Toyota 1PZ Manuals

Manuals and User Guides for Toyota 1PZ. We have 1 Toyota 1PZ manual available for free PDF download: Repair Manual

Toyota 1PZ Repair Manual

Toyota 1PZ Repair Manual (349 pages)

Brand: Toyota | Category: Engine | Size: 34.43 MB

Table of Contents

Caution
3
Introduction Contents
5
How to Use this Manual
6
Repair Procedures
6
Identification Information
8
Engine Serial Number
8
General Repair Instructions
8
Abbreviations Used in this Manual
11
Table of Contents
12
Engine Mechanical Contents
12
Description
13
Troubleshooting
15
- Diesel Engine Diagnosis
  15
  - General
    15
  - Preliminary Checks
    15
- Diesel Electrical System Diagnosis
  25
Check Cylinder Compression Pressure
41
Compression Check
41
Components
43
Timing Belt
43
- Removal of Timing Belt
  44
- Remove Timing Belt Cover
  44
- Set no 1 Cylinder to BDC
  44
- Remove Timing Belt Idler Pulley
  45
- Remove no 2 Camshaft Timing Pulley
  45
- Remove Intake Pipe
  45
- Remove Cylinder Head Cover
  46
- Remove no 1 Camshaft Timing Pulley
  46
- Inspection of Timing Belt Components
  47
- Inspect Idler Pulley
  48
- Inspect Tension Spring
  48
- Install Intake Pipe
  49
- Instal no 1 Camshaft Timing Pulley
  49
- Installation of Timing Belt
  49
- Install Cylinder Head Cover
  49
- Instal no 2 Camshaft Timing Pulley
  50
- Install Timing Belt Idler Pulley
  50
- Check Valve Timing
  51
- Install Timing Belt Cover
  52
- Timing Gears
  53
- Removal of Timing Gears
  54
- Remove Oil Pipe
  54
- Remove Vacuum Pump
  54
- Remove Crankshaft Pulley
  54
- Remove Timing Gear Cover
  55
- Check Thrust Clearance of Idler Gear
  55
- Remove Pump Drive Shaft Gear
  55
- Remove Crankshaft Timing Gear
  56
- Remove Idler Gear
  56
- Remove Injection Pump Drive Gear
  56
- Inspection of Timing Gears
  57
- Inspect Idler Gear
  57
- Inspect Injection Pump Drive Gear Bearing
  57
- Replace Injection Pump Drive Gear Bearing
  57
- Check Backlash of Timing Gears
  58
- Replacement of Crankshaft Front Oil Seal
  59
- Replacement of Injection Pump Drive Gear Oil Seal
  60
- Installation of Timing Gears
  61
- Install Crankshaft Timing Gear
  61
- Install Injection Pump Drive Gear
  61
- Install Idler Gear
  61
- Install Pump Drive Shaft Gear
  62
- Install Timing Gear Cover
  62
- Install no 1 Crankshaft Pulley
  63
- Install Vacuum Pump
  64
- Instal Oil Pipe
  64
Cylinder Head
65
- Removal of Cylinder Head
  66
- Remove Oil Dipstick and Oil Dipstick Guide
  66
- Remove Intake Manifold
  66
- Remove Nozzle Leakage Pipe
  66
- Remove Injection Nozzles
  67
- Remove Glow Plugs
  68
- Remove Exhaust Manifold
  68
- Separate Exhaust Manifold
  69
- Remove Camshaft
  70
- Remove Camshaft Oil Seal Retainer
  70
- Remove Cylinder Head
  71
- Disassembly of Cylinder Head
  72
- Remove Valves
  72
- Remove Combustion Chambers
  73
- Inspection, Cleaning and Repair of Cylinder Head Components
  74
- Clean Top of Pistons and Top of Block
  74
- Remove Gasket Material
  74
- Clean Combustion Chambers
  74
- Inspect Cylinder Head for Flatness
  75
- Inspect Cylinder Head for Cracks
  75
- Clean Valves
  75
- Inspect Valve Stems and Guide Bushings
  75
- Replace Valve Guide Bushings
  76
- Inspect and Grind Valves
  77
- Inspect and Clean Valve Seats
  78
- Inspect Valve Springs
  79
- Inspect Camshafts and Bearings
  80
- Inspect Valve Lifters and Lifter Bores
  81
- Inspect Intake and Exhaust Manifold
  82
- Inspect Cylinder Head Bolts
  82
- Replacement of Camshaft Oil Seal
  83
- Assembly of Cylinder Head
  84
- Install Half Circular Plug
  84
- Select Combustion Chamber Shim
  84
- Install Combustion Chambers
  84
- Install Valves
  85
- Install Valve Lifters and Shims
  85
- Installation of Cylinder Head
  86
- Check Piston Protrusion and Select Cylinder Head Gasket
  86
- Install Cylinder Head
  88
Cylinder Block
88
- Install Camshaft
  89
- Adjust Valve Clearance
  90
- Assembly Exhaust Manifolds
  90
- Install Camshaft Oil Seal Retainer
  90
- Install Pulleys and Timing Belt
  90
- Install Exhaust Manifold
  91
- Install Glow Plug
  92
- Install Injection Nozzles
  93
- Install Nozzle Leakage Pipe
  93
- Install Injection Pipes
  94
- Install Intake Manifold
  94
- Install Oil Dipstick Guide and Oil Dipstick
  94
- Install Water Outlet
  94
- Cylinder Block
  95
- Preparation for Disassembly
  96
- Check Connecting Rod Thrust Clearance
  97
- Disassembly of Cylinder Block
  97
- Remove Connecting Rod Caps and Check Oil Clearance
  97
- Remove Rear Oil Seal Retainer
  97
- Remove Piston and Connecting Rod Assemblies
  99
- Check Crankshaft Thrust Clearance
  100
- Remove Main Bearing Cap and Check Oil Clearance
  100
- Remove Check Valves and Oil Nozzles
  103
- Remove Crankshaft
  103
- Inspect Cylinder Bore Diameter
  104
- Inspect Cylinder for Vertical Scratches
  104
- Inspect Top of Cylinder Block for Flatness
  104
- Inspection of Cylinder Block
  104
- Inspect Main Bearing Cap Bolts
  105
- Remove Cylinder Ridge
  105
- Disassembly of Piston and Connecting Rod Assemblies
  106
- Disconnect Connecting Rod from Piston
  106
- Inspect Cylinder Block Orifice
  106
- Remove Piston Rings
  106
- Clean Piston
  108
- Inspect Piston Diameter and Oil Clearance
  108
- Inspection and Repair of Piston and Connecting Rod Assemblies
  108
- Inspect Clearance between Wall of Ring Groove and New Piston Ring
  109
- Inspect Piston Ring End Cap
  109
- Inspect Connecting Rod
  110
- Inspect Piston Pin Fit
  110
- Replace Connecting Rod Bushings
  111
- Bore and Hone Cylinders to Calculate Dimensions
  114
- Boring of Cylinders
  114
- Calculate Amount to Bore Cylinder
  114
- Keep Oversized Pistons
  114
- Grind and Hone Main Journals And/Or Crank Pins
  115
- Inspect Crankshaft for Runout
  115
- Inspect Main Journals and Crank Pins
  115
- Inspection and Repair of Crankshaft
  115
- Replacement of Crankshaft Oil Seal
  116
- Assembly of Piston and Connecting Rod Assemblies
  117
- Install Piston Rings
  117
- Install Bearings
  118
- Assembly of Cylinder Block
  119
- Install Main Bearings
  119
- Install Oil Nozzles and Check Valves
  119
- Install Main Bearing Cap
  120
- Install Thrust Washers
  120
- Install Connecting Rod Caps
  122
- Install Piston and Connecting Rod Assemblies
  122
- Install Rear Oil Seal Retainer
  123
- Post Assembly
  124
- Turbocharger Contents
  125
- Description
  126
  - Operation of Turbocharger
    127
  - Waste Gate Valve
    127
- Precautions
  128
- Troubleshooting
  129
- Turbocharger Electrical System Diagnosis (Hzj80
  131
  - Check Turbocharging Pressure
    132
  - Inspect Exhaust System
    132
  - Inspect Intake Air System
    132
  - On-Vehicle Inspection of Turbocharger
    132
  - Removal of Turbocharger
    134
  - Remove Exhaust Manifold Heater Insulator
    134
  - Remove Turbo Heat Insulator
    134
  - Remove Turbocharger Stay
    134
  - Remove no 2 Turbo Heat Insulator
    135
  - Remove Turbo Oil Pipe
    135
  - Remove Turbocharger and Exhaust Manifold Assembly
    135
  - Separate Turbocharger and Exhaust Manifold
    135
  - Inspect Axial Play of Impeller Wheel
    136
  - Inspect Impeller Wheel Rotation
    136
  - Inspect Radial Play of Turbine Shaft
    136
  - Inspection of Turbocharger
    136
  - Inspect Actuator Operation
    137
  - Install no 1 Turbo Water Pipe
    137
  - Install Turbine Outlet Elbow
    137
  - Installation of Turbocharger
    137
  - Assemble Turbocharger and Exhaust Manifold
    138
  - Install Turbo Oil Pipe
    138
  - Install Turbocharger and Exhaust Manifold Assembly
    138
  - Install Turbocharger Stay
    138
  - Install Exhaust Manifold Heat Insulator
    139
  - Install Turbocharger Heat Insulator
    139
  - Fuel System Contents
    140
- Description
  141
  - Injection Pump
    142
  - Operation
    142
  - Drain Fuel from Fuel Filter
    143
- Replacement of Fuel Filter
  143
- Fuel Heater System
  145
  - System Circuit
    145
  - Fuel Heater
    146
  - Inspection of Components
    146
  - Vacuum Switch
    146
  - Fuel Heater Relay
    147
- INJECTION NOZZLES (1PZ and 1 HZ
  148
  - Removal of Injection Nozzles
    148
  - Remove Injection Pipes
    148
  - Injection Pressure Test
    149
  - Remove Nozzleleakage Pipe
    149
  - Test of Injection Nozzles
    149
  - Adjusting Shim Thickness
    150
  - Leakage Test
    150
  - Spray Pattern Test
    150
  - Cleaning and Inspection of Injection Nozzles
    151
  - Disassembly of Injection Nozzles
    151
  - Inspect Nozzle Assembly
    152
  - Assembly of Injection Nozzles
    153
- Injection Nozzles (1Hd-T
  153
  - Installation of Injection Nozzles
    153
  - Disconnect Injection Pipes
    155
  - Adjust Pre-Lift
    159
  - Assembly and Adjustment of Injection Nozzle
    159
  - Check no 2 Opening Pressure
    161
  - Adjust no 1 Opening Pressure
    163
  - Removal of Injection Pump
    166
  - Disassembly of Injection Pump
    172
  - Remove Idle-Up Lever
    172
  - Remove Thermo Wax
    172
  - Remove Two Fuel Pipes
    172
  - Remove Fuel Cut Solenoid
    173
  - Remove PCS Actuator
    173
  - Remove Adjusting Lever
    174
  - Remove Governor Cover
    174
  - Disassembly High Altitude Compensator
    175
  - Remove Governor Adjusting Lever Shaft from Governor Cover
    175
  - Disassemble Boost Compensator
    177
  - Remove Distributive Head Plug
    179
  - Remove Governor Shaft and Flyweight Holder
    179
  - Remove Injection Pump Stay
    179
  - Remove Delivery Valve Holders
    180
  - Remove Distributive Head
    180
  - Remove Face Camplate and Coupling
    181
  - Remove Governor Link
    181
  - Remove Pump Plunger
    181
  - Remove Roller Ring and Drive Shaft
    182
  - Remove Timer
    183
  - Remove Fuel Feed Pump
    184
  - Remove Fuel Inlet Hollow Screw
    184
  - Remove Regulator Valve
    184
  - Inspect Delivery Valves
    185
  - Inspection of Injection Pump Components
    185
  - Inspect Plunger Springs for Squareness
    186
  - Inspect Pump Plunger, Spill Ring and Distributive Head
    186
  - Inspect Spring Length
    186
  - Inspect Fuel Cut Solenoid
    187
  - Inspect Pickup Sensor
    187
  - Inspect Roller Ring and Rollers
    187
  - Replace Oil Seal
    187
  - Assembly of Injection Pump
    188
  - Install Fuel Feed Pump
    188
  - Install Fuel Inlet Hollow Screw
    188
  - Install Regulator Valve
    188
  - Install Drive Shaft
    189
  - Install Roller Ring
    190
  - Install Timer Piston
    190
  - Adjust Plunger Spring Shim
    192
  - Plunger Spring Shim Selection Chart for 1 HD-T
    192
  - Plunger Spring Shim Selection Chart for 1 PZ and 1 HZ
    192
  - Plunger Adjusting Shim Selection Chart
    194
  - Install Face Cam Plate
    195
  - Install Governor Link
    195
  - Install Pump Plunger
    195
  - Install Distributive Head
    196
  - Check Flyweight Holder Thrust Clearance
    197
  - Install Delivery Valve Holders
    197
  - Install Governor Shaft and Flyweight Holder
    197
  - Adjust Protrusion of Governor Shaft
    198
  - Assemble High Altitude Compensator
    198
  - Assemble Boost Compensator
    199
  - Install Adjusting Lever
    200
  - Install Adjusting Lever Shaft to Governor Shaft
    200
  - Install Governor Cover
    200
  - Adjust Plunger Pre-Stroke
    202
  - Install Distributive Head Plug
    203
  - Install Fuel Cut Solenoid
    206
  - Install no 1 Pcs Lever
    206
  - Install Pcs Actuator
    207
  - Install Thermo Wax
    207
  - Install Idle-Up Lever
    208
  - Perform Air Tight Test
    208
  - Adjustment of Injection Pump
    209
  - Pretest Check and Preparation
    209
  - Preset Full Load Injection Volume
    214
  - Adjust Pump Inner Pressure
    215
  - Preset Maximum Speed
    215
  - Adjust Timer
    216
  - Check Overflow Volume
    216
  - Release Cold Starting System for Next Inspections
    216
  - Adjust Full Load Injection Volume
    217
  - Check Air Tightness of Boost Compensator
    217
  - Check Injection Volume
    220
  - Adjust Boost Compensator Characteristic
    223
  - Adjust Full Load Minimum Injection Volume
    223
  - Check Hysteresis
    224
  - Inspect Boost Compensator Characteristic Tendency
    224
  - Adjust Load Sensing Timer
    225
  - Adjust Cold Starting System
    229
  - Adjust Fast Idle
    230
  - Post Adjustment Check
    230
  - Install Two Fuel Pipes
    231
  - Seal Parts
    231
  - Installation of Injection Pump
    232
  - Inspect Power Control System
    234
  - Inspection of Power Control System Components
    234
  - On-Vehicle Inspection
    234
  - Power Control System
    234
  - Inspect Shift Position Switch
    235
  - Cooling System Components
    236
- Description
  237
  - Radiator
    238
  - Radiator Cap
    238
  - Reservoir Tank
    238
  - Thermostat
    238
  - Check and Replacement of Engine Coolant
    239
  - Check Engine Coolant Level at Reservoir Tank
    239
  - Check Engine Coolant Quality
    239
  - Replace Engine Coolant
    239
- Troubleshooting
  239
- Water Pump
  241
  - Removal of Water Pump
    242
  - Inspect Fluid Coupling
    243
  - Inspect of Water Pump
    243
  - Installation of Water Pump
    243
  - Install Water Pump Pulley, Fan and Drive Belt
    244
  - Inspection of Thermostat
    245
  - Removal of Thermostat
    245
  - Install Water Inlet to Cylinder Block
    246
  - Installation of Thermostat
    246
  - Place Thermostat in Cylinder Block
    246
  - Cleaning of Radiator
    247
  - Inspect Cooling System for Leaks
    247
  - Inspect Radiator Cap
    247
  - Inspection of Radiator
    247
  - Lubrication System Contents
    248
- Description
  249
  - Oil Filter
    250
  - Oil Pressure Regulator
    250
  - Oil Pump
    250
- Troubleshooting
  251
  - Check Engine Oil Level
    252
  - Check Engine Oil Quality
    252
- Oil Pressure Check
  252
  - Drain Engine Oil
    253
  - Replace Oil Filter
    253
- Replacement of Engine Oil and Oil Filter
  253
- Fill with Engine Oil
  254
- Oilpump
  255
  - Removal of Oil Pump
    256
  - Remove Oil Pan
    256
  - Disassembly of Oil Pump
    257
  - Inspect Drive and Driven Rotors
    258
  - Inspect Relief Valve
    258
  - Inspection of Oil Pump
    258
  - Assembly of Oil Pump
    259
  - Install Relief Valve
    259
  - Installation of Oil Pump
    259
  - Pour Engine Oil into Oil Pump
    260
  - Install Oil Pan
    261
  - Install Oil Strainer
    261
- Oil Cooler, Relief Valve and Check Valve
  262
- Oil Nozzles and Check Valves
  267
- Pre-Heating System
  270
- Super Glow Type (Europe and Australia
  270
  - Inspection of Pre-Heating System
    271
  - Timer Characteristic Diagram
    271
  - Inspect Preheating Timer Circuit
    273
  - Inspect Relay Continuity
    273
  - No. 1 Glow Plug Relay
    273
  - Inspect Relay Operation
    274
  - No.2 Glow Plug Relay
    274
  - Glow Plug
    275
  - Glow Plug Resistor
    275
  - Water Temperature Sensor
    276
- Fixed Delay Type (HZJ80 and HDJ80) Ex. (Europe and Australia
  277
- Fixed Delay Type (PZJ, HZJ75, HZB and HDB) Ex. (Europe and Australia
  279
- Glow Plug
  280
- Starting System Circuit
  281
- Troubleshooting
  281
- Starter
  283
  - Remove Brush Holder
    284
  - Remove Steel Ball
    284
  - Armature Coil
    285
  - Commutator
    285
  - Inspect Commutator for Open Circuit
    285
  - Inspection and Repair of Starter
    285
  - Brush Springs
    286
  - Brushes
    286
  - Field Coil (Field Frame)
    286
  - Inspect Undercut Depth
    286
  - Brush Holder
    287
  - Clutch and Gears
    287
  - Inspect Clutch Pinion Gear
    287
  - Inspect Gear Teeth
    287
  - Bearings
    289
  - Assembly of Starter
    290
  - Magnetic Switch
    290
  - Perform Pull/Hold-In Coil Open Circuit Test
    290
  - Place Armature into Field Frame
    290
  - Insert Steel Ball into Clutch Shaft Hole
    291
  - Install Gear, Clutch Assembly and Starter Housing
    291
  - Install Field Frame and Armature Assembly
    292
  - Inspect Clutch Pinion Gear Return
    293
  - Perform No-Load Performance Test
    293
  - Perform Pull/Hold-In Test
    293
  - Performance Test of Starter
    293
  - Inspection of Starter Relay
    294
  - Starter Relay (PZJ, HZJ and HDJ)
    294
  - Starter Relay (HZB and HDB)
    295
  - Inspection of Voltage Converter Timer
    296
- VOLTAGE CONVERTER TIMER (HZJ80 and HDJ80) (W/ 24 V Starter)
  296
- Inspection of Voltage Converter Relay
  297
- VOLTAGE CONVERTER RELAY (Hzj80And HDJ80) (W/24 V Starter)
  297
- HOLD WARNING RELAY (Hzj80And HDJ80) (W/ 24 V Starter)
  298
  - Inspection of 24 V Hold Warning Relay
    298
  - Charging System Contents
    299
- Precautions
  300
- Troubleshooting
  300
- Charging System Circuit
  301
- On-Vehicle Inspection
  303
- Alternator
  306
  - Disassembly of Alternator
    307
  - Remove Brush Holder and IC Regulator
    307
  - Remove Rear End Cover
    307
  - Remove Rectifier Holder
    307
  - Remove Pulley
    308
  - Remove Rectifier End Frime
    308
  - Inspection and Repair of Alternator
    310
  - Rotor
    310
  - Stator (Drive End Frame)
    310
  - Rectifiers (Rectifier Holder)
    311
  - Assembly of Alternator
    314
  - Install Rectifier End Frame
    314
  - Install Rotor to Drive End Frame
    314
  - Install Pulley
    315
  - Install Rectifier Holder
    315
  - Install IC Regulator and Brush Holder
    316
  - Install Rear End Cover
    317
  - Service Specifications Contents
    318
  - Torque Specifications
    324
  - Turbocharger System
    325
  - Fuel System
    326
  - Injection Pump Adjustment
    330
- 1HD-T Plus
  333
- Adjusting
  333
- Injection
  333
- Lever Angle
  333
- Item
  334
- Adjusting
  335
- Lever Angle
  335
- (Europe) Plus
  336
- 1Hd-T
  336
- Plus 21 - 3
  336
- Pump Rpm Measuring Strokes
  336
- Cooling System
  338
- Lubrication System
  338
- Starting System
  339
- Charging System
  339
- Standard Bolt Torque Specifications
  340
- How to Determine Bolt Strangth
  341
- SST and SSM
  343
- SST (Special Service Tools)
  344
- SSM (Special Service Materials)
  348

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