Toyota 1KZ-TE Repair Manual

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BACK TO ENGINE INDEX BACK TO MAIN MODEL IND
RM710E-D
REPAIR MANUAL
This
1KZ-TE ENGINE
for the
Applicable models:
Please note that the publications below have also been prepared as relevant service manuals for the compo-
nents and system in this engine.
S
HILUX Electrical Wiring Diagram
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.
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, 1999 01--990611--00--2
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 manu-
al 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.
Must read this manual thoroughly. It is especially important to have good understanding all the
S
contents written in the PRECAUTION of "IN" section.
The service method written in this manual is very effective to perform repair and service. When
S
performing the operations following the procedures using this manual, be sure to use tools spe-
cified 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.
If part replacement is necessary, must replace the part with the same part number or equivalent
S
part. Do not replace it with inferior quality.
It is important to note that this manual contains various "Cautions" and "Notices" that must be
S
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.
FOREWORD
TOYOTA MOTOR CORPORATION
has been prepared to provide information covering general service repairs
TOYOTA HILUX.
equipped on the
KZN165 series
Manual Name
CAUTION
VIEW THE MAIN INDEX
1KZ-TE
Pages From Manual
TO MODEL INDEX
Pub. No.
EWD307F

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Summary of Contents for Toyota 1KZ-TE

  • Page 1 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, 1999 01--990611--00--2 CAUTION This manual does not include all the necessary items about repair and service.
  • Page 2: Engine Mechanical

    BACK TO MAIN FOREWORD & To Engine Index 1KZ-TE Pages From Manual TO MODEL INDEX MAIN INDEX HILUX ENGINE 1KZ-TE: INTRODUCTION June 2000 PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS ENGINE MECHANICAL TURBOCHARGER EMISSION CONTROL ELECTRONIC CONTROL DIESEL ENGINE FUEL COOLING LUBRICATION STARTING...
  • Page 3: Table Of Contents

    BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX I NTRO DUCTI O N HOW TO USE THIS MANUAL ... . . IN--1 GENERAL INFORMATION ....
  • Page 4: In04V

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -1 INTRODUCTION HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN04V- -04 GENERAL INFORMATION 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.
  • Page 5: The Procedures Are Presented In A Step--By--Step Format

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -2 INTRODUCTION HOW TO USE THIS MANUAL The procedures are presented in a step--by--step format: The illustration shows what to do and where to do it.
  • Page 6: Engine Serial Number

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -3 INTRODUCTION IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION IN0E6- -02 ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration.
  • Page 7: Repair Instructions

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -4 INTRODUCTION REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS IN0E7- -02 GENERAL INFORMATION BAS I C RE PAI R HI NT Use fender, seat and floor covers to keep the vehicle clean and prevent damage.
  • Page 8 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -5 INTRODUCTION REPAIR INSTRUCTIONS Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service ma- terials (SSM) may be required, depending on the nature of the repair.
  • Page 9 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -6 INTRODUCTION REPAIR INSTRUCTIONS When either the front or rear wheels only should be jacked up, set rigid racks and place stoppers in front and behind the other wheels on the ground.
  • Page 10: Example

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -7 INTRODUCTION REPAIR INSTRUCTIONS Tag hoses before disconnecting them: Example When disconnecting vacuum hoses, use tags to identify how they should be reconnected. After completing a job, double check that the vacu- um hoses are properly connected.
  • Page 11 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -8 INTRODUCTION FOR ALL OF VEHICLES FOR ALL OF VEHICLES IN0E8- -02 PRECAUTION IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two--way radios and cellular telephones, observe the following precautions.
  • Page 12 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -9 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO T ROUBLESHOOT ECU CONTROLLED SYSTEMS IN050- -05 GE NE RAL I NFORMATI ON A large number of ECU controlled systems are used in the HILUX. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot.
  • Page 13: Symptom Confirmation And Diagnostic Trouble Code Check In

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO PROCEED WITH TROUBLESHOOTING IN-10 1. CUSTOMER PROBLEM ANALYSIS IN-11 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK IN-12/13 3.
  • Page 14 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -10 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN051- -05 HOW TO P ROCE E D WI T H T ROUBL E S HOOT I NG Carry out troubleshooting in accordance with the procedure on the following page.
  • Page 15: Erence

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -11 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CUS TO ME R P RO BLE M ANALY S I S In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgement.
  • Page 16 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -12 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS S Y MP TO M CO NFI RMATI O N AND DI AG NO S T I C TRO UBLE CO DE CHE CK The diagnostic system in the HILUX fulfills various functions.
  • Page 17 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -13 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Taking into account the above points, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms.
  • Page 18 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -14 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle.
  • Page 19 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -15 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HE AT M E T HO D: W h en t h e p ro b l em seems t o o ccu r w h en t h e su sp ect area i s h eat ed .
  • Page 20 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -16 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DI AG NO S T I C TRO UBLE CO DE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot- ing using the diagnostic trouble codes displayed in the diagnostic trouble code check.
  • Page 21 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -17 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS PROBLEM SYMPTOMS TABLE The suspect circuits or parts for each problem symptom are shown in the table below. Use this table to trou- bleshoot the problem when a ”Normal”...
  • Page 22: Erence

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -18 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CI RCUI T I NSPECTION How to read and use each page is shown below. D Diagnostic Trouble Code No. and Detection Item D Circuit Description The major role and operation, etc.
  • Page 23 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -19 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS D Indicates the position of the ignition switch during the check. D Inspection Procedure Use the inspection procedure to determine...
  • Page 24 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -20 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN052- -05 HOW TO US E THE DI AGNOS TI C CHART AND I NS P E CT I ON...
  • Page 25 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -21 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CO NTI NUI TY CHE CK (O P E N CI RCUI T CHE CK) Sensor Side ECU Side Disconnect the connectors at both ECU and sensor sides.
  • Page 26 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -22 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CO NNE CTO R HANDLI NG When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads.
  • Page 27 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -23 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check the voltage. Fig. 4 In a circuit in which voltage is applied (to the ECU connec- tor terminal), an open circuit can be checked for by con- ducting a voltage check.
  • Page 28 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -24 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Disconnect connector ”B” and measure the resis- Fig. 7 tance between terminal 1 of connector ”A” and body ground, and terminal 1 of connector ”B2”...
  • Page 29 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX IN- -25 INTRODUCTION TERMS TERMS IN00S- -13 ABBRE V I AT I O NS US E D I N T HI S M ANUAL Abbreviations Meaning Air Conditioning...
  • Page 30 Special Service Materials Special Service Tools Standard Switch TACH Tachometer Top Dead Center TEMP. Temperature Transmission TOYOTA Motor Corporation Three- -Way Catalyst Underdrive Vacuum Control Valve Vehicle Identification Number Vacuum Switching Valve With Wire Harness Without WU- -TWC Warm Up Three- -Way Catalytic Converter...
  • Page 31 BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PREPARATI O N ENGINE MECHANICAL ....PP--1 TURBOCHARGING ..... .
  • Page 32 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -1 PREPARATION ENGINE MECHANICAL ENGINE MECHANICAL PP2D0- -01 SST (Special Service Tools) 09992- -00500 Compression Gauge Attachment 09992- -00025 Cylinder Compression Check Gauge (09992- -00200) L Joint...
  • Page 33 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -2 PREPARATION ENGINE MECHANICAL 09223- -78010 Crankshaft Oil Seal Replacer Injection pump drive gear oil seal 09223- -00010 Cover & Seal Replacer 09214- -60010 Crankshaft Pulley & Gear...
  • Page 34 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -3 PREPARATION ENGINE MECHANICAL (09955- -04041) Claw No.4 (09955- -04061) Claw No.6 Camshaft timing pulley Oil pump drive gear shaft Crank shaft timing gear Injection pump drive gear...
  • Page 35 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -4 PREPARATION ENGINE MECHANICAL (09222- -06031) Base (09222- -06020) Guide 09223- -15030 Oil Seal & Bearing Replacer No. 1 Replacer Handle (09252- -10010) (09222- -06010) Remover & Replacer...
  • Page 36 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -5 PREPARATION ENGINE MECHANICAL PP2D1- -01 RECOMMENDED TOOLS 09040- -00011 Hexagon Wrench Set . 09200- -00010 Engine Adjust Kit . 09904- -00010 Expander Set . 09905- -00013 Snap Ring Pliers .
  • Page 37 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -6 PREPARATION ENGINE MECHANICAL PP1TO- -02 EQUIPMENT Carbide cutter Caliper gauge Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune- -up tester Gasket scraper...
  • Page 38 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -7 PREPARATION ENGINE MECHANICAL PP2D2- -01 SSM (Special Service Materials) 08826- -00080 Seal Packing Black or equivalent Timing belt cover (FIPG) Timing gear cover Camshaft oil seal retainer...
  • Page 39 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -8 PREPARATION TURBOCHARGING TURBOCHARGING PP2D3- -01 SST (Special Service Tools) 09992- -00242 Turbocharger Pressure Gauge 09350- -32014 TOYOTA Automatic Transmission Tool Set (09351- -32070) No.2 Piston Spring Compressor Bearing housing CONTINUED...
  • Page 40 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -9 PREPARATION TURBOCHARGING PP2D4- -01 RECOMMENDED TOOLS 09905- -00013 Snap Ring Pliers . CONTINUED...
  • Page 41 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -10 PREPARATION TURBOCHARGING PP1TR- -03 EQUIPMENT Dial indicator Impeller wheel Torque wrench...
  • Page 42 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -11 PREPARATION ELECTRONIC CONTROL DIESEL ELECTRONIC CONTROL DIESEL PP2CV- -01 SST (Special Service Tools) 09817- -16011 Back- -up Light Switch Tool First gear position sensor switch...
  • Page 43 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -12 PREPARATION ELECTRONIC CONTROL DIESEL PP1T6- -02 RECOMMENDED TOOLS 09082- -00040 TOYOTA Electrical Tester. 09200- -00010 Engine Adjust Kit . CONTINUED...
  • Page 44 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -13 PREPARATION ELECTRONIC CONTROL DIESEL PP15E- -03 EQUIPMENT 19 mm deep socket wrench Thermometer Torque wrench Vacuum gauge...
  • Page 45: Engine Fuel

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -14 PREPARATION ENGINE FUEL ENGINE FUEL PP2CW- -01 SST (Special Service Tools) 09228- -64040 Fuel Filter Wrench 09241- -76022 Injection Pump Stand Set 09245- -54010 Injection Pump Stand Arm...
  • Page 46 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -15 PREPARATION ENGINE FUEL (09953- -05020) Center Bolt 150 Injection pump (09954- -05010) Claw No.1 Injection pump CONTINUED...
  • Page 47 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -16 PREPARATION ENGINE FUEL PP2CX- -01 RECOMMENDED TOOLS 09040- -00011 Hexagon Wrench Set . 09082- -00040 TOYOTA Electrical Tester. CONTINUED...
  • Page 48 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -17 PREPARATION ENGINE FUEL PP1LS- -02 EQUIPMENT 19 mm deep socket wrench Fuel temp. sensor Brass brush Injection nozzle tester Injection pump tester Torque wrench Water pump pliers...
  • Page 49 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -18 PREPARATION COOLING COOLING PP2D5- -01 SST (Special Service Tools) 09230- -01010 Radiator Service Tool Set 09231- -14010 Punch CONTINUED...
  • Page 50 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -19 PREPARATION COOLING PP1TJ- -02 EQUIPMENT Heater Thermostat Radiator cap tester Thermometer Thermostat Torque wrench CONTINUED...
  • Page 51 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -20 PREPARATION COOLING PP2D6- -01 COOLANT Item Capacity Classification Engine coolant 10.5 liters (11.1 US qts, 9.2 Imp. qts) ”Toyota Long Life Coolant” or equivalent CONTINUED...
  • Page 52 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -21 PREPARATION COOLING PP2D7- -01 SSM (Special Service Materials) 08826- -00100 Seal Packing 1282B, Engine drain plug on oil cooler cover THREE BOND 1282B or equivalent...
  • Page 53 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -22 PREPARATION LUBRICATION LUBRICATION PP2D8- -01 SST (Special Service Tools) 09228- -10002 Oil Filter Wrench 09032- -00100 Oil Pan Seal Cutter CONTINUED...
  • Page 54 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -23 PREPARATION LUBRICATION PP2D9- -01 RECOMMENDED TOOLS 09200- -00010 Engine Adjust Kit . CONTINUED...
  • Page 55 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -24 PREPARATION LUBRICATION PP1T1- -02 EQUIPMENT Oil pressure gauge Precision straight edge Torque wrench CONTINUED...
  • Page 56 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -25 PREPARATION LUBRICATION PP2DA- -01 LUBRICANT Item Capacity Classification Engine oil API grade CF- -4 or CF Dry fill 7.5 liters (7.9 US qts, 6.2 Imp. qts)
  • Page 57 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -26 PREPARATION LUBRICATION PP2DB- -01 SSM (Special Service Materials) 08826- -00080 Seal Packing Black or equivalent Oil pump (FIPG) Oil pan 08833- -00080 Adhesive 1344 Oil pressure sender gauge...
  • Page 58 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -27 PREPARATION STARTING STARTING PP2CY- -01 SST (Special Service Tools) 09201- -41020 Valve Stem Oil Seal Replacer Armature front bearing 09286- -46011 Injection Pump Spline Shaft...
  • Page 59 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -28 PREPARATION STARTING PP1M1- -02 RECOMMENDED TOOLS 09082- -00040 TOYOTA Electrical Tester. CONTINUED...
  • Page 60 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -29 PREPARATION STARTING PP1M2- -02 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Plastic hammer Press Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator...
  • Page 61 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -30 PREPARATION CHARGING CHARGING PP2CZ- -01 SST (Special Service Tools) 09285- -76010 Injection Pump Camshaft Bearing Rotor rear bearing cover Cone Replacer 09286- -46011 Injection Pump Spline Shaft...
  • Page 62 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -31 PREPARATION CHARGING PP1M4- -02 RECOMMENDED TOOLS 09082- -00040 TOYOTA Electrical Tester. CONTINUED...
  • Page 63 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PP- -32 PREPARATION CHARGING PP1M5- -02 EQUIPMENT Ammeter (A) Battery specific gravity gauge Except maintenance free battery Belt tension gauge Torque wrench Vernier calipers Rotor (Slip ring), Brush...
  • Page 64: Service Specifications

    BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SERVICE SPECIFICATIONS STANDARD BOLT ......SS--1 ENGINE MECHANICAL .
  • Page 65 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -1 SERVICE SPECIFICATIONS STANDARD BOLT STANDARD BOLT SS0ZS- -01 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Class Stud Bolt Weld Bolt Normal Recess Bolt...
  • Page 66 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -2 SERVICE SPECIFICATIONS STANDARD BOLT SS0ZT- -01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Hexagon head bolt Hexagon flange bolt Class Class N∙m kgf∙cm ft∙lbf...
  • Page 67 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -3 SERVICE SPECIFICATIONS STANDARD BOLT SS0ZU- -01 HOW TO DETERMINE NUT STRENGTH Nut Type Old Standard Hexagon Nut Present Standard Class Hexagon Nut Cold Forging Nut...
  • Page 68 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -4 SERVICE SPECIFICATIONS ENGINE MECHANICAL ENGINE MECHANICAL SS16L- -02 SERVICE DATA Compresion 3,040 kPa (31.0 kgf/cm , 441 psi) or more pressure Minimium 1,961 kPa (20.0 kgf/cm...
  • Page 69 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -5 SERVICE SPECIFICATIONS ENGINE MECHANICAL Valve Stem diameter Intake 7.975 - - 7.990 mm (0.3140 - - 0.3146 in.) Exhaust 7.960 - - 7.975 mm (0.3134 - - 0.3140 in.)
  • Page 70 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -6 SERVICE SPECIFICATIONS ENGINE MECHANICAL Piston and Piston diameter STD Mark 1 95.940 - - 95.950 mm (3.7772 - - 3.7776 in.) piston ring Mark 2 95.950 - - 95.960 mm (3.7776 - - 3.7779 in.)
  • Page 71 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -7 SERVICE SPECIFICATIONS ENGINE MECHANICAL Crankshaft Thrust clearance 0.040 - - 0.240 mm (0.0016 - - 0.0094 in.) Maximum 0.30 mm (0.0118 in.) Thrust washer thickness STD (STD) 2.430 - - 2.480 mm (0.0957 - - 0.0976 in.)
  • Page 72: Torque Specification

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -8 SERVICE SPECIFICATIONS ENGINE MECHANICAL SS16K- -01 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Intake pipe x Intake manifold Injection pump x Timing gear case No.1 camshaft timing pulley x Camshaft 1,000 No.2 camshaft timing pulley x Injection pump drive gear...
  • Page 73: Service Data

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -9 SERVICE SPECIFICATIONS TURBOCHARGING TURBOCHARGING SS16E- -01 SERVICE DATA Turbocharger Turbocharging pressure 51 - - 67 kPa (0.52 - - 0.68 kgf/cm , 7.4 - - 9.7 psi)
  • Page 74: Torque Specification

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -10 SERVICE SPECIFICATIONS TURBOCHARGING SS16F- -01 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Turbine inlet elbow x Turbocharger 19.1 Turbo water pipe x Turbocharger Bolt 69 in.∙lbf...
  • Page 75 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -11 SERVICE SPECIFICATIONS ELECTRONIC CONTROL DIESEL ELECTRONIC CONTROL DIESEL SS0L2- -03 SERVICE DATA Throttle position Clearance between stop screw and lever sensor 0 mm (0 in.) VTA - - E2 0.2 - - 5.8 kΩ...
  • Page 76 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -12 SERVICE SPECIFICATIONS ELECTRONIC CONTROL DIESEL SS0YQ- -02 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Throttle body x Intake manifold Water temperature sensor x Cylinder block Fuel temperature sensor x Fuel pump 21.6...
  • Page 77 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -13 SERVICE SPECIFICATIONS ENGINE FUEL ENGINE FUEL SS0UD- -02 SERVICE DATA Injection nozzles Nozzle opening pressure New nozzle 14,808 - - 15,593 kPa (151 - - 159 kgf/cm...
  • Page 78 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -14 SERVICE SPECIFICATIONS ENGINE FUEL SS0UE- -02 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Nozzle holder body x Nozzle holder retaining nut Injection nozzle x Cylinder head...
  • Page 79 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -15 SERVICE SPECIFICATIONS COOLING COOLING SS16G- -01 SERVICE DATA 80 - - 84˚C (176 - - 183 ˚F) Thermostat Valve opening temperature Valve life (at 95˚C (203˚F)) 8 mm (0.31 in.) or more...
  • Page 80 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -16 SERVICE SPECIFICATIONS COOLING SS16H- -01 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Cylinder block x Drain plug 69 in.∙lbf Water pump x Cylinder block Alternator bracket x Cylinder block...
  • Page 81 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -17 SERVICE SPECIFICATIONS LUBRICATION LUBRICATION SS16I- -01 SERVICE DATA Oil presuure At idle speed (normal operating temperature) 29 kPa (0.3 kgf/cm , 43 psi) or more At 3,000 rpm (normal operating temperature) 250 - - 600 kPa (2.5 - - 6.1 kgf/cm...
  • Page 82 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -18 SERVICE SPECIFICATIONS LUBRICATION SS16J- -01 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Oil pan x Drain plug Relief valve x Oil pump Oil pump x Cylinder block...
  • Page 83 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -19 SERVICE SPECIFICATIONS STARTING STARTING SS0UJ- -02 SERVICE DATA Starter Rated voltage and output power 12 V 2.2 kW No- -load characteristics Current 120 A or less at 11.5 V...
  • Page 84 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -20 SERVICE SPECIFICATIONS STARTING SS0UK- -02 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Glow plug x Cylinder head Starter housing x Clutch assembly 82 in.∙lbf Field frame x Starter housing 12.7...
  • Page 85 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -21 SERVICE SPECIFICATIONS CHARGING CHARGING SS0UL- -02 SERVICE DATA Battery Specific gravity at 20˚C (68˚F) 1.25 - - 1.29 Voltage at 20˚C (68˚F) 12.5 - - 12.9 V...
  • Page 86 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX SS- -22 SERVICE SPECIFICATIONS CHARGING SS0UM- -02 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Drive end frame x Rectifier end frame 40 in.∙lbf Nut with cord clip 47 in.∙lbf...
  • Page 87 BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX DIAGNOSTICS NOTE: Please refer to Supplements that follow: Click here for: DIAGNOSTICS Engine Supplement:...
  • Page 88 BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ENGINE MECHANICAL AIR FILTER ......
  • Page 89 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -1 ENGINE MECHANICAL AIR FILTER AIR F ILTER EM0QH- -02 INSPECTION PAPER FILTER TYPE: Inspect the air filter. Visually check that the filter element is not excessively dirty, damaged or oily.
  • Page 90 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -2 ENGINE MECHANICAL COMPRESSION COMP RESSION EM0QI- -02 INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
  • Page 91 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -3 ENGINE MECHANICAL COMPRESSION If pressure stays low, a valve may be sticking or seating improperly, or there may be leakage past the gasket. RE I NS TALL I NJ E CTI O N NO ZZLE S...
  • Page 92: Valve Clearance

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -4 ENGINE MECHANICAL VALVE CLEARANCE VALVE CLEARANCE EM155- -01 INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. REMOVE INTAKE AIR PIPE...
  • Page 93 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -5 ENGINE MECHANICAL VALVE CLEARANCE Remove the adjusting shim with small screwdriver and magnetic finger. EM8464 Determine the replacement adjusting shim size by using following the formula or charts: Using a micrometer, measure the thickness of the shim which was removed.
  • Page 94: Example

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -6 ENGINE MECHANICAL VALVE CLEARANCE Ad j u st i n g S h i m S el ect i o n Usi n g Ch art...
  • Page 95 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -7 ENGINE MECHANICAL VALVE CLEARANCE Adjusting Shim Selection Using Chart EXHAUST New Shim Thickness Shim Shim Thickness Thickness 2.95 (0.1161) 2.50 (0.0984) 3.00 (0.1181) 2.55 (0.1004) 2.60 (0.1024)
  • Page 96 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -8 ENGINE MECHANICAL INJECTION TIMING INJECTION T IMING Punching Line EM0QK- -02 INSPECTION INSPECT INJ ECTION TIMING Using mirror, check that the punching line of the injection pump flange and the upper processing surface of the timing gear case aligned.
  • Page 97 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -9 ENGINE MECHANICAL IDLE SPEED AND MAXIMUM SPEED IDLE SPEED AND MAXIMUM SPEED EM0QL- -02 INSPECTION INITIAL CONDITIONS Engine at normal operating temperature Air cleaner installed...
  • Page 98 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -10 ENGINE MECHANICAL INTAKE CONSTRICTOR CONTROL INTAKE CONSTRICTOR CONTROL EM0QP- -02 INSPECTION INITIAL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected...
  • Page 99 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -11 ENGINE MECHANICAL INTAKE CONSTRICTOR CONTROL INSPECT HOT ENGINE CONDITION Check that the vacuum gauge in the chambers A and B will not move during idling.
  • Page 100 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ENGINE MECHANICAL – TIMING BELT TIMING BELT – COMPONENTS EM-12 REMOVEL 1. REMOVE TIMING BELT COVER EM-13 2. SET NO.4 CYLINDER TO TDC/COMPRESSION EM-13 3. IF RE-USING TIMING BELT, MARK TIMING BELT EM-13 4.
  • Page 101: Timing Belt

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -12 ENGINE MECHANICAL TIMING BELT TIMING BELT EM0RR- -02 COM P ONE NT S VSV for No.2 Intake VSV for No.1 Intake VSV for No.1 Intake...
  • Page 102 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual Pages From Manual TO MODEL INDEX EM- -13 ENGINE MECHANICAL TIMING BELT EM15A- -01 RE M O VAL HINT: If replacing the timing belt before the timing belt warning light comes on, (light comes on after 100,000 km of driving), be sure to reset the timing belt counter of the speedometer to zero.
  • Page 103 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -14 ENGINE MECHANICAL TIMING BELT RE MO V E TI MI NG BE LT I DLE R P ULLE Y Using a 10 mm hexagon wrench, remove the bolt, timing belt idler pulley and washer.
  • Page 104 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -15 ENGINE MECHANICAL TIMING BELT RE MO V E CY LI NDE R HE AD CO V E R Remove the 10 bolts, 2 nuts, cylinder head cover and gasket.
  • Page 105 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -16 ENGINE MECHANICAL TIMING BELT EM15B- -01 INSPECTION INSPECT TIMING BELT NOTICE: Do not bend, twist or turn the timing belt inside out. S S S S...
  • Page 106 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -17 ENGINE MECHANICAL TIMING BELT INSPECT TIMING BELT TENSIONER Visually check the seal portion of the tensioner for oil leak- age. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right.
  • Page 107 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -18 ENGINE MECHANICAL TIMING BELT EM0RU- -02 INSTALLATION INSTALL NO.1 CAMSHAFT TIMING PULLEY Install the set key to the key groove of the camshaft. Align the pulley set key with the key groove of the No.1 camshaft timing pulley, slide the No.1 camshaft timing...
  • Page 108 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -19 ENGINE MECHANICAL TIMING BELT Connect the vacuum hose to the acutuator of the cham- ber A. Connect the vacuum hose to the acutuator of the cham- ber B.
  • Page 109 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -20 ENGINE MECHANICAL TIMING BELT S E T TI MI NG BE LT TE NS I O NE R Using a press, slowly press in the push rod using 981 -- 9,807 N (100 -- 1,000 kgf, 220 --2,205 lbf) of force.
  • Page 110 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -21 ENGINE MECHANICAL TIMING BELT 11 . I NS TALL TI MI NG BE LT CO V E R Remove any old packing (FIPG) material. Apply seal packing to the camshaft oil seal retainer and timing gear cover as shown in the illustration.
  • Page 111 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ENGINE MECHANICAL – TIMING GEAR TIMING GEAR – COMPONENETS EM-22/23 REMOVEL 1. REMOVE TIMING BELT AND PULLEYS EM-24 2. REMOVE DRIVE BELT, FAN AND WATER PUMP PULLEY EM-24 3.
  • Page 112: Timing Gear

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -22 ENGINE MECHANICAL TIMING GEAR TIMING GEAR EM156- -01 COM P ONE NT S VSV for No.2 Intake VSV for No.1 Intake VSV for No.1 Intake...
  • Page 113 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -23 ENGINE MECHANICAL TIMING GEAR Camshaft Oil Seal Retainer Drive Belt Water Pump Pulley Fulid Coupling 9 (90, 78 in.∙lbf) 18 (185, 13) Crankshaft Pulley 13 (130, 9)
  • Page 114 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -24 ENGINE MECHANICAL TIMING GEAR EM0RW- -02 RE M O VAL NOTICE: When removing the crankshaft pulley and timing gear as the timing belt is off and the valve interferes with the piston, never,turn the crankshaft to the right beyond the dead point above the No.4 cylinder.
  • Page 115 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -25 ENGINE MECHANICAL TIMING GEAR Using SST, remove the crankshaft pulley. 09950 -- 50012, (09951 -- 05010, 09952 -- 05010, 09953 -- 05010, 09953 -- 05020, 09954 -- 05020)
  • Page 116 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -26 ENGINE MECHANICAL TIMING GEAR CHE CK THRUS T CLE ARANCE O F I DLE R G E AR Using a dial indicator, measure the thrust clearance.
  • Page 117 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -27 ENGINE MECHANICAL TIMING GEAR Remove the injection pump drive gear. Using SST, remove the injection pump drive gear set nut. 09960 -- 10010 (09962 -- 01000, 09963 -- 00600) Remove the O--ring.
  • Page 118 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -28 ENGINE MECHANICAL TIMING GEAR Remove the wave washer. Wave Washer Remove the No.1 idler sub--gear. No.1 Idler Remove the idler gear spring. Sub--Gear Remove the idler gear assembly from the vice and turn it Idler upside down.
  • Page 119 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -29 ENGINE MECHANICAL TIMING GEAR EM157- -01 INSPECTION INSPECT IDLER GEAR Using a cylinder gauge, measure the inside diameter of the idler gear. Idler gear inside diameter: 44.000 - - 44.025 mm (1.7323 - - 1.7333 in.)
  • Page 120 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -30 ENGINE MECHANICAL TIMING GEAR CHE CK BACKLAS H O F T I MI NG G E ARS Using a dial indicator, measure the backlash. Standard gear backlash: 0.02 - - 0.15 mm (0.0008 - - 0.0060 in.)
  • Page 121 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -31 ENGINE MECHANICAL TIMING GEAR EM158- -01 REPLACEMENT HINT: There are 2 methods (a and b) to replace the oil seal as follows: RE P L ACE CRANKS HAFT F RO NT O I L S E AL...
  • Page 122 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -32 ENGINE MECHANICAL TIMING GEAR RE P L ACE I NJ E CTI O N P UMP DRI V E G E AR O I L S E AL...
  • Page 123 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -33 ENGINE MECHANICAL TIMING GEAR Using SST and a press, press in a new bearing. 09214 -- 76011, 09223 -- 00010 SST: 09214 -76011 P12381...
  • Page 124 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -34 ENGINE MECHANICAL TIMING GEAR EM159- -01 INSTALLATION ASSEMBLE IDLER GEAR Mount the idler gear in a vise. HINT: Install the idler gear with the cut--off mark facing downward.
  • Page 125 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -35 ENGINE MECHANICAL TIMING GEAR Remove the service bolt. Service Bolt P11688 Install the idler gear spring. Wave Install the No.1 idler sub--gear. Washer No.1 Idler Install the wave washer.
  • Page 126 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -36 ENGINE MECHANICAL TIMING GEAR Install the crankshaft timing gear. With the crankshaft key groove facing upward, install the crankshaft timing gear into the crank- shaft.
  • Page 127 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -37 ENGINE MECHANICAL TIMING GEAR Install the idler gear shaft to the cylinder block. Idler Gear Shaft P12632 Align the idler gear assembly timing marks ”5” and ”4”...
  • Page 128 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -38 ENGINE MECHANICAL TIMING GEAR INSTALL TIMING GEAR COVER Install a new O--ring to the timing gear case. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing gear cover and cylinder block.
  • Page 129 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -39 ENGINE MECHANICAL TIMING GEAR CHE CK I NJ E CTI O N P UMP DRI V E S HAFT T HRUS T CLE ARANCE Temporarily install the No.2 camshaft timing pulley and flange with the 4 bolts.
  • Page 130 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -40 ENGINE MECHANICAL TIMING GEAR Install the vacuum pump with the 2 nuts. Torque: 21 N∙m (210 kgf∙cm, 15 ft∙lbf) I NS TALL CAMS HAFT O I L S E AL RE TAI NE R...
  • Page 131 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ENGINE MECHANICAL – CYLINDER HEAD PAGE 1 OF 3 CYLINDER HEAD – COMPONENTS EM-41/43 REMOVEL 1. DRAIN ENGINE COOLANT EM-44 2. REMOVE INTAKE PIPE EM-44 3. REMOVE TURBOCHARGER EM-44 4.
  • Page 132 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ENGINE MECHANICAL – CYLINDER HEAD PAGE 2 OF 3 10. INSPECT AND GRIND VALVES EM-53/54 11. INSPECT AND CLEAN VALVE SEATS EM-54/55 12. INSPECT VALVE SPRINGS EM-55 13.
  • Page 133 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ENGINE MECHANICAL – CYLINDER HEAD PAGE 3 OF 3 18. INSTALL INJECTION NOZZLES EM-70 19. INSTALL NOZZLE LEAKAGE PIPE EM-70 20. INSTALL INTAKE MANIFOLD EM-70 21. INSTALL WATER OUTLET EM-70 22.
  • Page 134: Cylinder Head

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -41 ENGINE MECHANICAL CYLINDER HEAD CYLINDER HEAD EM15C- -01 COM P ONE NT S VSV for No.1 Intake VSV for No.2 Intake Constrictor Control Constrictor Control...
  • Page 135 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -42 ENGINE MECHANICAL CYLINDER HEAD Injection Pipe 15 (150, 11) 9 (90, 78 in.∙lbf) Clamp 15 (150, 11) Oil Filler Cap x 10 Nozzle Leakage z Gasket...
  • Page 136 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -43 ENGINE MECHANICAL CYLINDER HEAD Adjusting Shim Valve Lifter Keeper Spring Retainer Valve Spring Spring Seat Engine Hanger Heater Water Inlet Pipe z Oil Seal 47 (460, 34)
  • Page 137 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -44 ENGINE MECHANICAL CYLINDER HEAD EM15D- -01 RE M O VAL DRAI N E NG I NE CO O L ANT REMOVE INTAKE PIPE Disconnect the VSV for the No.1 and No.2 intake constrictor control connectors.
  • Page 138 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -45 ENGINE MECHANICAL CYLINDER HEAD RE MO V E I NTAKE MANI FO LD Disconnect the throttle position sensor connector. Remove the grommet and nut, and disconnect the glow plug wire.
  • Page 139 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -46 ENGINE MECHANICAL CYLINDER HEAD SET NO.4 CYLINDER TO TDC / COMPRESSION Turn the crankshaft pulley clockwise, set both No.1 and No.2 camshaft pulley grooves at TDC marks.
  • Page 140 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -47 ENGINE MECHANICAL CYLINDER HEAD 1 5 . RE MO V E CY LI NDE R HE AD CO V E R Remove the 10 bolts, 2 nuts, cylinder head cover and gasket.
  • Page 141 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -48 ENGINE MECHANICAL CYLINDER HEAD RE MO V E G L O W P L UG CO NNE CTO R AND G L O W PLUGS...
  • Page 142 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -49 ENGINE MECHANICAL CYLINDER HEAD EM15E- -01 DI SASSEMBLY RE MO V E E NG I NE HANG E R Remove the engine hanger from the cylinder head.
  • Page 143 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -50 ENGINE MECHANICAL CYLINDER HEAD RE MO V E CO MBUS TI O N CHAMBE RS Using SST, remove the 4 combination chambers. 09208 -- 48010 HINT: Arrange the combustion chambers in correct order.
  • Page 144 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -51 ENGINE MECHANICAL CYLINDER HEAD EM15F- -01 INSPECTION Gasket Scraper CLE AN TO P S URFACE S O F P I S TO NS AND CY L-...
  • Page 145 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -52 ENGINE MECHANICAL CYLINDER HEAD CLEAN CYLINDER HEAD Using soft brush and solvent, thoroughly clean the cylinder head. P11636 INSPECT FOR FLATNESS Precision Using a precision straight edge and feeler gauge, measure the...
  • Page 146 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -53 ENGINE MECHANICAL CYLINDER HEAD INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 8.010 - - 8.030 mm (0.3154 - - 0.3161 in.)
  • Page 147 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -54 ENGINE MECHANICAL CYLINDER HEAD Check the valve overall length. Standard overall length: 103.29 - - 103.69 mm (4.0665 - - 4.0823 in.) Minimum overall length: 102.79 mm (4.0468 in.) If the overall length is less than minimum, replace the valve.
  • Page 148 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -55 ENGINE MECHANICAL CYLINDER HEAD If the seating is too low on the valve face, use 60˚ 60˚ 45˚ and 45˚ cutters to correct the seat.
  • Page 149 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -56 ENGINE MECHANICAL CYLINDER HEAD INSPECT CAMSHAFT FOR RUNO UT Place the camshaft on V--blocks. Using a dial indicator, measure the circle runout at the center journal.
  • Page 150 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -57 ENGINE MECHANICAL CYLINDER HEAD INSPECT CAMSHAFT J OURNAL O I L CLE ARANCE Plastigage Clean the bearing caps and camshaft journals. Place the camshaft on the cylinder head.
  • Page 151 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -58 ENGINE MECHANICAL CYLINDER HEAD INSPECT INTAKE AND EX HAUS T MANI FO LDS Intake Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
  • Page 152 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -59 ENGINE MECHANICAL CYLINDER HEAD EM15G- -01 REPLACEMENT RE P L ACE VALV E G UI DE BUS HI NG S Using SST and a hammer, tap out the guide bushing.
  • Page 153 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -60 ENGINE MECHANICAL CYLINDER HEAD RE P L ACE CAMS HAFT O I L S E AL HINT: There are 2 methods (a and b) to replace the oil seal which are...
  • Page 154 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -61 ENGINE MECHANICAL CYLINDER HEAD EM15H- -01 RE AS S E M BLY HINT: Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all slid- ing and rotating surfaces.
  • Page 155 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -62 ENGINE MECHANICAL CYLINDER HEAD I NS TALL CO MBUS TI O N CHAMBE RS Knock Align the knock pin of the combustion chamber with the notch of the cylinder head.
  • Page 156 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -63 ENGINE MECHANICAL CYLINDER HEAD Using a plastic--faced hammer, lightly tap the valve stem tip to assure a proper fit. A11106 I NS TALL VALV E LI FTE RS AND S HI MS Install the valve lifter and shim.
  • Page 157 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -64 ENGINE MECHANICAL CYLINDER HEAD EM15I- -01 INSTALLATION CHECK PISTON PROTRUSION AND SELECT CYL - I NDE R HE AD G AS KE T Check the piston protrusions for each cylinder.
  • Page 158 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -65 ENGINE MECHANICAL CYLINDER HEAD Select a new cylinder head gasket. HINT: There are 5 types of cylinder head gasket (hole number 1 to 5) Hole Number installed at factory, but only 3 types for supply parts (hole num- ber ”1”, ”3”...
  • Page 159 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -66 ENGINE MECHANICAL CYLINDER HEAD INSTALL CYLINDER HEAD BOLTS HINT: The cylinder head bolts are tightened in 3 progressive steps (steps (b), (d) and (e)). If any bolts is broken or deformed, replace it.
  • Page 160 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -67 ENGINE MECHANICAL CYLINDER HEAD Install and uniformly tighten the 10 bearing cap bolts in several passes in the sequence shown. Torque: 18 N∙m (185 kgf∙cm, 13 ft∙lbf)
  • Page 161 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -68 ENGINE MECHANICAL CYLINDER HEAD INSTALL NO.1 CAMSHAFT TIMING PULLEY Install the set key to the key groove of the camshaft. Align the pulley set key with the key groove of the cam- shaft timing pulley, slide the camshaft timing pulley.
  • Page 162 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -69 ENGINE MECHANICAL CYLINDER HEAD INSTALL TIMING BELT TENSIONER Temporarily install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.
  • Page 163 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -70 ENGINE MECHANICAL CYLINDER HEAD 1 8 . I NS TALL I NJ E CTI O N NO ZZLE S Place the nozzle seats and new gaskets into the injection nozzle holes of the cylinder head.
  • Page 164 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -71 ENGINE MECHANICAL CYLINDER HEAD 2 4 . I NS TALL I NTAKE P I P E Install the VSV for the No.1 and No.2. intake constrictor control.
  • Page 165 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PAGE 1 OF 2 ENGINE MECHANICAL – CYLINDER BLOCK CYLIDER BLOCK – COMPONENTS EM-72/74 DISASSEMBLY 1. REMOVE CLUTCH COVER AND DISC EM-75 2. REMOVE FLYWHEEL EM-75 3. REMOVE REAR END PLATE EM-75 4.
  • Page 166 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ENGINE MECHANICAL – CYLINDER BLOCK PAGE 2 OF 2 10. INSPECT RH AND LH BALANCE SHAFT EM-88/89 11. INSPECT CRANKSHAFT FOR RUNOUT EM-89 12. INSPECT MAIN JOURNALS AND CRANK PINS...
  • Page 167: Cylinder Block

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -72 ENGINE MECHANICAL CYLINDER BLOCK CYLINDER BLOCK EM15J- -01 COM P ONE NT S 21 (210, 15) Alternator Alternator Bracket 62 (620, 45) z Gasket 21 (210, 15)
  • Page 168 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -73 ENGINE MECHANICAL CYLINDER BLOCK RH Engine Mounting Bracket 68 (693, 50) z O--Ring Water Inlet Thermostat 68 (693, 50) 16 (160, 12) Alternator z Gasket...
  • Page 169 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -74 ENGINE MECHANICAL CYLINDER BLOCK Piston Ring (No.1 Compression) Piston Ring (No.2 Compression) Piston Ring (Side Rail and Expander) Piston Pin z Snap Ring Piston 178 (1,820, 131)
  • Page 170 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -75 ENGINE MECHANICAL CYLINDER BLOCK EM15K- -01 DI SASSEMBLY RE MO V E CLUTCH CO V E R AND DI S C REMOVE FLYWHEEL Remove the 8 bolts and flywheel.
  • Page 171 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -76 ENGINE MECHANICAL CYLINDER BLOCK 1 9 . CHE CK THRUS T CLE ARANCE S O F RH AND LH BAL - ANCE S HAFTS O F E NG I NE BALANCE R...
  • Page 172 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -77 ENGINE MECHANICAL CYLINDER BLOCK REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE Using a punch or numbering stamp, place matchmarks on the connecting rod and cap to ensure correct reassembly.
  • Page 173 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -78 ENGINE MECHANICAL CYLINDER BLOCK HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, se-...
  • Page 174 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -79 ENGINE MECHANICAL CYLINDER BLOCK 2 5 . CHE CK CRANKS HAFT T HRUS T CLE ARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
  • Page 175 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -80 ENGINE MECHANICAL CYLINDER BLOCK Place the crankshaft on the cylinder block. plastigage Lay a strip of Plastigage across each journal. Install the main bearing caps.
  • Page 176 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -81 ENGINE MECHANICAL CYLINDER BLOCK Crankshaft journal diameter: Mark ”1” 69.994 - - 70.000 mm (2.7557 - - 2.7559 in.) Mark ”2” 69.988 - - 69.994 mm (2.7554 - - 2.7557 in.) Mark ”3”...
  • Page 177 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -82 ENGINE MECHANICAL CYLINDER BLOCK REMOVE PISTON RINGS Using a piston ring expander, remove the 2 compression rings and oil ring. P11732 Remove the coil by hand.
  • Page 178 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -83 ENGINE MECHANICAL CYLINDER BLOCK EM15L- -01 INSPECTION Gasket Scraper CLE AN CY L I NDE R BLO CK Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
  • Page 179 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -84 ENGINE MECHANICAL CYLINDER BLOCK Using a cylinder gauge, measure the cylinder bore diameter at Thrust positions A, B and C in the thrust and axial directions.
  • Page 180: Piston Diameter

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -85 ENGINE MECHANICAL CYLINDER BLOCK CLEAN PISTON Using a gasket scraper, remove the carbon from the pis- ton top. Gasket Scraper P11741 Using a groove cleaning tool or broken ring, clean the pis- ton ring grooves.
  • Page 181 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -86 ENGINE MECHANICAL CYLINDER BLOCK Subtract the piston diameter measurement from the cylinder bore diameter measurement. Front Standard oil clearance: 0.050 - - 0.070 mm (0.0020 - - 0.0028 in.) Maximum oil clearance: 0.14 mm (0.0055 in.)
  • Page 182 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -87 ENGINE MECHANICAL CYLINDER BLOCK Using a feeler gauge, measure the end gap. Standard end gap: No.1 0.350 - - 0.570 mm (0.0138 - - 0.0224 in.) No.2...
  • Page 183 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -88 ENGINE MECHANICAL CYLINDER BLOCK Using vernier calipers, measure the minimum diameter of the compressed bolt at the measuring point. Standard diameter: 8.400 - - 8.600 mm (0.3307 - - 0.3385 in.) Minimum diameter: 8.20 mm (0.3228 in.)
  • Page 184 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -89 ENGINE MECHANICAL CYLINDER BLOCK Using a micrometer, measure the diameter of the balance shaft main journals. Main journal diameter (from front side): No.1 41.941 - - 41.960 mm (1.6512 - - 1.6520 in.) No.2...
  • Page 185 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -90 ENGINE MECHANICAL CYLINDER BLOCK Crank pin diameter: 58.982 - - 59.000 mm (2.3221 - - 2.3228 in.) U/S 0.25 58.745 - - 58.755 mm (2.3128 - - 2.3132 in.) U/S 0.50...
  • Page 186 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -91 ENGINE MECHANICAL CYLINDER BLOCK EM15M- -01 REPLACEMENT REPLACE OVERSIZED (O/S) PISTONS HINT: Bore all the 4 cylinders to the O/S piston outside diameter. Replace all the piston rings with ones to match the O/S pistons.
  • Page 187 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -92 ENGINE MECHANICAL CYLINDER BLOCK Using a round file, lightly file off any roughness from the Round File small end of the connecting rod. EM8176 Attach the bushing to SST with the ball of SST inside the oil hole of the bushing.
  • Page 188 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -93 ENGINE MECHANICAL CYLINDER BLOCK Check the piston pin fit at normal room temperature. Coat Piston the piston pin with engine oil, and push it into the connect- ing rod with your thumb.
  • Page 189 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -94 ENGINE MECHANICAL CYLINDER BLOCK EM15N- -01 REASSEMBLY HINT: Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all slid- ing and rotating surfaces.
  • Page 190 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -95 ENGINE MECHANICAL CYLINDER BLOCK Position the piston rings so that the ring ends are as No.2 Ring shown. Oil Ring NOTICE: Do not align the ring ends.
  • Page 191 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -96 ENGINE MECHANICAL CYLINDER BLOCK I NS TALL MAI N BE ARI NG S Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.
  • Page 192 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -97 ENGINE MECHANICAL CYLINDER BLOCK Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts. Install and uniformly tighten the 10 bolts of the main bear- ing caps in several passes, in the sequence shown.
  • Page 193 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -98 ENGINE MECHANICAL CYLINDER BLOCK Install the connecting rod cap bolts. HINT: The connecting rod cap nuts are tightened in 2 progres- sive steps (steps (b) and (d)).
  • Page 194 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -99 ENGINE MECHANICAL CYLINDER BLOCK Immediately remove nozzle from the tube and rein- stall cap. Install the retainer with the 5 bolts. Torque: 13 N∙m (130 kgf∙cm, 9 ft∙lbf)
  • Page 195 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EM- -100 ENGINE MECHANICAL CYLINDER BLOCK INSTALL TIMING BELT AND PULLEYS (See page EM - - 18) 2 9 . DI S CO NNE CT E NG I NE F RO M E NG I NE S TAND INSTALL REAR END PLATE Install the rear end plate with the bolt.
  • Page 196 BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TURBOCHARGING TROUBLESHOOTING ....TC--1 TURBOCHARGER ..... . .
  • Page 197 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -1 TURBOCHARGING TROUBLESHOOTING T ROUBL ESHOOT I NG TC01W- -02 PROBLEM SYMPTOMS TABLE HINT: Before troubleshooting the turbocharger, first check the engine itself. (valve clearance, engine compression, etc.)
  • Page 198 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX PAGE 1 OF 2 TURBOCHARGING – TURBOCHARGER TURBOCHARGER PRECAUTION MAINTENANCE PRECAUTION TC-2 ON-VEHICLE INSPECTION 1. INSPECT INTAKE AIR SYSTEM TC-3 2. INSPECT EXHAUST SYSTEM TC-3 3. CHECK TURBOCHARGER PRESSURE TC-3 4.
  • Page 199 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TURBOCHARGING – TURBOCHARGER PAGE 2 OF 2 INSTALLATION 1. INSTALL AIR INLET ELBOW TO TURBOCHARGER TC-16 2. INSTALL EXHAUST MANIFOLD TO TURBOCHARGER TC-16 3. INSTALL TURBO OIL PIPE TO TURBOCHARGER TC-16 4.
  • Page 200 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -2 TURBOCHARGING TURBOCHARGER TURBOCHARGER TC030- -01 PRECAUTION MAI NTE NANCE P RE CAUTI O N Do not stop the engine immediately after pulling a trailer or after high speed or uphill driving. Idle the engine for 20 -- 120 seconds, depending on how hard the vehicle has been driven.
  • Page 201 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -3 TURBOCHARGING TURBOCHARGER TC01P- -02 ON - - V E HI CL E I NS P E CT I O N INSPECT INTAKE AIR SYSTEM Check for leakage or clogging between the air cleaner housing and turbocharger inlet and between the turbocharger outlet and cylinder head.
  • Page 202 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -4 TURBOCHARGING TURBOCHARGER TC031- -01 COM P ONE NT S VSV for VSV for No.1 Intake No.2 Intake Constrictor Control Constrictor Connector Control VSV for No.1 Intake...
  • Page 203 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -5 TURBOCHARGING TURBOCHARGER Exhaust Manifold 52 (530, 38) Gasket Turbocharger Gasket Air Inlet Elbow 19.1 (195, 14) 19 (195, 14) Turbo Oil Pipe Gasket N∙m (kgf∙cm, ft∙lbf) : Specified torque...
  • Page 204 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -6 TURBOCHARGING TURBOCHARGER TC032- -01 RE M O VAL DRAI N E NG I NE CO O L ANT REMOVE INTAKE PIPE (See pa ge EM - - 44) RE MO V E TURBO CHARG E R HE AT I NS ULATO R Remove the 3 bolts and heat insulator.
  • Page 205 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -7 TURBOCHARGING TURBOCHARGER TC033- -01 DI SASSEMBLY INSPECT TURBI NE S HAFT RO TAT I O N Grasp the edge of the turbine shaft, and turn it. Check that the turbine shaft turns smoothly.
  • Page 206 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -8 TURBOCHARGING TURBOCHARGER RE MO V E ACTUATO R Actuator Disconnect the actuator hose form the compressor hous- ing. Using SST, apply pressure to the actuator.
  • Page 207 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -9 TURBOCHARGING TURBOCHARGER Using a plastic--faced hammer, tap out the bearing hous- Bearing ing. Housing NOTICE: Remove the bearing housing as straight as possible and so not make the turbine wheel interfere with the turbine hous- ing.
  • Page 208 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -10 TURBOCHARGING TURBOCHARGER TC034- -01 INSPECTION CLEAN AND INSPECT TURBI NE HO US I NG Spray the engine conditioner to the section where the car- bon dirt is adhered.
  • Page 209 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -11 TURBOCHARGING TURBOCHARGER CLEAN COMPRESSOR HOUSING Be careful not to drop any oil on the contact surfaces of the compressor housing and bearing housing. Wipe off the dirt from the inside of the housing with a shop rag.
  • Page 210 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -12 TURBOCHARGING TURBOCHARGER TC035- -01 RE AS S E M BLY I NS TALL BE ARI NG HO US I NG Install the snap ring to the turbocharger.
  • Page 211 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -13 TURBOCHARGING TURBOCHARGER Align the matchmarks on the V--band, turbine housing and bearing housing, and temporarily tighten with a new New V--Band bolt and nut. Torque: 4.8 N∙m (49 kgf∙cm, 42 in.∙lbf)
  • Page 212 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -14 TURBOCHARGING TURBOCHARGER Remove the SST. ADJ US T ACTUATO R P US H RO D S T RO KE Stroke NOTICE: Never apply more than 141 kPa (1.44 kgf/cm , 20.5 psi) of...
  • Page 213 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -15 TURBOCHARGING TURBOCHARGER Using SST, apply approx. 119 kPa (1.21 kgf/cm , 17.2 psi) Selected of pressure to the actuator, and install the selected plate Plate Washer washers between the actuator and compressor housing with the 2 bolts.
  • Page 214 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -16 TURBOCHARGING TURBOCHARGER TC036- -01 INSTALLATION Oil Inlet Hole NOTICE: After replacing the turbocharger assembly, pour approx. 20 cm (1.2 cu in.) of fresh oil into the oil inlet hole and turn the turbine wheel by hand to splash oil on the bearing.
  • Page 215 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX TC- -17 TURBOCHARGING TURBOCHARGER I NS TALL T URBI NE O UTLE T E LBO W Install a new gasket and the outlet elbow with 4 new nuts. Uni- formly tighten the nuts in several passes.
  • Page 216 BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EMISSION CONTROL POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM ..EC--1...
  • Page 217 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX EC- -1 EMISSION CONTROL POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM EC0DP- -01 INSPECTION VISUALLY INSPECT HOSE AND CONNECTIONS Check for cranks, leaks or damage.
  • Page 218 BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ELECTRONIC CONTROL DIESEL NOTE: Please refer to Supplements that follow: Click here for: ELECTRONIC CONTROL DIESEL Engine Supplement:...
  • Page 219 CLICK HERE TO VIEW CHAPTER INDEX Pages From Manual TO MODEL INDEX ED- -13 ELECTRONIC CONTROL DIESEL VSV FOR INTAKE CONSTRICTOR CONTROL VSV FOR I NTAKE CONSTRICTOR CONTROL ED03J- -01 COM P ONE NT S VSV for No.1 Intake Constrictor Control VSV for No.2 Intake Constrictor Control VSV for No.1 Intake...
  • Page 220 CLICK HERE TO VIEW CHAPTER INDEX Pages From Manual TO MODEL INDEX ED- -15 ELECTRONIC CONTROL DIESEL WATER TEMPERATURE SENSOR WATER T EMPERAT URE SENSOR ED01T- -02 INSPECTION DRAI N E NG I NE CO O L ANT REMOVE WATER TEMPERATURE SENSOR Disconnect the sensor connector.
  • Page 221 BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ENGINE FUEL FUEL FILTER ......
  • Page 222: Fuel Filter

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -1 ENGINE FUEL FUEL FILTER FUEL FILTER FU064- REPLACEMENT REMOVE FUEL FILTER ASSEMBLY FROM FUEL FILTER SUPPORT DRAIN FUEL FROM FUEL FILTER Loosen the drain plug, and drain the fuel from the fuel filter.
  • Page 223 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -2 ENGINE FUEL FUEL FILTER RE FI LL FUE L FI LTE R WI TH FUE L Operate Operate the hand pump until you feel more resistance.
  • Page 224 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ENGINE FUEL – INJECTION NOZZLE INJECTION NOZZLE – COMPONENTS FU-3/4 REMOVEL 1. REMOVE INTAKE PIPE FU-5 2. REMOVE INJECTION PIPES FU-5 3. REMOVE NOZZLE LEAKAGE PIPE FU-5 4.
  • Page 225: Injection Nozzle

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -3 ENGINE FUEL INJECTION NOZZLE INJECTION NOZZLE FU06R- -01 COM P ONE NT S VSV Connector for VSV for No.1 Intake Constrictor Control Vacuum Hose No.1 Intake Constrictor Control...
  • Page 226 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -4 ENGINE FUEL INJECTION NOZZLE Adjusting Shim Nozzle Assembly Pressure Pin Nozzle Body Nozzle Needle Nozzle Holder Retaining Nut 37 (375, 27) Nozzle Holder Body Pressure Spring Distance Piece N∙m (kgf∙cm, ft∙lbf) : Specified torque...
  • Page 227 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -5 ENGINE FUEL INJECTION NOZZLE FU06S- -01 RE M O VAL REMOVE INTAKE PIPE Disconnect the 2 VSV connectors. Disconnect the 2 vacuum hoses from the actuator.
  • Page 228 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -6 ENGINE FUEL INJECTION NOZZLE RE MO V E I NJ E CTI O N NO ZZLE S Using SST, remove the 4 injection nozzles, gaskets and seats.
  • Page 229 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -7 ENGINE FUEL INJECTION NOZZLE FU06T- -01 DI SASSEMBLY DISASSEMBLE INJ ECTION NOZZLES Using SST, remove the nozzle holder retaining nut. 09268 -- 64010 (09268 -- 64020)
  • Page 230 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -8 ENGINE FUEL INJECTION NOZZLE FU06U- -01 INSPECTION NOZZLE CLEANING To wash the nozzles, use a wooden stick and brass brush. Wash them in clean diesel fuel.
  • Page 231 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -9 ENGINE FUEL INJECTION NOZZLE When released, the needle should stick down into the body vent smoothly by its own weight. Repeat this test, rotating the needle slightly each time.
  • Page 232 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -10 ENGINE FUEL INJECTION NOZZLE FU06V- -01 RE AS S E M BLY ASSEMBLE I NJ ECTION NO ZZLE HO LDERS Assemble the nozzle holder retaining nut, the nozzle as-...
  • Page 233 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -11 ENGINE FUEL INJECTION NOZZLE FU06W- -01 TEST INJECTION PRESSURE TEST Install the injection nozzle to the injection nozzle hand tester and bleed air from the union nut.
  • Page 234 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -12 ENGINE FUEL INJECTION NOZZLE Adjusting shim thickness: mm (in.) mm (in.) mm (in.) 0.900 (0.0354) 1.275 (0.0502) 1.650 (0.0650) 0.925 (0.0364) 1.300 (0.0512) 1.675 (0.0659) 0.950 (0.0374)
  • Page 235 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -13 ENGINE FUEL INJECTION NOZZLE FU06X- -01 INSTALLATION I NS TALL I NJ E CTI O N NO ZZLE S Place the 4 nozzle seats and new gaskets into the injec- tion nozzle holes of the cylinder head.
  • Page 236 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -14 ENGINE FUEL INJECTION NOZZLE I NS TALL I NTAKE P I P E Install the PCV pipe with the 2 nuts to the intake pipe.
  • Page 237 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ENGINE FUEL – INJECTION PUMP INJECTION PUMP ON-VEHICLE INSPECTION 1. INSPECT ENGINE SPEED SENSOR FU-15 2. INSPECT SPILL CONTROL VALVE FU-15 3. INSPECT INJECTION PUMP CORRECTION RESISTORS FU-15 4.
  • Page 238: Injection Pump

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -15 ENGINE FUEL INJECTION PUMP INJECTION PUMP FU06Y- -01 ON - - VEHICLE INSPECTION INSPECT ENGINE SPEED SENSOR (See page ED - - 20) INSPECT SPILL CONTROL VALVE...
  • Page 239 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -16 ENGINE FUEL INJECTION PUMP FU03P- -02 COM P ONE NT S Vacuum Hose VSV Connector for No.1 Intake Constrictor Control VSV for No.1 Intake Constrictor Control...
  • Page 240 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -17 ENGINE FUEL INJECTION PUMP 23 (230, 17) z Gasket Fuel Inlet Pipe Distributive Head Plug (No.1) z Gasket z O--Ring 36.8 (375, 27) Fuel Inlet Hollow...
  • Page 241 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -18 ENGINE FUEL INJECTION PUMP FU06Z- -01 REMOVAL REMOVE INTAKE PIPE (See pa ge EM - - 44) REMOVE INJECTION PIPES (See pa ge FU - - 5)
  • Page 242 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -19 ENGINE FUEL INJECTION PUMP Loosen the 2 nuts holding the injection pump to the timing gear case. Remove the 3 bolts and injection pump stay.
  • Page 243 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -20 ENGINE FUEL INJECTION PUMP FU03R- -02 DI SASSEMBLY MOUNT PUMP ASSEMBLY TO SST (STAND) 09241 -- 76022, 09245 -- 54010 RE MO V E S E T KE Y O F DRI V E P ULLE Y F RO M DRI V E...
  • Page 244 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -21 ENGINE FUEL INJECTION PUMP Remove the distributive head plug and O--ring. Remove the strainer and wave washer. S04825 RE MO V E DI S T RI BUTI V E HE AD P LUG (NO . 1 ) Using SST, remove the distributive head plug.
  • Page 245 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -22 ENGINE FUEL INJECTION PUMP FU03S- -02 INSPECTION NOTICE: Do not touch the sliding surfaces of the delivery valves. INSPECT DELIVERY VALVES Pull up the valve, release it.
  • Page 246 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -23 ENGINE FUEL INJECTION PUMP FU03T- -02 RE AS S E M BLY MO UNT P UMP BO DY TO S S T (S TAND) 09241 -- 76022, 09245 -- 54010...
  • Page 247 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -24 ENGINE FUEL INJECTION PUMP INSTALL TIMING CONTROL VALV E Using a 5 mm hexagon wrench, install the timing control valve with the 2 bolts. 5 mm...
  • Page 248 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -25 ENGINE FUEL INJECTION PUMP FU070- -01 INSTALLATION INSTALL INJ ECTION PUMP Install a new O--ring to the pump. Apply a light coat of engine oil on the O--ring.
  • Page 249 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX FU- -26 ENGINE FUEL INJECTION PUMP CHE CK I NJ E CTI O N P UMP DRI V E S HAFT T HRUS T CLE ARANCE Move the No.2 camshaft timing pulley back and forth to check that the injection pump drive shaft has sufficient thrust clear- ance.
  • Page 250 BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX COOLING COOLANT ......
  • Page 251 The engine coolant level should be between the ”L” and ”F” lines. If low, check for leaks and add ”Toyota Long Life Coolant” or equivalent up to between the ”L” and ”F” lines. CHE CK E NG I NE CO O L ANT Q UALI T Y Remove the radiator cap.
  • Page 252 Drain Plug ing system. B09314 Use ”Toyota Long Life Coolant” or equivalent and mix it with plan water according to the manufactur- er’s directions. Using of coolant which includes more than 50 % [freezing protection down to --35˚C (--31˚F)] or 60 % [freezing protection down to --50˚C (--58˚F)] of...
  • Page 253 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX COOLING – WATER PUMP WATER PUMP – COMPONENTS CO-3/4 REMOVEL 1. DRAIN ENGINE COOLANT CO-5 2. REMOVE DRIVE BELTAS, FAN AND WATER PUMP PULLEY CO-5 3. REMOVE TIMING BELT AND IDLER PULLEY CO-5 4.
  • Page 254 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -3 COOLING WATER PUMP WAT E R P U M P CO0WL- -02 COM P ONE NT S VSV for No.2 Intake VSV for No.1 Intake VSV for No.1 Intake...
  • Page 255 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -4 COOLING WATER PUMP Camshaft Oil Seal Retainer Alternator 9 (90, 78 in.∙lbf) 21 (210, 15) 62 (620, 45) Alternator Bracket 21 (210, 15) Water Pump...
  • Page 256 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -5 COOLING WATER PUMP CO0WM- -01 RE M O VAL DRAI N E NG I NE CO O L ANT RE MO V E DRI V E BE LTAS , FAN AND WATE R P UMP...
  • Page 257 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -6 COOLING WATER PUMP Remove the bolt, water pump cover and gasket. Water Pump Cover P12881...
  • Page 258 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -7 COOLING WATER PUMP CO0WN- -01 INSPECTION INSPECT WATER PUMP Turn the pulley and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump.
  • Page 259 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -8 COOLING WATER PUMP CO0WO- -01 INSTALLATION INSTALL WATER PUMP ASSEMBLY Install a new gasket to the water pump cover. New Gasket P12880 Temporarily install the water pump and water pump cover with the bolt.
  • Page 260 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -9 COOLING WATER PUMP Install the alternator with the pivot bolt and lock bolt. Pivot Bolt Torque: 21 N∙m (210 kgf∙cm, 15 ft∙lbf) for Lock bolt 62 N∙m (620 kgf∙cm, 45 ft∙lbf) for Pivot bolt...
  • Page 261 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -10 COOLING THERMOSTAT THERMOSTAT CO0NI- -02 COM P ONE NT S Thermostat z Gasket 13 (130, 9) Water Inlet 13 (130, 9) Radiator Lower Hose N∙m (kgf∙cm, ft∙lbf) : Specified torque...
  • Page 262 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -11 COOLING THERMOSTAT CO0WP- -01 RE M O VAL HINT: Removal of the thermostat would have an adverse effect, caus- ing a lowering of cooling efficiency. Do not remove the thermo- stat, even if the engine tends to overheat.
  • Page 263 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -12 COOLING THERMOSTAT CO0NK- -02 INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening tempera- ture. B09317 Immerse the thermostat in water and gradually heat the water.
  • Page 264 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -13 COOLING THERMOSTAT CO0NL- -02 INSTALLATION PLACE THERMOSTAT IN CYLINDER BLOCK Install a new gasket to the thermostat. New Gasket B09318 Install the thermostat with the jiggle valve upward.
  • Page 265 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX COOLING – RADIATOR RADIATOR ON-VEHICLE CLEANING CO-14 ON-VEHICLE INSPECTION 1. REMOVE RADIATOR CAP CO-15 2. INSPECT RADIATOR CAP CO-15 3. INSPECT COOLING SYSTEM FOR LEAKS CO-15 4. REINSTALL RADIATOR CAP...
  • Page 266 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -14 COOLING RADIATOR RADIATOR CO0WQ- -01 ON- -VEHICLE CLEANING Using water or a steam cleaner, remove any mud and dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Main-...
  • Page 267 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -15 COOLING RADIATOR CO0WR- -01 ON- -VEHICLE INSPECTION REMOVE RADIATOR CAP CAUTION: To avoid the danger of being burned, do not remove the ra- diator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure.
  • Page 268 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -16 COOLING RADIATOR CO0NM- -02 COM P ONE NT S Bushing Upper Tank Radiator Cap Radiator Support O--Ring Bushing Radiator Support O--Ring O--Ring Lower Tank Drain Plug...
  • Page 269 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -17 COOLING RADIATOR CO0NN- -02 DI SASSEMBLY RE MO V E RADI ATO R S UP P O RTS Remove the 2 bolts, nuts, pipe, bushing and radiator support.
  • Page 270 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -18 COOLING RADIATOR CO0NQ- -02 RE AS S E M BLY Lock Plate Lock Plate INSPECT LOCK PLATE FOR DAMAGE HINT: If the sides of the lock plate groove are deformed, reas- sembly of the tank will be impossible.
  • Page 271 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -19 COOLING RADIATOR CAULK LO CK P LATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper bolt.
  • Page 272 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CO- -20 COOLING RADIATOR CHE CK FO R WAT E R LE AKS Tighten the drain plug. Using SST, plug the inlet and outlet pipes of the radiator.
  • Page 273 BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LUBRICATION OIL AND FILTER ......
  • Page 274 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -1 LUBRICATION OIL AND FILTER OIL AND FILTER Recommended Viscosity (SAE): LU0BW- -02 INSPECTION CHECK ENGINE OIL QUALITY 20W- -50 Check the oil for deterioration, entry of water, discoloring or thin- 15W- -40 ning.
  • Page 275 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -2 LUBRICATION OIL AND FILTER LU0HW- -01 REPLACEMENT CAUTION: Prolonged and repeated contact with mineral oil will S S S S result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis.
  • Page 276 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -3 LUBRICATION OIL AND FILTER Tighten the oil filter by hand until the rubber gasket con- tacts the seat of the filter mounting. B09323 Using SST, give it an additional 3/4 turn to seat the filter.
  • Page 277 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LUBRICATION – OIL PUMP OIL PUMP – COMPONENTS LU-4/6 REMOVEL 1. DRAIN ENGINE COOLANT LU-7 2. DRAIN ENGINE OIL LU-7 3. REMOVE DRIVE BELT, FAN AND WATER PUMP PULLEY LU-7 4.
  • Page 278 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -4 LUBRICATION OIL PUMP OI L P UMP LU0HX- -01 COM P ONE NT S VSV for No.2 Intake VSV for No.1 Intake VSV for No.1 Intake...
  • Page 279 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -5 LUBRICATION OIL PUMP Alternator Camshaft Oil Seal Retainer 21 (216, 15) Alternator Bracket 62 (620, 45) 21 (216, 15) Water Pump 9 (90, 78 in.∙lbf)
  • Page 280 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -6 LUBRICATION OIL PUMP L Taper Screw Plug 16 (160, 12) z O--Ring 42 (425, 31) Driven Rotor Spring 21 (210, 15) z Gasket z O--Ring...
  • Page 281 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -7 LUBRICATION OIL PUMP LU0HY- -01 RE M O VAL HINT: When repairing the oil pump, oil pan and strainer should be re- moved and cleaned.
  • Page 282 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -8 LUBRICATION OIL PUMP Insert the blade of SST between the cylinder block and oil pan, and cut off applied sealer and remove the oil pan.
  • Page 283 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -9 LUBRICATION OIL PUMP LU0IA- -01 DI SASSEMBLY RE MO V E DRI V E RO TO R Driven Pull out the driven rotor. Rotor P12235 RE MO V E RE LI E F VALV E Remove the plug, gasket, spring and relief valve.
  • Page 284 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -10 LUBRICATION OIL PUMP LU0I0- -01 INSPECTION Relief Valve INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight.
  • Page 285 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -11 LUBRICATION OIL PUMP LU0I1- -01 RE AS S E M BLY INSTALL RELIEF VALVE Insert the relief valve and spring into the installation hole Relief Valve of the timing gear case.
  • Page 286 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -12 LUBRICATION OIL PUMP LU0I2- -01 INSTALLATION INSTALL OIL PUMP (TIMING GEAR CASE) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing gear case and cylinder block.
  • Page 287 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -13 LUBRICATION OIL PUMP Install 3 new O--rings to the cylinder block and injection pump. Install the timing gear case. O--Ring P12102 The matchmark on the No.1 balance shaft driven gear should be aligned with the ”2”...
  • Page 288 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -14 LUBRICATION OIL PUMP Pour in approx. 20 cc (0.12 cu in.) of engine oil into the oil pump. P13085 Apply adhesive to 2 or 3 threads of the taper screw.
  • Page 289 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -15 LUBRICATION OIL PUMP Install the oil pan with the 22 bolts and 2 nuts. Torque: 16 N∙m (165 kgf∙cm, 12 ft∙lbf) B09002 INSTALL OIL LEVEL SENSOR Install the oil level sensor with the 4 bolts.
  • Page 290 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LUBRICATION – OIL COOLER OIL COOLER – COMPONENTS LU-16/17 REMOVEL 1. DRAIN ENGINE COOLANT LU-18 2. REMOVE TIMING BELT LU-18 3. REMOVE INJECTION PIPES LU-18 4. REMOVE INJECTION PUMP LU-18 5.
  • Page 291 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -16 LUBRICATION OIL COOLER OI L C OOL ER LU0I3- -01 COM P ONE NT S VSV for No.1 Intake VSV for No.1 Intake Constrictor Control...
  • Page 292 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -17 LUBRICATION OIL COOLER Vacuum Pipe z Gasket Oil Cooler z Gasket z Gasket 39 (400, 129) z Gasket Spring z Oil Filter Relief Valve Relief Valve Body...
  • Page 293 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -18 LUBRICATION OIL COOLER LU0I4- -01 RE M O VAL DRAI N E NG I NE CO O L ANT REMOVE TIMING BELT (See page EM - - 13)
  • Page 294 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -19 LUBRICATION OIL COOLER 1 0 . RE MO V E RE LI E F VALV E Remove the relief valve from the oil cooler cover.
  • Page 295 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -20 LUBRICATION OIL COOLER LU0I5- -01 INSPECTION INSPECT RELIEF VALVE Push the valve with a wooden stick to check if it is stuck. If stuck, replace the relief valve.
  • Page 296 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -21 LUBRICATION OIL COOLER LU0I6- -01 INSTALLATION I NS TALL E NG I NE DRAI N P LUG Install the engine drain plug to the oil cooler cover.
  • Page 297 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -22 LUBRICATION OIL COOLER INSTALL OIL COOLER AND OIL COOLER COVER AS - SEMBLY Install a new gasket, the oil cooler and oil cooler cover assembly with the 13 bolts.
  • Page 298 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -23 LUBRICATION OIL NOZZLE OIL NOZZLE LU0C0- -02 COM P ONE NT S Oil Nozzle Check Valve 26 (260, 19) 16 (165, 12) Oil Pan x 22...
  • Page 299 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -24 LUBRICATION OIL NOZZLE LU0I7- -01 RE M O VAL DRAI N E NG I NE O I L REMOVE OIL PAN (See page LU - - 7 ) RE MO V E CHE CK VALV E AND O I L NO ZZLE S Remove the 4 check valves and oil nozzles.
  • Page 300 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -25 LUBRICATION OIL NOZZLE LU0I8- -01 INSPECTION INSPECT CHECK VALVES Push the valve with a wooden stick to check if it is stuck. If stuck, replace the check valve.
  • Page 301 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX LU- -26 LUBRICATION OIL NOZZLE LU0I9- -01 INSTALLATION I NS TALL O I L NO ZZLE S AND CHE CK VALV E S Align the pin of the oil nozzle with the pin hole of the cylin- der block.
  • Page 302 BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX STARTING PRE--HEATING SYSTEM ....ST--1 STARTER .......
  • Page 303 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -1 STARTING PRE- -HEATING SYSTEM PRE - - HEATING SYSTEM ST0HH- -01 COM P ONE NT S Glow Plug VSV for No.1 Intake Constrictor Control VSV Connector for No.1 Intake Constrictor Control...
  • Page 304 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -2 STARTING PRE- -HEATING SYSTEM ST0HI- -01 INSPECTION INSPECT LIGHTING TIME OF GLOW INDICATOR LIGHT Turn the ignition switch ON, measure the lighting time. Light lighting time (T1): Refer to the chart graph...
  • Page 305 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -3 STARTING PRE- -HEATING SYSTEM Inspect the glow plug relay operation. Ohmmeter Continuity Apply battery voltage across terminals 3 and 4. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
  • Page 306 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -4 STARTING PRE- -HEATING SYSTEM ST0HJ- -01 REPLACEMENT RE P L ACE G L O W P L UG S NOTICE: The cylinder head and glow plug hole can seize up S S S S with carbon deposits.
  • Page 307 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -5 STARTING PRE- -HEATING SYSTEM Insert the taped 54 mm (2.13 in.) of the drill into the 6 mm Drill plug hole and turn the drill by hand to remove the carbon.
  • Page 308 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX STARTING – STARTER STARTER – COMPONENTS ST-6 DISASSEMBLY 1. REMOVE FIELD FRAME AND ARMATURE ST-7 2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS ST-7 3. REMOVE STEEL BALL ST-7 4.
  • Page 309 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -6 STARTING STARTER STARTER ST0BK- -02 COM P ONE NT S Brush Holder Armature z O--Ring Field Frame (Field Coil) z Front Bearing Through Bolt Starter Housing...
  • Page 310 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -7 STARTING STARTER ST0BL- -02 DI SASSEMBLY RE MO V E FI E L D F RAME AND ARMAT URE Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
  • Page 311 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -8 STARTING STARTER RE MO V E BRUS H HO L DE R Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes and re- move the brush holder.
  • Page 312 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -9 STARTING STARTER ST0HK- -01 INSPECTION INSPECT ARMATURE COIL Check the commutator for open circuit. Ohmmeter Using an ohmmeter, check that there is continuity be- tween the segments of the commutator.
  • Page 313 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -10 STARTING STARTER INSPECT FIELD FRAME Ohmmeter Check the field coil for open circuit. Continuity Using an ohmmeter, check that there is continuity be- tween the lead wire and field coil brush lead.
  • Page 314 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -11 STARTING STARTER INSPECT BRUS H HO L DE R Ohmmeter No Continuity Check the brush holder insulation. Using an ohmmeter, check that there is no continuity be- tween the positive (+) and negative (--) brush holders.
  • Page 315 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -12 STARTING STARTER ST0HL- -01 REPLACEMENT RE P L ACE FRO NT BE ARI NG Using SST and a press, press out the bearing. 09950 -- 00020 ST1110 Using SST and a press, press in a new bearing.
  • Page 316 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -13 STARTING STARTER Inspect the contact plate for wear. Using vernier calipers, measure the contact plate for depth of wear. Maximum wear: 0.9 mm (0.035 in.) If the depth of wear is greater than the maximum, replace the contact plate.
  • Page 317 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -14 STARTING STARTER Install new terminal C kit parts. Lead Terminal Temporarily install a new terminal insulator (inside). Temporarily install a new contact plate. Temporarily install a new terminal bolt.
  • Page 318 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -15 STARTING STARTER Using SST, tighten the nuts to the specified torque. 09810 -- 38140 Torque: 17 N∙m (173 kgf∙cm, 13 ft∙lbf) NOTICE: If the nut is over tightened, it may cause cracks on the in- side of the insulator.
  • Page 319 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -16 STARTING STARTER ST0BO- -02 RE AS S E M BLY HINT: Use high--temperature grease to lubricate the bearings and gears when assembling the starter. P L ACE ARMAT URE I NTO FI E L D F RAME Apply a grease to the armature bearings.
  • Page 320 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -17 STARTING STARTER Place the starter housing, pinion gear, bearing, idler gear Pinion Gear Idler Gear and clutch assembly on the starter housing. Bearing Clutch Assembly...
  • Page 321 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -18 STARTING STARTER Connect the lead wire to terminal C, and install the nut. Torque: 5.9 N∙m (60 kgf∙cm, 52 in.∙lbf) P13020...
  • Page 322 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -19 STARTING STARTER ST0BP- -02 TEST Terminal C NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. PERFORM PULL - - IN TEST Disconnect the field coil lead wire from terminal C.
  • Page 323: Starter Relay

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX ST- -20 STARTING STARTER RELAY STARTER RELAY Engine Room R/B No.2 ST0HM- -01 INSPECTION RE MO V E S TARTE R RE LAY Remove the starter relay. (Marking: ST RLY)
  • Page 324 BACK TO MAIN INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CHARGING CHARGING SYSTEM ....CH--1 ALTERNATOR ......
  • Page 325: Charging System

    CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -1 CHARGING CHARGING SYSTEM CHARGING SYSTEM CH08P- -02 PRECAUTION Check that the battery cables are connected to the correct terminals. S S S S Disconnect the battery cables when the battery is given a quick charge.
  • Page 326 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -2 CHARGING CHARGING SYSTEM CH0C4- -01 ON- -VEHICLE INSPECTION CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. Maintenance--Free Battery: If under the lower level, replace the battery (or add distilled wa- ter if possible).
  • Page 327 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -3 CHARGING CHARGING SYSTEM INSPECT DRIVE BELTS Clearance WRONG CORRECT Visually check the drive belt for cracks, oiliness or wear. Check that the belt does not touch the bottom of the pulley groove.
  • Page 328 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -4 CHARGING CHARGING SYSTEM INSPECT CHARGING CIRCUIT WITHOUT LOAD Disconnect Wire Ammeter HINT: from Terminal B If a battery / alternator tester is available, connect the tester to the charging circuit as per the manufacturer’s instructions.
  • Page 329 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CHARGING – ALTERNATOR ALTERNATOR – COMPONENTS CH-5 DISASSEMBLY 1. REMOVE REAR END COVER CH-6 2. REMOVE BRUSH HOLDER AND IC REGULATOR CH-6 3. REMOVE RECTIFIER HOLDER CH-6 4.
  • Page 330 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -5 CHARGING ALTERNATOR ALTERNATOR CH08R- -02 COMPONENTS Alternator Washer Bearing Cover Rotor Retainer Drive End Frame (Stator) Pulley z Rear Bearing Brush Holder Cover z Front Bearing...
  • Page 331 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -6 CHARGING ALTERNATOR CH08S- -02 DISASSEMBLY REMOVE REAR END COVER Remove the nut and terminal insulator. Remove the 3 nuts and end cover. B00762 REMOVE BRUSH HOLDER AND IC REGULATOR Remove the 5 screws, bush holder and IC regulator.
  • Page 332 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -7 CHARGING ALTERNATOR Mount SST (C) in a vise. Install the pulley nut to SST (C). SST (C) P04210 To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.
  • Page 333 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -8 CHARGING ALTERNATOR CH0C5- -01 INSPECTION INSPECT ROTOR Check the rotor for open circuit. Using an ohmmeter, check that there is continuity be- tween the slip rings.
  • Page 334 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -9 CHARGING ALTERNATOR INSPECT BRUSHES Using a scale, measure the exposed brush length. Standard exposed length: 9.5 - - 11.5 mm (0.374 - - 0.453 in.) Minimum exposed length: 1.5 mm (0.059 in.)
  • Page 335 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -10 CHARGING ALTERNATOR CH0C6- -01 REPLACEMENT REPLACE BRUSHES Unsolder and remove the brush and spring. Run the wire of a new brush through the spring and the hole in the brush holder, and insert the spring and brush into the brush holder.
  • Page 336 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -11 CHARGING ALTERNATOR Place the bearing cover on the rotor. Bearing Cover P05052 Using SST and a press, press in a new bearing. 09820--00030 N00578 Using SST, push in the bearing cover.
  • Page 337 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -12 CHARGING ALTERNATOR CH0C7- -01 RE AS S E M BLY I NS TALL RO TO R TO DRI V E E ND F RAME Place the rectifier end frame on the pulley.
  • Page 338 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual TO MODEL INDEX CH- -13 CHARGING ALTERNATOR Turn SST (B) and remove SST (A and B). SST (A) INSTALL RECTIFIER HOLDER SST (C) Install the rectifier holder with the bolt and 4 screws.
  • Page 339: How To Proceed With Troubleshooting In

    BACK TO MAIN INDEX 1KZ-TE Pages From Manual ALPHABETI CAL I NDEX TO MODEL INDEX ID - - 1 ALPHABETICAL INDEX (A - - S) Page Page ABBREVIATIONS USED IN THIS MANUAL HOW TO PROCEED WITH TROUBLESHOOTING (TERMS) ........
  • Page 340 CLICK HERE TO VIEW CHAPTER INDEX 1KZ-TE Pages From Manual ALPHABETI CAL I NDEX TO MODEL INDEX ID - - 2 ALPHABETICAL INDEX (T - - W) Page TERMINALS OF ECU (ENGINE) (DIAGNOSTICS) ......

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