323
- Charging System Precaution
  325
- Charging System On-Vehicle Inspection
  326
- Check Battery Electrolyte Level
  326
- Erence
  327
- Inspect Discharge Warning Light Circuit
  327
- Inspect Drive Belts
  327
- Inspect Charging Circuit with Load
  328
- Inspect Charging Circuit Without Load
  328
- Alternator
  329
- Alternator Components
  330
- Alternator Disassembly
  331
- Remove Brush Holder and IC Regulator
  331
- Remove Rear End Cover
  331
- Remove Rectifier Holder
  331
- Remove Rectifier End Frame
  332
- Remove Rotor from Drive End Frame
  332
- Alternator Inspection
  333
- Inspect Rotor
  333
- Inspect Stator (Drive End Frame)
  333
- Inspect Rectifier (Rectifier Holder)
  334
- Alternator Replacement
  335
- Replace Brushes
  335
- Replace Front Bearing
  335
- Replace Rear Bearing
  335
- Alternator Reassembly
  337
- Install Rectifier End Frame
  337
- Install IC Regulator and Brush Holder
  338
- Install Rear End Cover
  338
- Install Rectifier Holder
  338
- How to Proceed with Troubleshooting in
  339
- Index
  339

Toyota 1KZ-TE Repair Manual (284 pages)

Brand: Toyota | Category: Engine | Size: 8.63 MB

Toyota 1KZ-TE Supplemental Repair Manual (118 pages)

Brand: Toyota | Category: Engine | Size: 9.62 MB

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