Toyota 1PZ Repair Manual

Table of Contents

Quick Links

Download this manual

Table of Contents

Troubleshooting

Summary of Contents for Toyota 1PZ

Page 2 FOREWORD This repair manual has been prepared to provide information covering general service repairs for the 1 PZ, 1 HZ and 1HD-T engines equipped on the TOYOTA LAND CRUISER and COASTER. Applicable models: PZJ70, 73, 75 series HZJ70, 73, 75, 80 series...
Page 3 CAUTION 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.
Page 4 SSTANDSSM ©2001 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be repro- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: Feb. 8,1990 01-900208-00 34th Printing: Aug. 28,2001 34-010828-06-2...
Page 5 IN-1 INTRODUCTION Page HOW TO USE THIS MANUAL IN-2 IDENTIFICATION INFORMATION IN-4 GENERAL REPAIR INSTRUCTIONS IN-4 ABBREVIATIONS USED IN THIS MANUAL IN-7...
Page 6: How To Use This Manual
IIM-2 INTRODUCTION How to Use This Manual HOW TO USE THIS MANUAL To assist you in finding your way through this manual, the Section Title and major heading are given at the top of every page. An INDEX is provided on the 1st page of each section to guide you to the item to be repaired.
Page 7 IN-3 INTRODUCTION - How to Use This Manual The procedures are presented in a step-by-step format: • The illustration shows what to do and whereto do it. • The task heading tells what to do. • The detailed text tells how to perform the task and gives other information such as specifications and warnings.
Page 8: Engine Serial Number
IIM-4 INTRODUCTION - Identification Information, General Repair Instructions IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the left side of the cylinder block. GENERAL REPAIR INSTRUCTIONS Use fender, seat and floor covers to keep the vehicle clean and prevent damage.
Page 9 IN-5 INTRODUCTION - General Repair Instructions Recoating of Precoated Parts Clean off the old adhesive from the part's threads. Dry with compressed air. (3) Apply the specified seal lock adhesive to the part's threads. Precoated parts are indicated in the component illus- trations by the "...
Page 10 INTRODUCTION General Repair Instructions IIM-6 (d) When steam cleaning an engine, protect the air filter, and injection pump from water. (e) Never use an impact wrench to remove or install temp, switches or temp, sensors. When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending.
Page 11 IN-7 INTRODUCTION - Abbreviations Used in This Manual ABBREVIATIONS USED IN THIS MANUAL Air Conditioner Air Control Valve ACSD Automatic Cold Start Device Approx. Approximately Automatic Transmission BACS Boost and Altitude Compensation Stopper Bottom Dead Center Except Fusible Link FIPG Formed in Place Gasket High Altitude Compensator Left-Hand...
Page 12: Table Of Contents
EM-1 ENGINE MECHANICAL Page DESCRIPTION EM-2 TROUBLESHOOTING EM-4 Diesel Engine Diagnosis EM-4 Diesel Electrical System Diagnosis EM -14 ENGINETUNE-UP EM-17 COMPRESSION CHECK EM-30 TIMING BELT EM-32 TIMINGGEARS EM-42 CYLINDER HEAD EM-54 CYLINDER BLOCK EM-84...
Page 13: Description
ENGINE MECHANICAL - Description EM-2 DESCRIPTION The 1 PZ engine is an in-line 5-cylinder 3.5 liter OHC engine. The 1 HZ and 1 HD-T engines are an in-line 6-cylinder 4.2 liter OHC engine. 1HD-T EM8795 EM8792 EM8965 EM8793 EM8966 EM8794...
Page 14 EM-3 ENGINE MECHANICAL Description The 1 PZ engine is an in-line 5-cylinder engine Adjustment of the valve clearance is done by with the cylinders numbered 1 - 2 - 3 - 4 - 5 from means of an outer shim type system, in which valve adjusting shims are located above the valve lifters.
Page 15: Troubleshooting
ENGINE MECHANICAL - Troubleshooting (Diesel Engine Diagnosis) EM-4 TROUBLESHOOTING Diesel Engine Diagnosis GENERAL Diesel engine problems are usually caused by the engine or fuel system. The injection pump is very rarely the cause of fuel system problems. Before beginning fuel system tests, first check that the engine compression, valve timing and other major systems are within specifications.
Page 16 EM-5 ENGINE MECHANICAL - Troubleshooting (Diesel Engine Diagnosis) PRECAUTION: The basic troubleshooting procedures for the diesel engine (valve clearance, compression, bearings, valves, pistons, etc.) are the same checks you would make for gasoline engine. Repair of the injection pump requires considerable skill and use of a special test bench. (Possible Cause) (Check Procedure and Correction Method) 1.
Page 17 ENGINE MECHANICAL Troubleshooting (Diesel Engine Diagnosis) EM-6 ENGINE CRANKS NORMALLY BUT WILL NOT START (Possible Cause) (Check Procedure and Correction Method) 1. NO FUEL TO NOZZLE Loosen any one injection pipe union nut from its nozzle holder. Crank engine for about 5 seconds while confirming that fuel is being discharged from pipe.
Page 18 ENGINE MECHANICAL - Troubleshooting (Diesel Engine Diagnosis) EM-7 6. FAULTY GLOW PLUG Check glow plug for continuity. OPERATION If no continuity, a broken wire is indicated and glow plug should be replaced. 7. IMPROPER INJECTION TIMING Check injection timing. (See page EM-27) Plunger stroke: 0.82 —0.88 mm (0.0323-0.0346 in.)
Page 19 EM-8 ENGINE MECHANICAL Troubleshooting (Diesel Engine Diagnosis) ROUGH IDLE WITH WARM ENGINE (Possible Cause) (Check Procedure and Correction Method) 1. IMPROPER ADJUSTMENT OF With accelerator pedal released, check that adjusting ACCELERATOR CABLE lever is in contact with idle speed adjusting screw. Also check if accelerator cable or linkage is catching on something.
Page 20 EM-9 ENGINE MECHANICAL - Troubleshooting (Diesel Engine Diagnosis) With engine idling, loosen injection pipe to each 5. IMPROPER OPERATION OF cylinder in order, and check if idle speed changes. INJECTION NOZZLES OR DELIVERY VALVES If no change, a faulty cylinder is indicated. Check according to following procedure.
Page 21 EM-10 ENGINE MECHANICAL - Troubleshooting (Diesel Engine Diagnosis) ENGINE SUDDENLY STOPS (Possible Cause) (Check Procedure and Correction Method) 1. ENGINE WILL NOT RE-START Check to see if engine re-starts according to pre- scribed procedure. If not, refer to ENGINE CRANKS NORMALLY BUT WILL NOT START, above, and repair as necessary.
Page 22 ENGINE MECHANICAL Troubleshooting (Diesel Engine Diagnosis) EM-11 3. INTERCHANGED OVERFLOW HINT: Overflow screw is marked "OUT" and has SCREW (OUT) AND INLET (NO an inner jet. Although both fittings are same size, MARK) FITTING they must not be interchanged. 4. FUEL LEAKAGE Refer to step 3 of ROUGH IDLE WITH WARM EN- GINE.
Page 23 If not as above, adjust with idle speed adjusting screw. 3. MAXIMUM SPEED TOO HIGH Check maximum speed. (See page EM-27) Maximum speed: 1PZ and 1 HZ 4,500 - 4,700 rpm 1H D -T 4,300 - 4,500 rpm If not as above, adjust with maximum speed adjust- ing screw.
Page 24 ENGINE MECHANICAL - Troubleshooting (Diesel Engine Diagnosis) EM-13 ENGINE NOISE WHEN WARM (Cranking Noise with Excessive Vibration) (Possible Cause) (Check Procedure and Correction Method) 1. ENGINE COOLANT Check coolant temperature with coolant temperature TEMPERATURE TOO LOW gauge. If not sufficiently warm, thermostat is faulty and should be replaced.
Page 25: Diesel Electrical System Diagnosis
EM-14 ENGINE MECHANICAL - Troubleshooting (Diesel Electrical System Diagnosis) Diesel Electrical System Diagnosis ENGINE DOES NOT START COLD HINT: • Battery voltage at least 12 V (or 24 V) - starter switch OFF. • Engine cranks normally. • Fusible link okay. •...
Page 26 ENGINE MECHANICAL - Troubleshooting (Diesel Electrical System Diagnosis) EM-15 CONTINUED FROM PAGE EM-14 * Place starter switch at ON and check if current flow to terminal Pre-heating Duration Differs from the Specified 5 of timer is in accordance. Duration. Current f low: 120 seconds Timer is faulty and should be replaced.
Page 27 ENGINE MECHANICAL Troubleshooting (Diesel Electrical System Diagnosis) EM-16 Fuel Cut Solenoid Valve With starter switch turned ON, Fuel cut solenoid valve okay. check for fuel cut solenoid valve Noise operation noise (clicking sound) while repeatedly connecting and disconnecting fuel cut solenoid valve.
Page 28: Enginetune-Up
ENGINE MECHANICAL - Engine Tune-Up EM-17 ENGINE TUNE-UP INSPECTION OF ENGINE COOLANT (See steps 1 and 2 on page CO-4) INSPECTION OF ENGINE OIL (See steps 1 and 2 on page LU-5) INSPECTION OF BATTERY (See pages 1 and 2 on page CH-5) Standard specific gravity: 95D31 R and 95D31L 1.27-1.29 when fully charged at 20°C (68°F)
Page 29 ENGINE MECHANICAL - Engine Tune-Up EM-18 (b) Submerge the filter element in the water and agitate it up and down more than ten times. (c) Repeat rinsing in clean water unitil rinse water is clear. (d) Remove excess water by shaking the filter element or blowing with compressed air.
Page 30: Adjustment Of Valve Clearance
SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley clockwise, and align its groove with the timing gear cover groove. (b) (1PZ) Check that the valve lifters on the No.1 cylinder are loose and exhaust valve lifter on the No.5 cylinder is tight.
Page 31 EM-20 ENGINE MECHANICAL - Engine Tune-Up (d) Remove the adjusting shim. • Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. • Using SST, press down the valve lifter. SST 09248-64011 HINT: Before pressing down the valve lifter, position the notch on the exhaust manifold side.
Page 32 ENGINE MECHANICAL - Engine Tune-Up EM-21 Adjusting Shim Selection Using Chart (Intake) Intake valve clearance (Cold): 0.15-0.25 mm (0.006-0.010 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed and the measured clearance is 0.300 mm (0.0118 in.). Replace the 2.800 mm (0.1102 in.) shim with a No.21 shim.
Page 33 EM-22 ENGINE MECHANICAL - Engine Tune-Up Adjusting Shim Selection Using Chart (Exhaust) Exhaust valve clearance: 0.35-0.45 mm (0.014-0.018 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed and the measured clearance is 0.300 mm (0.0118 in.). Replace the 2.800 mm (0.1102 in.) shim with a No.11 shim.
Page 34 ENGINE MECHANICAL - Engine Tune-Up EM-23 ADJUSTMENT OF INJECTION TIMING (1PZ) REMOVE TIMING BELT COVER (See step 1 on page EM-33) (1PZ) SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley clockwise, and align each pul- ley groove with the timing marks (TDC mark) as shown in the illustration.
Page 35 Compared with previous four cylinder en- gines, the 0 mm (0 in.) position (crank angle) is reduced, so perform the operation carefully, (ex. 1PZ) (b) Turn the crankshaft to the left and right and check that the dial indicator shows the minimum value.
Page 36 ENGINE MECHANICAL - Engine Tune-Up EM-25 (4) Bolt holding injection pump to injection pump stay. (5) Two nuts holding injection pump to timing gear case. (g) Adjust plunger stroke by slightly tilting the injection pump body. If the stroke is less than specification, tilt the pump toward the engine.
Page 37 IPZ and 1HZ 170 kg-cm (12 ft-lb, 17 Nm) 1HD-T 260kg-cm (19 ft-lb, 25 Nm) 10. TORQUE UNION NUTS OF INJECTION PIPES Torque: 1PZ and 1HZ 150kg-cm (11 ft-lb, 15 Nm) 1HD-T 250kg-cm (18 ft-lb, 25 N-m) 11. (1HD-T w/BACS) INSTALL AIR CONTROL VALVE (ACV) 12.
Page 38 EM-27 ENGINE MECHANICAL Engine Tune-Up ADJUSTMENT OF IDLE SPEED AND MAXIMUM SPEED INITIAL CONDITIONS (a) Engine at reach normal operating temperature (b) Air cleaner installed (c) All accessories switched OFF (d) All vacuum lines properly connected (e) Valve clearance set correctly Injection timing set correctly (g) Transmission in N range CONNECT TACHOMETER...
Page 39 (b) Start the engine. (c) Depress the accelerator pedal all the way. (d) Check the maximum speed. Maximum speed: 1PZ and 1 HZ 4,500 - 4,700 rpm 1HD-T 4,300-4,500 rpm (e) Adjust the maximum speed. • Disconnect the accelerator linkage.
Page 40 ENGINE MECHANICAL - Engine Tune-Up EM-29 ADJUSTMENT OF AIR CONDITIONER IDLE-UP SETTING SPEED INITIAL CONDITIONS (a) Engine at reach normal operating temperature (b) Air cleaner installed (c) All vacuum lines properly connected (d) Valve clearance set correctly (e) Injection timing set correctly (f) Transmission in N range (g) Idle speed set correctly CONNECT TACHOMETER...
Page 41: Compression Check
EM-30 ENGINE MECHANICAL Compression Check COMPRESSION CHECK HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. WARM UP AND STOP ENGINE Allow the engine to reach normal operating temperature. DISCONNECT INJECTION PUMP (FUEL CUT SOLENOID) CONNECTOR REMOVE GLOW PLUGS (See step 9 on page EM-57)
Page 42 ENGINE MECHANICAL - Compression Check EM-31 (c) Fully open the throttle valve. (d) While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine revolution of 250 rpm or more. (e) Repeat steps (a) through (d) for each cylinder. NOTICE: This measurement must be done in as short a time as possible.
Page 43: Timing Belt
EM-32 ENGINE MECHANICAL - Timing Belt TIMING BELT 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 44 EM-33 ENGINE MECHANICAL - Timing Belt REMOVAL OF TIMING BELT (See page EM-32) REMOVE TIMING BELT COVER Remove the three seal washer, bolts, four clips, timing belt cover and gasket. SET NO.1 CYLINDER TO BDC Turn the crankshaft pulley clockwise, set the No.1 and No.2 camshaft pulley grooves at each position (BDC mark).
Page 45 EM-34 ENGINE MECHANICAL - Timing Belt (c) Remove the timing belt. REMOVE TIMING BELT IDLER PULLEY Using SST, remove the bolt, timing belt idler pulley and plate. SST 09923-00020 REMOVE NO.2 CAMSHAFT TIMING PULLEY (a) Place matchmarks on the camshaft timing pulley No.2 flange and No.2 camshaft timing pulley.
Page 46 ENGINE MECHANICAL Timing Belt REMOVE CYLINDER HEAD COVER Remove the twelve bolts (1PZ) or fourteen bolts (1HZ and 1HD-T), two nuts, cylinder head cover and gasket. REMOVE NO.1 CAMSHAFT TIMING PULLEY (a) Hold the hexagonal wrench head portion of the cam- shaft with a wrench, and remove the No.1 camshaft...
Page 47 EM-36 ENGINE MECHANICAL - Timing Belt INSPECTION OF TIMING BELT COMPONENTS INSPECT TIMING BELT NOTICE: • Do not bend, twist or turn the timing belt inside out. • Do not allow the timing belt to come into contact with oil, water or steam. •...
Page 48 EM-37 ENGINE MECHANICAL Timing Belt (e) If there is noticeable wear on the belt teeth, check timing belt cover for damage and check for correct gasket installation. Check for foreign material on the pulley teeth. If necessary, replace the timing belt. INSPECT IDLER PULLEY (a) Check the turning smoothness of the idler pulley.
Page 49 Seal packing: Part No.08826-00080 or equivalent Install the gasket to the cylinder head cover. Install the cylinder head cover with the twelve bolts (1PZ) or fourteen bolts (1 HZ and 1HD-T) and two nuts. INSTALL INTAKE PIPE (1PZand1HZ)
Page 50 ENGINE MECHANICAL - Timing Belt EM -39 INSTALL N0.2 CAMSHAFT TIMING PULLEY (a) Align the knock pin of the injection pump drive gear with the knock pin hole of the camshaft timing pulley No.1 flange and cutout portion of the No.2 camshaft timing pulley.
Page 51 EM-40 ENGINE MECHANICAL - Timing Belt (a) Remove any oil or water on each pulley, and keep them clean. (b) Install the timing belt in following order: (1) No.2 camshaft timing pulley (2) No.1 camshaft timing pulley (3) Timing belt idler pulley (c) Using SST, install the tension spring.
Page 52 EM-41 ENGINE MECHANICAL - Timing Belt INSTALL TIMING BELT COVER (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the camshaft oil seal retainer and timing gear cover as shown in the illustration. Seal packing: Part No.08826-00080 or equivalent (c) Install the gasket to the timing belt cover.
Page 53: Timinggears
EM-42 ENGINE MECHANICAL - Timing Gears TIMING GEARS COMPONENTS...
Page 54 ENGINE MECHANICAL - Timing Gears EM-43 REMOVAL OF TIMING GEARS (See page EM-42) REMOVE DRIVE BELT, FAN AND WATER PUMP PULLEY (See step 2 on page CO-7) REMOVE TIMING BELT AND PULLEYS (See page EM-32) REMOVE CAMSHAFT OIL SEAL RETAINER (See step 14 on page EM-59) REMOVE OIL PIPE Remove the two union bolts and four gaskets.
Page 55 EM-44 ENGINE MECHANICAL - Timing Gears (b) Using SST, remove the No.1 crankshaft pulley. SST 09213-60017 (09213-00020, 09213-00030, 09213-00060) and 09950-20017 (c) Remove the O-ring from the No.1 crankshaft pulley. REMOVE TIMING GEAR COVER (a) Remove the fourteen bolts. (b) Pry out the timing gear cover. CHECK THRUST CLEARANCE OF IDLER GEAR Using a thickness gauge, measure the thrust clearance.
Page 56 EM-45 ENGINE MECHANICAL - Timing Gears 11. REMOVE IDLER GEAR Remove the two bolts, thrust plate, idler gear and idler gear shaft. 12. REMOVE INJECTION PUMP DRIVE GEAR (a) Using SST, remove the injection pump drive gear set nut. SST 09330-00021 (b) Remove the O-ring.
Page 57 EM-46 ENGINE MECHANICAL Timing Gears INSPECTION OF TIMING GEARS INSPECT IDLER GEAR (a) Using a cylinder gauge, measure the inside diameter of the idler gear. Idler gear inside diameter: 45.000-45.025 mm (1.7717-1.7726 in.) (b) Using a micrometer, measure the diameter of the idler gear shaft.
Page 58 ENGINE MECHANICAL - Timing Gears EM-47 Install bearing Using SST and a press, press in a new bearing. SST 09214-76011 CHECK BACKLASH OF TIMING GEARS Using a dial indicator, measure the backlash. Standard gear backlash: 0.05-0.15 mm (0.0020-0.0060 in.) Maximum gear backlash: 0.30 mm (0.0118 in.) If the gear backlash is greater than maximum, replace the gears as a set.
Page 59 EM-48 ENGINE MECHANICAL - Timing Gears REPLACEMENT OF CRANKSHAFT FRONT OIL SEAL HINT: There are two methods (A and B) to replace the oil seal as follows: REPLACE CRANKSHAFT FRONT OIL SEAL If timing gear cover is removed from cylinder block: (a) Using a screwdriver and hammer, tap out the oil seal.
Page 60 ENGINE MECHANICAL Timing Gears EM-49 REPLACEMENT OF INJECTION PUMP DRIVE GEAR OIL SEAL HINT: There are two methods (A and B) to replace the oil seal as follows: REPLACE INJECTION PUMP DRIVE GEAR OIL SEAL If timing gear cover is removed from cylinder block: (a) Using a screwdriver and hammer, tap out the oil seal.
Page 61 ENGINE MECHANICAL - Timing Gears EM-50 INSTALLATION OF TIMING GEARS (See page EM-42) INSTALL CRANKSHAFT TIMING GEAR (a) Put the timing crankshaft timing gear with the timing mark facing frontward. (b) Align the timing gear set key with the key groove of the timing gear.
Page 62 EM-51 ENGINE MECHANICAL - Timing Gears (c) Align the thrust plate set bolt holes. (d) Install the thrust plate with the two bolts. Torque the bolts. Torque: 400 kg-cm (29 ft-lb, 39 N m) INSTALL PUMP DRIVE SHAFT GEAR (a) Align the pump drive shaft gear set key with the key groove of the drive shaft gear.
Page 63 EM-52 ENGINE MECHANICAL - Timing Gears (c) Install the timing gear cover with the fourteen bolts. Torque: 200 kg-cm (14 ft-lb, 20 N m) INSTALL NO.1 CRANKSHAFT PULLEY (a) Install a new O-ring in the No.1 crankshaft pulley groove. (b) Align the pulley set key with the key groove of the pulley.
Page 64 ENGINE MECHANICAL - Timing Gears EM-53 INSTALL VACUUM PUMP (a) Install a new O-ring to the vacuum pump. (b) Install the vacuum pump with the two nuts. Torque: 400 kg-cm (29 ft-lb, 39 N m ) INSTALL OIL PIPE Install the oil pipe with the bolt, two union bolts and four new gaskets.
Page 65: Cylinder Head
EM-54 ENGINE MECHANICAL - Cylinder Head CYLINDER HEAD COMPONENTS...
Page 66 (b) Remove the O-ring from the oil dipstick guide. REMOVE INTAKE MANIFOLD (a) Disconnect the fuel hose from the nozzle leakage pipe. (b) (1PZ) Remove the ten bolts, seal washers, intake manifold and five gaskets. (c) (1 HZ and 1HD-T) Remove the twelve bolts, seal washers, intake mani- fold and six gaskets.
Page 67 EM-56 ENGINE MECHANICAL - Cylinder Head (1HD-T) Remove the six hollow bolts, nozzle leakage pipe and twelve gaskets. REMOVE INJECTION NOZZLES (1PZ and 1HZ) (a) (1PZ) Using SST, remove the five injection nozzles, seats and gaskets. SST 09268-64010 (b) (1HZ) Using SST, remove the six injection nozzles, seats and gaskets.
Page 68 (a) Remove the five screw grommets (1 PZ) or six screw grommets (1 HZ and 1 HD-T). (b) Remove the five nuts (1PZ) or six nuts (1 HZ and 1HD-T) and glow plug connector. (c) Using a 12 mm deep socket wrench, remove the five glow plugs (1 PZ) or six glow plugs (1 HZ and 1 HD- 10.
Page 69 EM-58 ENGINE MECHANICAL - Cylinder Head (b) Remove the ten nuts (1 PZ) or twelve nuts (1HZ), exhaust manifold and two gaskets. 11. (1HD-T) REMOVE TURBOCHARGER AND EXHAUST MANIFOLD ASSEMBLY (See steps 3 to 8 on pages TC-9, 10) 12. (1HZ and 1HD-T) SEPARATE EXHAUST MANIFOLDS (a) Separate the front and rear exhaust manifolds.
Page 70 (a) Remove the four bolts holding the camshaft oil seal retainer to the cylinder head. (b) Pry out the camshaft oil seal retainer. 15. REMOVE CAMSHAFT (a) (1PZ) Uniformly loosen and remove the twelve bearing cap bolts in several passes in the sequence shown. (b) (1 HZ and 1HD-T) Uniformly loosen and remove the fourteen bearing cap bolts in several passes in the sequence shown.
Page 71 EM-60 ENGINE MECHANICAL - Cylinder Head 16. REMOVE CYLINDER HEAD (a) Using SST, uniformly loosen and remove the twenty- two cylinder head bolts (1 PZ) or twenty-six cylinder head bolts (1 HZ and 1 HD-T) in several passes in the sequence shown.
Page 72 EM-61 ENGINE MECHANICAL - Cylinder Head DISASSEMBLY OF CYLINDER HEAD (See page EM-54) REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in correct order. REMOVE VALVES Using SST, compress the valve spring and remove the two keepers. SST 09202-43013 Remove the spring retainer, valve spring, valve and spring seat.
Page 73 EM-62 ENGINE MECHANICAL - Cylinder Head (IPZ and 1HZ) REMOVE COMBUSTION CHAMBERS Using SST, remove the five (1 PZ) and six (1 HZ) combus- tion chambers (and shims). SST 09208-48010 HINT: Arrange the combustion chambers (and shims) in correct order. REMOVE HALF CIRCULAR PLUG REMOVE FRONT AND REAR ENGINE HANGERS...
Page 74 EM-63 ENGINE MECHANICAL Cylinder Head INSPECTION, CLEANING AND REPAIR OF CYLINDER HEAD COMPONENTS CLEAN TOP OF PISTONS AND TOP OF BLOCK (a) Turn the crankshaft and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top.
Page 75 EM-64 ENGINE MECHANICAL - Cylinder Head INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder block mani- folds for warpage. Maximum warpage: 0.20 mm (0.0079 in.) If warpage is greater than maximum, replace the cylinder head.
Page 76 EM-65 ENGINE MECHANICAL - Cylinder Head (b) Using a micrometer, measure the diameter of the valve stem. 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.) (c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.020-0.055 mm...
Page 77 EM-66 ENGINE MECHANICAL - Cylinder Head (d) Using SST and a hammer, tap in a new guide bushing to where there is 11.8 - 12.2 mm (0.465 - 0.480 in.) protruding from the cylinder head. SST 09201-60011 (e) Using a sharp 8 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page EM-65) between the guide bushing and valve stem.
Page 78 ENGINE MECHANICAL - Cylinder Head EM-67 (e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off more than the minimum overall length.
Page 79 EM-68 ENGINE MECHANICAL - Cylinder Head (2) (Intake) If the seating is too low on the valve face, use 70° and 45° cutters to correct the seat. (Exhaust) If the seating is too low on the valve face, use 60° and 45°...
Page 80 If the circle runout is greater than maximum, replace the camshaft. Inspect cam lobes Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 1PZ and 1HZ 55.090-55.110 mm (2.1689-2.1697 in.) 1 HD-T 54.440-54.460 mm (2.1433-2.1441 in.) Exhaust 55.940 - 55.960 mm...
Page 81 EM-70 ENGINE MECHANICAL - Cylinder Head Inspect camshaft journal oil clearance Install the camshaft bearings to the No.1 bearing cap and No.1 journal of the cylinder head. (See step 4 (b) on page EM-78) Clean the bearings and camshaft journals. Place the camshaft on the cylinder head.
Page 82 EM-71 ENGINE MECHANICAL Cylinder Head (b) Using a micrometer, measure the lifter diameter. Lifter diameter: 40.892-40.902 mm (1.6099-1.6103 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.058-0.083 mm (0.0023-0.0033 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the lifter.
Page 83 ENGINE MECHANICAL Cylinder Head EM-72 REPLACEMENT OF CAMSHAFT OIL SEAL HINT: There are two methods (A and B) to replace the oil seal as follows: REPLACE CAMSHAFT OIL SEAL If camshaft oil seal retainer is removed from cylinder head: (a) Using a screwdriver and hammer, tap out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
Page 84 ENGINE MECHANICAL Cylinder Head EM-73 ASSEMBLY OF CYLINDER HEAD (See page EM-54) HINT: • Thoroughly clean all parts to be assembled. • Before installing the parts, apply new engine oil to all sliding and rotating surfaces. • Replace all gaskets and oil seals with new ones. INSTALL FRONT AND REAR ENGINE HANGERS Install the engine hangers as shown in the illustration.
Page 85 EM-74 ENGINE MECHANICAL - Cylinder Head (c) Using a dial indicator, measure the protrusion of the combustion chamber from the cylinder head. Protrusion: Minus 0.04-Plus 0.04 mm (Minus 0.0016- Plus 0.0016 in.) If the protrusion is less than specified, adjust with shims. Shim thickness: 0.03 mm (0.0012 in.) If the protrusion is greater than specification, replace the chamber and recheck the protrusion.
Page 86 (e) Measure each cylinder at two places as shown in the illustration, making a tatal of ten measurements (1PZ) or twelve measurements (1 HZ and 1HD-T). For the piston protrusion value of each cylinder, use the average of the two measurements of each cylinder.
Page 87 ENGINE MECHANICAL - Cylinder Head EM-76 Select new cylinder head gasket (1PZ) HINT: There are five types of cylinder head gasket (hole number 1 to 5) installed at factory, but only three types for supply parts (hole number " 1 " , "3" and "5"), so when replacing the gasket select from one of three types above.
Page 88 EM-77 ENGINE MECHANICAL Cylinder Head SET N0.1 CYLINDER TO BDC Turn the crankshaft pulley, and align the BDC mark of the timing gear cover with the No.1 flange groove of the No.2 camshaft timing pulley. INSTALL CYLINDER HEAD Place cylinder head on cylinder block (a) Place a new cylinder head gasket in position on the cylinder block.
Page 89 No.1 journal of the cylinder head. (c) Place the camshaft on the cylinder head, facing the key groove upward. (d) Install the six (1PZ) or seven (1 HZ and 1HD-T) bear- ing caps in their proper locations. (e) (1PZ) Install and uniformly tighten the twelve bearing cap bolts in several passes in the sequence shown.
Page 90 ENGINE MECHANICAL - Cylinder Head EM-79 (1HZ and 1HD-T) Install and uniformly tighten the fourteen bearing cap bolts in several passes in the sequence shown. Torque: No.1 journal 250 kg-cm (18 ft-lb, 25 N-m) Others 185 kg-cm (13 ft-lb, 18 N-m) ADJUST VALVE CLEARANCE (See page EM-19) Valve clearance (Cold): Intake...
Page 91 INSTALL EXHAUST MANIFOLD (a) Install new gaskets in direction as shown in the illustration. (b) Install the exhaust manifold with the ten nuts (1PZ) or twelve nuts (1HZ). Torque: 400 kg-cm (29 ft-lb, 39 N-m) HINT: Apply 330 kg-cm (24 ft-lb, 32 N-m) of torque...
Page 92 ENGINE MECHANICAL - Cylinder Head EM-81 (c) Install the heat insulator with the four bolts (1PZ) or five bolts (1HZ). 10. (1HD-T) INSTALL TURBOCHARGER AND EXHAUST MANIFOLD (See steps 4 to 10 on pages TC-13 to 15) 11. INSTALL GLOW PLUG...
Page 93 EM-82 ENGINE MECHANICAL Cylinder Head 12. INSTALL INJECTION NOZZLES (1PZ and 1HZ) (a) Place new gaskets and the nozzle seats into the injection nozzle holes of the cylinder head. (b) Using SST, install the injection nozzles. SST 09268-64010 Torque: 650 kg-cm (47 ft-lb, 64 N-m) NOTICE: Over torquing could cause nozzle deforma- tion and needle adhesion or other defects.
Page 94 Torque: 200 kg-cm (14 ft-lb, 20 Nm) (b) (1HD-T) Connect the water by-pass hose. 15. INSTALL INTAKE MANIFOLD (a) (1PZ) Install five new gaskets and the intake manifold with the ten bolts and seal washers. Torque: 200 kg-cm (14 ft-lb, 20 N m )
Page 95: Cylinder Block
ENGINE MECHANICAL Cylinder Block EM-84 CYLINDER BLOCK COMPONENTS...
Page 96 EM -85 ENGINE MECHANICAL - Cylinder Block PREPARATION FOR DISASSEMBLY (M/T) REMOVE CLUTCH COVER AND DISC (M/T) REMOVE FLYWHEEL (A/T) REMOVE DRIVE PLATE AND FLYWHEEL Remove the drive plate rear spacer, drive plate and fly- wheel. REMOVE REAR END PLATE Remove the bolt, end plate and dust cover.
Page 97 EM-86 ENGINE MECHANICAL - Cylinder Block DISASSEMBLY OF CYLINDER BLOCK (See page EM-84) REMOVE REAR OIL SEAL RETAINER Remove the six bolts and retainer. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.10-0.20 mm (0.0038-0.0079 in.)
Page 98 EM-87 ENGINE MECHANICAL Cylinder Block (d) Clean crank pin and bearing. (e) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. Lay a strip of Plastigage across the crank pin.
Page 99 ENGINE MECHANICAL - Cylinder Block EM-88 HINT: If using a standard bearing, replace with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers inprinted on the crankshaft and connecting rod, then selecting the bearing with the same number as the total.
Page 100 EM-89 ENGINE MECHANICAL - Cylinder Block HINT: • Keep the bearings, connecting rod and cap together. • Arrange the piston and connecting rod assemblies in correct order. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Page 101 EM -90 ENGINE MECHANICAL - Cylinder Block (c) Using a screwdriver, pry out the main bearing cap. HINT: Keep the lower main bearings and main bearing cap together. NOTICE: Do not scratch the surface which will be coated with FIPG. (d) Lift out the crankshaft.
Page 102 EM-91 ENGINE MECHANICAL - Cylinder Block Remove the main bearing cap bolts and cap. (k) Measure the Plastigage at its widest point. Standard clearance: 0.036-0.054 mm (0.0014-0.0021 in.) U/S 0.25 and U/S 0.50 0.037-0.077 mm (0.0015-0.0030 in.) Maximum clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the bearings.
Page 103 ENGINE MECHANICAL - Cylinder Block EM-92 (Reference) (Cont'd) Standard sized bearing center wall thickness: Mark "2" 1.979-1.982 mm (0.0779-0.0780 in.) Mark "3" 1.982 -1.985 mm (0.0780-0.0781 in.) Mark "4" 1.985 -1.988 mm (0.0781-0.0783 in.) Mark "5" 1.988-1.991 mm (0.0783-0.0784 in.) Mark "6"...
Page 104 If warpage is greater than maximum, replace the cylinder block. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all five (1PZ) or six (1HZ and 1HD-T) cylinders. If necessary, replace the cylinder block. INSPECT CYLINDER BORE DIAMETER...
Page 105 ENGINE MECHANICAL - Cylinder Block EM-94 Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust axial directions. Standard diameter: STD Mark " 1 " 94.000-94.010 mm (3.7008-3.7012 in.) Mark "2" 94.010-94.020 mm (3.7012-3.7016 in.) Mark "3"...
Page 106 ENGINE MECHANICAL - Cylinder Block EM-95 INSPECT CYLINDER BLOCK ORIFICE Check that the oifice is not clogged. DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
Page 107 EM-96 ENGINE MECHANICAL - Cylinder Block (b) Gradually heat the piston to approx. 80°C (176°F). (c) Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: • The piston and pin are a matched set. •...
Page 108 (a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, at the indicated distance from the piston head. Distance: 1PZ and 1 HZ 58.6 mm (2.3071 in.) 1HD-T 65.7 mm (2.5866 in.) Piston diameter: STD Mark "...
Page 109 ENGINE MECHANICAL - Cylinder Block EM-98 (b) Measure the cylinder bore diameter in the thrust directions. (See step 5 on page EM-93) (c) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.04-0.06 mm (0.0016-0.0024 in.) Maximum oil clearance: 0.14 mm (0.0055 in.) If the oil clearance is greater than maximum, replace all five (1 PZ) or six (1 HZ and 1 HD-T) pistons and rebore all five...
Page 110 EM-99 ENGINE MECHANICAL - Cylinder Block (c) Using a thickness gauge, measure the end gap. Standard end gap: No.1 0.27-0.54 mm (0.0106-0.0213 in.) No.2 0.40-0.62 mm (0.0157-0.0244 in.) 0.20-0.52 mm (0.0079-0.0205 in.) Maximum end gap: No.1 1.34 mm (0.0591 in.) No.2 1.42 mm (0.0551 in.) 1.32 mm (0.0520 in.) If the end gap is greater than maximum, replace the piston...
Page 111 29.008-29.020 mm (1.1420-1.1425 in.) 1HD-T 33.008-33.020 mm (1.2995-1.3000 in.) (b) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 1PZ and 1HZ 29.000-29.012 mm (1.1417-1.1422 in.) 1HD-T 33.000-33.012 mm (1.2992-1.2997 in.) (c) Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Page 112 ENGINE MECHANICAL - Cylinder Block EM-101 Install new connecting rod bushings (a) Using a round file, lightly file off any roughness from the small end of the connecting rod. (b) (1HD-T) Attach the bushing to SST with the ball of SST inside the oil hole of the bushing.
Page 113 EM-102 ENGINE MECHANICAL - Cylinder Block (d) Using SST and a press, press in the bushing. SST 1PZ and 1HZ 09222-66010 1HD-T 09222-17010(09222-05020, 09222-05030, 09222-05040) Hone connecting rod bushing and check piston pin fit (a) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (see page EM-100) between the bushing and piston pin.
Page 114 ENGINE MECHANICAL Cylinder Block EM-103 BORING OF CYLINDERS HINT: • Bore all five (1 PZ) or six (1 HZ and 1 HD-T) cylinders for the oversized piston outside diameter. • Replace the piston rings with ones to match the over- sized pistons.
Page 115 EM-104 ENGINE MECHANICAL - Cylinder Block INSPECTION AND REPAIR OF CRANKSHAFT INSPECT CRANKSHAFT FOR RUNOUT (a) Place the crankshaft on V-blocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft.
Page 116 ENGINE MECHANICAL - Cylinder Block EM-105 REPLACEMENT OF CRANKSHAFT OIL SEAL HINT: There are two methods (A and B) to replace the oil seal as follows: REPLACE CRANKSHAFT REAR OIL SEAL If rear oil seal retainer is removed from cylinder block: (a) Using a screwdriver and hammer, tap out the oil seal.
Page 117 ENGINE MECHANICAL Cylinder Block EM-106 ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLIES ASSEMBLE PISTON AND CONNECTING ROD (a) Install a new snap ring on one side of the piston pin hole. • Position the snap ring so that end (B) of the snap ring is aligned with the hollow, then push the snap ring into the piston groove starting from end (A).
Page 118 EM-107 ENGINE MECHANICAL - Cylinder Block HINT: Face the end gap of the oil ring in the opposite direction of coil joint. (c) Using a piston ring expander, install the two compres- sion rings with the code mark facing upward. Code mark: No.1 1T No.2 2T (d) Position the piston rings so that the ring ends are as...
Page 119 (a) Align the pin of the oil nozzle with the pin hole of the cylinder block. (b) Install the oil nozzle with the check valve. Install the five (1PZ) or six (1 HZ and 1HD-T) oil nozzles and check valves. Torque: 275 kg-cm (20 ft-lb, 27 N m )
Page 120 EM-109 ENGINE MECHANICAL Cylinder Block INSTALL THRUST WASHERS (a) Push the crankshaft toward the front (rear) side. (b) Install the thrust washers to the No.4 main journal position of the cylinder block with the oil grooves facing outward. INSTALL MAIN BEARING CAP Install main bearing cap on cylinder block (a) Remove any old packing (FIPG) material and be careful not to drop any oil the contact surfaces of the...
Page 121 ENGINE MECHANICAL - Cylinder Block EM-110 (a) Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts. (b) 1st, install and uniformly tighten the twelve (1 PZ) or fourteen (1 HZ and 1 HD-T) main bearing cap bolts in several passes in the sequence shown.
Page 122 ENGINE MECHANICAL - Cylinder Block EM-111 INSTALL PISTON AND CONNECTING ROD ASSEMBLIES Using a piston ring compressor, push the correctly num- bered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. INSTALL CONNECTING ROD CAPS Place connecting rod cap on connecting rod (a) Match the numbered connecting rod cap with the connecting rod.
Page 123 ENGINE MECHANICAL - Cylinder Block EM-112 (c) Mark the front of the connecting rod cap bolt with paint. (d) 2nd, retighten the connecting rod cap bolts by an additional 90°. (e) Check that the painted mark is now at a 90° angle to the front.
Page 124 EM-113 ENGINE MECHANICAL - Cylinder Block POST ASSEMBLY INSTALL ENGINE MOUNTING INSTALL THERMOSTAT AND WATER INLET (See page CO-11) INSTALL OIL COOLER (See page LU-18) INSTALLTIMING GEAR CASE (OIL PUMP) AND OIL PAN (See page LU-12) INSTALL INJECTION PUMP (See page FU-93) INSTALL TIMING GEARS (See page EM-50) INSTALL ALTERNATOR INSTALL WATER PUMP (See page CO-8)
Page 125 TC-1 TURBOCHARGER Page DESCRIPTION TC-2 PRECAUTIONS TC-4 TROUBLESHOOTING TC-5 TURBOCHARGER ELECTRICAL SYSTEM DIAGNOSIS (HZJ80) TC-7 TURBOCHARGER TC-8...
Page 126 TC-2 TURBOCHARGER SYSTEM - Description DESCRIPTION System which increase the amount of air sent to air to the engine. This allows a proportional in- the engine are either turbocharger type (using crease in the fuel that can be burned and hence exhaust gas to turn the turbine) or supercharger raises the potential power output, type (using the engine crankshaft, etc.
Page 127 TURBOCHARGER SYSTEM - Description TC-3 Operation of Turbocharger Waste Gate Valve Exhaust gas acts on the turbine wheel inside the If the turbocharged air pressure exceeds the turbine housing, causing it to revolve. When the prescribed air pressure, the flow of exhaust gas turbine wheel revolves, the impeller wheel which by-passes the turbine, controlling turbine wheel revolutions and turbocharged air pressure.
Page 128 TC-4 TURBOCHARGER SYSTEM Precautions PRECAUTIONS Do not stop the engine immedialtely after pulling a trailer or high speed or uphill driving. Idle the engine for 20-120 seconds, depending on the severity of the driving condition. Avoid sudden racing or acceleration immediately after starting a cold engine.
Page 129 TURBOCHARGER SYSTEM Precautions, Troubleshooting TC-5 1 1 . If the engine is running with the air cleaner, case cover and hose removed, foreign particles entering will damage the wheels which run at extremely high speed. TROUBLESHOOTING HINT: Before troubleshooting the turbocharger, first check the engine itself.
Page 130 TC-6 TURBOCHARGER SYSTEM - Troubleshooting ABNORMAL NOISE (Possible Cause) (Check Procedure and Correction Method) EXCESSIVE OIL CONSUMPTION OR WHITE EXHAUST (Possible Cause) (Check Procedure and Correction Method)
Page 131 TURBOCHARGER SYSTEM - Turbocharger Electrical System Diagnosis (HZJ80) TC-7 TURBOCHARGER ELECTRICAL SYSTEM DIAGNOSIS (HZJ80) TROUBLESHOOTING OF TURBOCHARGER INDICATOR LIGHT AND WARNING LIGHT OPERATION...
Page 132 TC-8 TURBOCHARGER SYSTEM Turbocharger TURBOCHARGER ON-VEHICLE INSPECTION OF TURBOCHARGER INSPECT INTAKE AIR SYSTEM Check for leakage or clogging between the air cleaner and turbocharger inlet and between the turbocharger outlet and cylinder head. • Clogged air cleaner ..Clean or replace the element •...
Page 133 TURBOCHARGER SYSTEM - Turbocharger TC-9 COMPONENTS...
Page 134 TC-10 TURBOCHARGER SYSTEM - Turbocharger REMOVAL OF TURBOCHARGER (See page TC-9) DRAIN ENGINE COOLANT (See page CO-4) REMOVE INTAKE PIPE (a) Disconnect the vacuum hose for the boost compen- sator. (b) Disconnect the air hose clamp bolt. (c) Remove the three bolts and intake pipe. REMOVE EXHAUST MANIFOLD HEAT INSULATOR Remove the five bolts and heat insulator.
Page 135 TURBOCHARGER SYSTEM Turbocharger TC-11 REMOVE TURBO OIL PIPE (a) Remove the union bolt and two gaskets holding the turbo oil pipe to the cylinder block. (b) Disconnect the turbo oil hose. (c) Remove the two nuts, turbo oil pipe and gasket. REMOVE TURBOCHARGER AND EXHAUST MANIFOLD ASSEMBLY Remove the twelve nuts, the turbocharger and exhaust...
Page 136 TC-12 TURBOCHARGER SYSTEM - Turbocharger 12. REMOVE TURBINE OUTLET ELBOW Remove the four nuts, turbine outlet elbow and gasket. INSPECTION OF TURBOCHARGER INSPECT IMPELLER WHEEL ROTATION Grasp the edge of the turbine wheel and turn it. Check that the impeller wheel turns smoothly. If the impeller wheel does not turn or if it turns with a drag, replace the turbocharger assembly.
Page 137 TURBOCHARGER SYSTEM Turbocharger TC-13 INSPECT ACTUATOR OPERATION (a) Disconnect the actuator hose. (b) Using SST (turbocharger pressure gauge), apply ap- prox. 0.92 kg/cm (13.1 psi, 90 kpa) of pressure to the actuator and check that the rod moves. SST 09992-00241 If the rod does not move, replace the turbocharger assem- bly.
Page 138 TC-14 TURBOCHARGER SYSTEM - Turbocharger ASSEMBLE TURBOCHARGER AND EXHAUST MANIFOLD Install a new gasket and the turbocharger to the exhaust manifold with the four nuts. Torque: 530 kg-cm (38 ft-lb, 52 N-m) INSTALL TURBOCHARGER AND EXHAUST MANIFOLD ASSEMBLY (a) Install two new gaskets to the cylinder head. (b) Install the turbocharger and exhaust manifold assem- bly with the twelve nuts.
Page 139 TURBOCHARGER SYSTEM - Turbocharger TC-15 INSTALL TURBOCHARGER HEAT INSULATOR Install the heat insulator with the two bolts. Torque: 185 kg-cm (13 ft-lb, 18 Nm) CONNECT WATER BY-PASS HOSES 10. INSTALL EXHAUST MANIFOLD HEAT INSULATOR Install the heat insulator with the five bolts. Torque: 185 kg-cm (13 ft-lb, 18 N m ) 11.
Page 140 NOTE: For troubleshooting procedures, refer to TROUBLE- SHOOTING (EM Section). Page DESCRIPTION FU-2 REPLACEMENT OF FUEL FILTER FU-4 FUEL HEATER SYSTEM FU-6 INJECTION NOZZLES (1PZ and 1 HZ) FU-9 INJECTION NOZZLES (1HD-T) FU-16 INJECTION PUMP FU-27 POWER CONTROL SYSTEM (PCS) (HDB30(w/ M/T) only) FU-95...
Page 141 FU-2 FUEL SYSTEM Description DESCRIPTION FUEL SYSTEM Fuel is drawn up from the fuel tank through the fuel filter (sedimenter) by the feed pump built into the injection pump. The fuel drawn up is then sent into the pump housing. Fuel compressed in the pump housing is distributed to the injection nozzles according to the injection order, and injected at high pressure into the combustion chamber.
Page 142 FU-3 FUEL SYSTEM Description Injection Pump (VE Pump) OPERATION • The centrifugal force type feed pump takes up a fixed volume of fuel with each turn. The fuel expulsion pressure from the feed pump is controlled by operation of the pressure regulator valve. •...
Page 143 FU-4 FUEL SYSTEM - Replacement of Fuel Filter REPLACEMENT OF FUEL FILTER DISCONNECT FUEL FILTER WARNING SWITCH CONNECTOR DRAIN FUEL FROM FUEL FILTER (a) Connect a vinyl hose to the drain cock, and insert the other end of the vinyl hose in a container. (b) Loosen the drain plug, and drain the fuel.
Page 144 FUEL SYSTEM - Replacement of Fuel Filter FU-5 Install new fuel filter (a) Check and clean the fuel filter installation surface. (b) Apply fuel to the gasket of a new fuel filter. (c) Lightly screw the fuel filter into place, and tighten it until the gasket comes into contact with the seat.
Page 145 FUEL SYSTEM - Fuel Heater System FU-6 FUEL HEATER SYSTEM SYSTEM CIRCUIT...
Page 146 FU-7 FUEL SYSTEM - Fuel Heater System INSPECTION OF COMPONENTS Fuel Heater INSPECT FUEL HEATER (a) Apply a vacuum of 350 ± 50 mmHg (13.78 ± 1.97 in.Hg, 46.7 ± 6.7 kPa) or more to the vacuum switch port. (b) Using an ohmmeter, measure the resistance between terminal 1 and the switch body.
Page 147 FU-8 FUEL SYSTEM Fuel Heater System Fuel Heater Relay (HZJ80 and HDJ80 only) LOCATION: In the engine compartment relay box. INSPECT RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 3. (c) Check that there is no continuity between terminals 2 and 4.
Page 148 FUEL SYSTEM - Injection Nozzles (1 PZ and 1 HZ) FU-9 INJECTION NOZZLES (1 PZ and 1 HZ) REMOVAL OF INJECTION NOZZLES REMOVE INTAKE PIPE (See step 6 on page EM-34) REMOVE INJECTION PIPES (a) Loosen the union nuts of the injection pipes from the injection nozzles.
Page 149 FU-10 FUEL SYSTEM - Injection Nozzles (1 PZ and 1 HZ) REMOVE NOZZLE LEAKAGE PIPE (a) Disconnect the fuel hose from the nozzle leakage pipe. (b) Remove the nuts, leakage pipe and gaskets. REMOVE INJECTION NOZZLES Using SST, remove the injection nozzles, seats and gaskets. SST 09268-64010 HINT: Arrange the injection nozzles in correct order.
Page 150 • Varying the adjusting shim thickness by 0.025 mm (0.0010 in.) changes the injection pressure by about 4.5 kg/cm (64 psi, 441 kPa) (1PZ). • Varying the adjusting shim thickness by 0.025 mm (0.0010 in.) changes the injection pressure by about 3.5 kg/cm (50 psi, 343 kPa) (1HZ).
Page 151 FU-12 FUEL SYSTEM - Injection Nozzles (1 PZ and 1 HZ) COMPONENTS DISASSEMBLY OF INJECTION NOZZLES DISASSEMBLE INJECTION NOZZLES (a) Using SST, remove the nozzle holder retaining nut. SST 09268-64010 NOTICE: When disassembling the nozzle, be careful not to drop the inner parts. (b) Remove the pressure spring, shim, pressure pin, dis- tance piece and the nozzle assembly.
Page 152 FUEL SYSTEM - Injection Nozzles (1 PZ and 1 HZ) FU-13 Using a wooden stick, remove the carbon adhering to the nozzle needle tip. Using a brass brush, remove the carbon from the exterior of the nozzle body (except lapped surface). Check the seat of the nozzle body for burns or corrosion.
Page 153 FU-14 FUEL SYSTEM - Injection Nozzles (1 PZ and 1 HZ) ASSEMBLY OF INJECTION NOZZLES (See page FU-12) ASSEMBLE INJECTION NOZZLE HOLDERS (a) Assemble the nozzle holder retaining nut, the nozzle assembly, distance piece, pressure pin, pressure spring, adjusting shim and nozzle holder body, and finger tighten the retaining nut.
Page 154 FUEL SYSTEM - Injection Nozzles (1 PZ and 1 HZ) FU-15 INSTALL INJECTION PIPES (a) Place the two clamps on the intake manifold. (b) Connect the injection pipes to injection nozzle. Torque: 150 kg-cm (11 ft-lb, 15 Nm) (c) Connect the injection pipes to injection pump. Torque: 150 kg-cm (11 ft-lb, 15 Nm) (d) Secure the injection pipes with clamps and bolts.
Page 155 FU-16 FUEL SYSTEM - Injection Nozzles (1 HD-T) INJECTION NOZZLES (1HD-T) REMOVAL OF INJECTION NOZZLES REMOVE INTAKE PIPE (See step 6 on page EM-34) DISCONNECT INJECTION PIPES Loosen the union nuts of the six injection pipes from the six injection nozzles. REMOVE NOZZLE LEAKAGE PIPE (a) Disconnect the fuel hose from the nozzle leakage pipe.
Page 156 FUEL SYSTEM - Injection Nozzles (1 HD-T) FU-17 REMOVE INJECTION NOZZLES (a) Remove the bolt, washer, nozzle holder clamp, injec- tion nozzle and seat. (b) Remove the O-ring from the injection nozzle. HINT: Arrange the injection nozzles in correct order. TEST OF INJECTION NOZZLES LEAKAGE TEST While maintaining pressure at about 1 0 - 2 0 kg/cm...
Page 157 FU-18 FUEL SYSTEM - Injection Nozzles (1 HD-T) COMPONENTS DISASSEMBLY OF INJECTION NOZZLES DISASSEMBLE INJECTION NOZZLES (a) Remove the nozzle holder retaining nut. NOTICE: When disassembling the nozzle, be careful not to drop the inner parts. (b) Remove the nozzle sub-assembly and distance piece, straight pins, No.1 pressure pin, No.1 pressure spring, adjusting shim, capsule sub-assembly and adjusting shim.
Page 158 FUEL SYSTEM Injection Nozzles (1 HD-T) FU-19 (b) Using a wooden stick, remove the carbon adhering to the nozzle needle tip. (c) Using a brass brush, remove the carbon from the exterior of the nozzle body (except lapped surface). (d) Check the seat of the nozzle body for burns or corrosion.
Page 159 FU-20 FUEL SYSTEM - Injection Nozzles (1 HD-T) ASSEMBLY AND ADJUSTMENT OF INJECTION NOZZLES (Seepage FU-18) ADJUST PRE-LIFT NOTICE: Pre-lift adjustment requires great preci- sion, so when performing this operation, make sure everything is clean and that no foreign substances are trapped.
Page 160 FUEL SYSTEM - Injection Nozzles (1 HD-T) FU-21 Install SST to the dial indicator so that the protrusion shown in the illustration is 7.0 mm (0.276 in.) or less. SST 09268-17010 Set the dial indicator scale to 0 mm (0 in.) on top of SST or surface plate.
Page 161 FU-22 FUEL SYSTEM - Injection Nozzles (1 HD-T) Subtract the dimension £2 from the dimension £1. Pre-lift: 0.08 - 0.10 mm (0.0031 - 0.0039 in.) If the pre-lift dimension is not as specified, change the adjusting shim on the top of the capsule sub-assembly. HINT: If the shim is made thicker, the pre-lift is decreased.
Page 162 FUEL SYSTEM - Injection Nozzles (1 HD-T) FU-23 HINT: Align the holes of the nozzle body, distance piece and nozzle holder body. Using a 14 mm deep socket wrench, torque the retaining nut. Torque: 350 kg-cm (25 ft-lb, 34 N m) NOTICE: Over torquing could cause nozzle deforma- tion and needle adhesion or other defects.
Page 163 FU-24 FUEL SYSTEM - Injection Nozzles (1 HD-T) After checking the No.2 opening pressure, remove the capsule sub-assembly and tighten the plug screw with SST. SST 09268-17010 Torque: 25 kg-cm (21 in.-lb, 2.5 N-m) ADJUST NO.1 OPENING PRESSURE (a) Assemble the nozzle holder body, adjusting shim selected in step 1, the capsule sub- assembly, adjust- ing shim for adjustment of No.1 opening pressure, No.1 pressure spring, No.1 pressure pin, distance...
Page 164 FUEL SYSTEM - Injection Nozzles (1 HD-T) FU-25 Pump the tester handle slowly and observe the pres- sure gauge. Read the pressure gauge just as the injection pressure begins to drop. l\lo.1 opening pressure: 180-190 kg/cm (2,560-2,702 psi) (17,652-18,633 kPa) HINT: Proper nozzle operation can be determined by a swishing sound.
Page 165 FU-26 FUEL SYSTEM - Injection Nozzles (1 HD-T) INSTALLATION OF INJECTION NOZZLES (See page FU-17) INSTALL INJECTION NOZZLES (a) Install a new O-ring to the injection nozzle. (b) Install new nozzle seats into the injection nozzle hole of the cylinder head. (c) Install the injection nozzles with the washer, nozzle holder clamp and bolt.
Page 166: Injection Pump
FUEL SYSTEM - Injection Pump FU-27 INJECTION PUMP REMOVAL OF INJECTION PUMP...
Page 167 FU-28 FUEL SYSTEM Injection Pump (w/ACSD) DRAIN COOLANT (See page CO-5) REMOVE TIMING BELT (See steps 1 to 3 on pages EM-33 to 34) REMOVE NO.2 CAMSHAFT TIMING PULLEY (See step 5 on pages EM-34) DISCONNECT ACCELERATOR CONNECTING ROD (A/T) DISCONNECT THROTTLE CABLE (w/ A/C) DISCONNECT A/C IDLE-UP VACUUM HOSE...
Page 168 FUEL SYSTEM Injection Pump FU-29 (c) Before removing the injection pump, check if the period lines are aligned. If not, place new matchmarks for reinstallation. (d) Remove the two nuts holding the injection pump to the timing gear case. (e) Using SST, remove the injection pump. SST 09213-60017 (09213-00020, 09213-00030, 09213-00060) and 09950-20017 NOTICE:...
Page 169 FU-30 FUEL SYSTEM - Injection Pump COMPONENTS...
Page 170 FUEL SYSTEM - Injection Pump FU-31 COMPONENTS (Cont'd)
Page 171 FU-32 FUEL SYSTEM Injection Pump COMPONENTS (Cont'd)
Page 172 FUEL SYSTEM - Injection Pump FU-33 DISASSEMBLY OF INJECTION PUMP (See pages FU-30, 31 and 32) MOUNT PUMP ASSEMBLY TO SST (STAND) SST 09241 -76022 and 09245-54010 REMOVE SET KEY OF DRIVE PULLEY FROM DRIVE SHAFT (w/ A/C) REMOVE IDLE-UP ACTUATOR REMOVE TWO FUEL PIPES Place the matchmarks on the fuel inlet pipe and governor cover.
Page 173 FU-34 FUEL SYSTEM - Injection Pump (w/ PCS) REMOVE PCS ACTUATOR (a) Remove the PCS adjusting screw. (b) Remove the clip. (c) Using a 5 mm hexagon wrench, remove the two bolts and PCS actuator assembly. (w/ PCS) REMOVE NO.1 PCS LEVER Remove the nut and No.1 PCS lever.
Page 174 FUEL SYSTEM - Injection Pump FU-35 (d) Remove the fuel cut solenoid, O-ring, spring, valve, strainer and wave washer. 11. (w/TACHOMETER) REMOVE PICKUP SENSOR Remove the pickup sensor and O-ring. 12. REMOVE ADJUSTING LEVER (a) Place the matchmarks on adjusting lever and shaft. (b) Remove the nut, return spring guide, adjusting lever and return spring.
Page 175 Remove the following parts from the governor cover. (1) Adjusting lever shaft, O-ring and washer assembly (2) O-ring (3) Washer (1PZ(w/HAC) and1HZ(w/HAC)) DISASSEMBLE HIGH ALTITUDE COMPENSATOR Remove lever control spring Remove the bolt, gasket and lever control spring. Remove pneumatic bellows...
Page 176 FUEL SYSTEM - Injection Pump FU-37 (b) Remove the following parts: (1) Pneumatic bellows cover (2) Gasket (3) Shims NOTICE: Note the number of the shims. (4) Pneumatic bellows (5) Two rubber caps (6) Push rod (7) Pneumatic bellows spring Remove control lever (a) Using a 4 mm hexagon wrench, remove the two bolts and gaskets.
Page 177 FU-38 FUEL SYSTEM - Injection Pump 16. (1HD-T) DISASSEMBLE BOOST COMPENSATOR Remove lever control spring Remove the bolt, gasket and lever control spring. Remove boost compensator diaphragm (a) Using a 5 mm hexagon wrench, remove the four bolts. (b) Remove the following parts: (1) Diaphragm cover (2) Diaphragm (3) Spring...
Page 178 FUEL SYSTEM - Injection Pump FU-39 (b) Using a small screwdriver, push out the support pin and remove the control lever. (c) Using needle nose pliers, remove the connecting pin. NOTICE: Be careful not to damage the connecting pin. Tape the tip of the pliers. Remove ISIo.2 PCS lever Remove the following pars from the the governor cover.
Page 179 FU-40 FUEL SYSTEM Injection Pump 18. REMOVE GOVERNOR SHAFT AND FLYWEIGHT HOLDER (a) Remove the governor shaft lock nut by turning it clockwise. NOTICE: The governor shaft and lock nut have LH threads. (b) Using a 5 mm hexagon wrench, remove the governor shaft clockwise, and remove the following part: (1) Flyweight holder assembly (2) No.1 flyweight washer...
Page 180 FUEL SYSTEM - Injection Pump FU-41 21. REMOVE DELIVERY VALVE HOLDERS (a) Using SST, remove the delivery valve holders, springs and spring seats. SST 09260-5401 2 (09269-54020) (b) Remove the delivery valves and gaskets. NOTICE: Do not touch the sliding surfaces of the delivery valve with your hand.
Page 181 FU-42 FUEL SYSTEM Injection Pump (b) Remove the distributive head and following parts: (1) Two lever support springs (2) Two plunger spring guides (3) Two plunger spring shims (4) Two upper spring seats (5) Two plunger springs 23. REMOVE PUMP PLUNGER Using SST, remove the pump plunger and plunger adjust- ing shim together with the following parts: (1) Spill ring...
Page 182 26. REMOVE ROLLER RING AND DRIVE SHAFT (a) Remove the timer clip and stopper pin. (b) Push the slide pin toward inside. (c) (1PZ) Push the drive shaft, and remove the roller ring, three rollers and shims assembly. (1 HZ and 1HD-T) Push the drive shaft, and remove the roller ring, four rollers and shims assembly.
Page 183 FU-44 FUEL SYSTEM Injection Pump (d) Remove the drive shaft, governor drive gear, two joint rubbers assembly, set key and drive shaft washer. (e) Remove the drive gear and two joint rubbers from the drive shaft. 27. REMOVE TIMER (a) Using a 5 mm hexagon wrench, remove the four bolts. (b) Remove the following parts: (1) LH timer cover, timer adjusting screw and nut assembly...
Page 184 FUEL SYSTEM Injection Pump FU-45 28. REMOVE FUEL FEED PUMP (a) Remove the two screws. (b) Using a piece of wire, remove the feed pump cover. (c) Remove the feed pump rotor, four blades and liner. NOTICE: • Be careful not to interchange the blade positions. •...
Page 185 FU-46 FUEL SYSTEM - Injection Pump INSPECTION OF INJECTION PUMP COMPONENTS NOTICE: Do not touch the sliding surfaces of the pump plunger and delivery valves. INSPECT DELIVERY VALVES (IPZandiHZ) (a) Pull up the valve and close the hole at the valve seat bottom end with your thumb.
Page 186 FUEL SYSTEM - Injection Pump FU-47 INSPECT PUMP PLUNGER, SPILL RING AND DISTRIBUTIVE HEAD (a) Tilt the spill ring (distributive head) slightly and pull out the plunger. (b) When released, the plunger should sink down smoothly into the spill ring (distributive head) by its own weight.
Page 187 FU-48 FUEL SYSEM Injection Pump INSPECT ROLLER RING AND ROLLERS Using a dial indicator, measure the roller height. Roller height variation: 0.02 mm (0.0008 in.) If the variation is greater than specification, replace the roller ring and roller as a set. INSPECT FUEL CUT SOLENOID (a) Connect the solenoid valve body and terminal to the battery terminals.
Page 188 FUEL SYSTEM - Injection Pump FU-49 ASSEMBLY OF INJECTION PUMP (See pages FU-30, 31,32) MOUNT PUMP BODY TO SST (STAND) SST 09241 -76022 and 09245-54010 INSTALL FUEL INLET HOLLOW SCREW Install a new gasket and the hollow screw. Torque: 375 kg-cm (27 ft-lb, 37 Nm) INSTALL REGULATOR VALVE (a) Install the two O-rings to the regulator valve.
Page 189 FU-50 FUEL SYSTEM - Injection Pump INSTALL DRIVE SHAFT (a) Install the drive gear on the drive shaft as shown. (b) Install two new joint rubbers into the drive gear. (c) Position the key groove of the feed pump rotor upward.
Page 190 (b) Install the sub-piston into the timer piston. (c) Insert the timer piston into the pump housing. INSTALL ROLLER RING (a) (1PZ) Install the slide pin, three rollers and washers on the roller ring as shown in the illustration. (b) (1 HZ and 1HD-T) Install the slide pin, four rollers and washers on the roller ring.
Page 191 FU-52 FUEL SYSTEM Injection Pump (e) Install the stopper pin and clip. INSTALL TIMER SPRING (a) Install a new O-ring to the timer adjusting screw. (b) Using a 5 mm hexagon wrench, install the timer adjusting screw to the LH timer cover and temporarily install the nut.
Page 192 FUEL SYSTEM Injection Pump FU-53 (b) Using a 5 mm hexagon wrench, adjust the protrusion of the adjusting screw from the timer cover. 10. ADJUST PLUNGER SPRING SHIM (a) Install the following parts to the distributive head: (1) Two plunger spring guides (2) Two upper spring seats (3) Two plunger springs (4) Lower spring seat...
Page 193 FU-54 FUEL SYSTEM Injection Pump HINT: • For a measurement between listed sizes, use the next larger size. Ex. If thickness is 1.1 mm (0.043 in.) by calculation, use a 1.2 mm (0.047 in.) shim. • Select two shims which have the same thickness. 11.
Page 194 FUEL SYSTEM - Injection Pump FU-55 (g) Determine the plunger adjusting shim size by using the following formula and chart. New adjusting shim thickness = T + (B - 3.3) T ... Thickness of used shim B ... Measured plunger position Plunger adjusting shim selection chart EXAMPLE: The 2.4 mm (0.094 in.) shim is installed and measured clearance is 3.7 mm (0.146 in.).
Page 195 Torque: 140 kg-cm (10 ft-lb, 14 N-m) SST 09260-54012 (09269-54040) (b) Check that the governor link moves smoothly. 15. INSTALL PUMP PLUNGER (a) (1PZ) Place the previously used plunger adjusting shim on center of the camplate. (1 HZ and 1HD-T) Place the previously used plunger adjusting shim on the center of the camplate.
Page 196 FUEL SYSTEM - Injection Pump FU-57 (b) Install the following parts to the pump plunger: (1) Lower plunger plate (2) Upper plunger plate (3) Lower spring seat (4) Spill ring HINT: Face the spill ring with the hole facing the lower spring seat.
Page 197 (b) Install the spring seats and springs into the delivery valve holders. (c) Using SST, install the delivery valve holders. SST 09260-54012 (09269-54020) Torque: 1PZ and 1HZ 500 kg-cm (36 ft-lb, 49 IM-m) 1HD-T 550 kg-cm (40 ft-lb, 54 Nm) 18. (IPZonly) INSTALL DISTRIBUTIVE HEAD PLUG (a) Install a new O-ring to the head plug.
Page 198 FUEL SYSTEM Injection Pump FU-59 If the thrust clearance is not as specified, adjust with a governor gear adjusting washer. Governor gear adjusting washer thickness: 1.05 mm (0.0413 in.) 1.25 mm (0.0492 in.) 1.45 mm (0.0571 in.) 1.65 mm (0.0650 in.) 1.85 mm (0.0728 in.) 21.
Page 199 FU-60 FUEL SYSTEM - Injection Pump (c) Using a 4 mm hexagon wrench, install two new gaskets and the two bolts. 23. (1HD-T) ASSEMBLE BOOST COMPENSATOR Install No.2 overflow screw Install the No.2 overflow screw and cover. Install No.2 PCS lever Install the following parts to the governor cover: (1) Plate washer (2) O-ring...
Page 200 FUEL SYSTEM - Injection Pump FU-61 (c) Using a 4 mm hexagon wrench, install two new gaskets and the two bolts. 24. INSTALL ADJUSTING LEVER SHAFT TO GOVERNOR SHAFT Install the following parts to the governor cover: (1) Plate washer New O-ring (3) Adjusting lever shaft, O-ring and plate washer assembly...
Page 201 FU-62 FUEL SYSTEM - Injection Pump (b) Hook the return spring to the adjusting lever, and turn and place the adjusting lever on the governor shaft. (c) Align the lines of the adjusting lever shaft and adjust- ing lever. (d) Install the adjusting lever with the spring guide and nut.
Page 202 FUEL SYSTEM Injection Pump FU-63 28. (1HZand1HD-Tonly) ADJUST PLUNGER PRE-STROKE (a) Install SST to the fuel cut solenoid installation screw section. SST 09275-17010 (b) Set the dial indicator so that the tip of the dial indicator push rod touches the upper surface of the plunger.
Page 203 FU-64 FUEL SYSTEM - Injection Pump 29. (1HZand 1HD-T) INSTALL DISTRIBUTIVE HEAD PLUG (a) Install a new O-ring to the head plug. (b) Using SST, install the head plug. SST 09260-5401 2 (09262-54010) Torque: 1HZ 700 kg-cm (51 ft-lb, 69 Nm) 1HD-T 900 kg-cm (65 ft-lb, 88 Nm) 30.
Page 204 FUEL SYSTEM Injection Pump FU-65 Install lever control spring Install the lever control spring with a new gasket and the bolt. 31. (1HD-T) ASSEMBLE BOOST COMPENSATOR Install guide bushing Install and adjust the guide bushing to the dimension "A" as shown in the illustration. Dimension "A": Europe 19.2-19.3 mm (0.755- 0.760 in.) Others...
Page 205 FU-66 FUEL SYSTEM - Injection Pump (b) Adjust the installation direction of boost compensator diaphragm. (1) Install the shim and diaphragm. HINT: Do not assemble the spring. (2) While pushing on the diaphragm, measure dimen- sion " X " with vernier calipers as shown. Dimension "X": 6.9-7.1 mm (0.272-0.280 in.) HINT: Measure at the center of the hole.
Page 206 FUEL SYSTEM - Injection Pump FU-67 Install lever control spring Install the lever control spring with a new gasket and the bolt. 32. INSTALL FUEL CUT SOLENOID (a) Install a new O-ring on the fuel cut solenoid. (b) Install the strainer, valve, spring, a new gasket and the fuel cut solenoid.
Page 207 FU-68 FUEL SYSTEM - Injection Pump (b) Install the nut. 35. (w/ PCS) INSTALL PCS ACTUATOR (a) Using a 5 mm hexagon wrench, install the PCS actuator assembly with the two bolts. (b) Install the clip. (c) Install the PCS adjusting screw. 36.
Page 208 FUEL SYSTEM - Injection Pump FU-69 37. (w/ ACSD) INSTALL IDLE-UP LEVER Using a 5 mm hexagon wrench, install the idle-up lever with the three bolts. 38. (w/ A/C) INSTALL IDLE-UP ACTUATOR 39. REMOVE INJECTION PUMP FROM SST (STAND) SST 09241 -76022 and 09245-54010 40.
Page 209: Adjustment Of Injection Pump
FU-70 FUEL SYSTEM Injection Pump ADJUSTMENT OF INJECTION PUMP PRETEST CHECK AND PREPARATION (a) The specifications for test nozzle and nozzle holders are as follows. Test nozzle: DN12SD12 (NIPPONDENSO) Test nozzle opening pressure: 145-155 kg/cm (2,062- 2,205 psi, 14,220-15,200 kPa) (b) Check the accuracy of the tachometer.
Page 210 FUEL SYSTEM - Injection Pump FU-71 (h) Install the overflow hose with the overflow screw. HINT: Always use the overflow screw installed on the pump to be adjusted. Using a 5 mm hexagon wrench, remove the two bolts and RH timer cover. Install the inner pressure gauge with the timer mea- suring device.
Page 211 FU-72 FUEL SYSTEM Injection Pump (12 V type) Apply approx. 6 volts of DC power to the fuel cut solenoid. (m) (24 V type) Apply approx. 12 volts of DC power to the fuel cut solenoid. NOTICE: • When applying voltage to the solenoid, position the battery as far away from the solenoid as possible so that a spark does not occur.
Page 212 FUEL SYSTEM - Injection Pump FU-73 (q) Check the installation direction of the camplate as follow: • (1PZ) Disconnect the injection pipe from the position marked "A" on the distributive head. • (1 HZ and 1HD-T) Disconnect the injection pipe from the position marked "C"...
Page 213 FU-74 FUEL SYSTEM - Injection Pump (r) Bleed the air from the injection pipes. Race the injection pump for 5 minutes at 2,000 rpm. NOTICE: Check that there is no fuel leakage or ab- normal noise. HINT: • Measure the volume of each injection cylinder with a measuring cylinder.
Page 214 FU-75 PRESET FULL LOAD INJECTION VOLUME (a) Set the adjusting lever to maximum position. (b) (1PZ (w/ HAC) and 1 HZ (w/ HAC)) Apply 760 ± 1.5 mmHg (29.92 ± 0.06 in.Hg, 101.3 ± 0.2 kPa) absolute pressure. (1HD-T (w/o BACS)) Apply 0.81 kg/cm...
Page 215 FU-76 FUEL SYSTEM Injection Pump (w/o HIGH ALTITUDE) PRE-SETTING OF LOAD SENSING TIMER Using a 5 mm hexagon wrench, adjust the protrusion of the governor shaft. Protrusion: 0.5-2.0 mm (0.020-0.079 in.) PRESET MAXIMUM SPEED (a) Set the adjusting lever to maximum position. (b) (1 PZ (w/ HAC) and 1 HZ (w/ HAC)) Apply 760 ±...
Page 216 FUEL SYSTEM - Injection Pump FU-77 (b) If the pressure is low, adjust by lightly tapping the regulator valve piston while watching the pressure gauge. HINT: If the pressure is too high or if the regulator valve was tapped in too far, the regulator valve must be replaced. CHECK OVERFLOW VOLUME Measure the overflow volume at the below listed rpm.
Page 217 FU-78 FUEL SYSTEM Injection Pump (b) Measure the timer piston stroke at the below listed rpms. HINT: Check that the hysteresis is within 0.3 mm (0.012 in.) (c) Using a 5 mm hexagon wrench, adjust by the timer adjusting screw. HI NT: The stroke will decrease with turn to clockwise and increase with turn to counterclockwise.
Page 218 FUEL SYSTEM Injection Pump FU-79 (b) (1 PZ (w/ HAC) and 1 HZ (w/ HAC)) Apply 760 ± 1.5 mmHg (29.92 ± 0.06 in.Hg, 101.3 ± 0.2 kPa) absolute pressure. (1HD-T (w/o BACS)) Apply 081 kg/cm (11.5 psi, 79 kPa) of pressure to the boost compensator.
Page 219 No.1 PCS lever and adjusting screw at least 3 mm (0.12 in.). 11. ADJUST MAXIMUM SPEED (a) (1PZ (w/HAC) and 1HZ (w/HAC)) Apply 760 ± 1.5 mmHg (29.92 ± 0.06 in.Hg, 101.3 ± 0.2 kPa) absolute pressure. (b) (1HD-T (w/o BACS)) Apply 0.81 kg/cm...
Page 220 FUEL SYSTEM Injection Pump FU-81 Adjust by turning the maximum speed adjusting screw. 12. CHECK INJECTION VOLUME (a) (1 PZ (w/ HAC) and 1 HZ (w/ HAC)) Apply 760 ± 1.5 mmHg (29.92 ± 0.06 in.Hg, 101.3 ± 0.2 kPa) absolute pressure. (1PZand1HZ) Measure the injection volume at each pump rpm.
Page 221 FU-82 FUEL SYSTEM Injection Pump (1HD-T (w/ PCS)) Apply vacuum to the PCS actuator. (d) (1HD-T) Measure the injection volume at each pump rpm and boost pressure. If the injection volume at 100 rpm is not as specified, replace the governor sleeve plug as follows: •...
Page 222 FUEL SYSTEM - Injection Pump FU-83 • Measure the head thickness of the sleeve plug, and select a new sleeve plug. HINT: Lengthening the plug 0.1 mm (0.004 in.) will decrease injection volume by 0.6 cc (0.04 cu in.). • Install the following parts to the new sleeve plug with a new E-ring: (1) Bearing and two retainers (2) Stop ring...
Page 223 FU-84 FUEL SYSTEM Injection Pump 13. (1HD-T) ADJUST FULL LOAD MINIMUM INJECTION VOLUME (a) Measure the injection volume. (b) Using a hexagon wrench, adjust the tinner slide pin. 14. (1HD-T) ADJUST BOOST COMPENSATOR CHARACTERISTIC (a) Apply pressure to the boost compensator. (b) Measure the injection volume bushing.
Page 224 FUEL SYSTEM Injection Pump FU-85 15. (1HD-T) INSPECT BOOST COMPENSATOR CHARACTERISTIC TENDENCY (a) Apply pressure to the boost compensator. (b) Measure injection volume. 16. (1HD-T) CHECK HYSTERESIS (w/o BACS) Compare the injection volume when the boost compensa- tor pressure is lowered from 0.81 kg/cm (11.5 psi, 79 kPa) to 0 kg/cm (0 psi, 0 kPa) and, conversely, when it is...
Page 225 FU-86 FUEL SYSTEM Injection Pump Cont'd If not within standard value, check each sliding part of the boost compensator and check whether or not there is any oil. 17. (w/o HIGH ALTITUDE) ADJUST LOAD SENSING TIMER (a) Using a 5 mm hexagon wrench, adjust the starting and end points of the load sensing timer by turning the governor shaft.
Page 226 FUEL SYSTEM - Injection Pump FU-87 Using a 5 mm hexagon wrench, adjust by turning the governor shaft, and perform the measurement again it is as specified. HINT: The injection volume will increase approx. 3 cc (0.2 cu in.) with each 1 /2 turn of the governor shaft. (1PZand1HZ) Check the end point injection volume by slowly moving the adjusting lever from the maximum speed...
Page 227 FU-88 FUEL SYSTEM Injection Pump (n) Check the protrusion of the governor shaft. Protrusion: 0.5-2.0 mm (0.020-0.079 in.) 18. ADJUST IDLE SPEED (a) (w/ Dash Pot) Using pliers, remove the dash pot cover. (b) (w/ Dash Pot) Fully loosen the dash pot adjusting screw. (c) Measure the injection volume for each pump rpm.
Page 228 FUEL SYSTEM Injection Pump FU-89 Cont'd (d) Adjust by turning the idle speed adjusting screw. (e) (w/ Dash Pot) Set the adjusting lever to the angle for the injection volume shown below. (w/ Dash Pot) Adjust the injection volume with the dash pot adjust- ing screw.
Page 229 FU-90 FUEL SYSTEM - Injection Pump (g) (w/ Dash Pot) Install the dash pot cover. 19. (w/ACSD) ADJUST COLD STARTING SYSTEM (a) Remove the overflow screw and check the fuel tem- perature in the fuel pump. Fuel temperature: 15 - 35°C (59 - 95 ° F) (b) Set the set key of the pump drive shaft in a vertical or horizontal position.
Page 230 FUEL SYSTEM - Injection Pump FU-91 (h) Adjust by turning the timer adjusting screw. HINT: Screw in for stroke decrease. 20. (w/ ACSD) ADJUST FAST IDLE (a) Measure the clearance between the adjusting lever and idle speed adjusting screw. (b) Adjust by turning the fast idle adjusting screw. 21.
Page 231 FU-92 FUEL SYSTEM - Injection Pump (b) Check the adjusting lever movement. Adjusting lever angle: 38-48° 22. SEAL PARTS Seal the maximum speed adjusting screw and full load set screws with new lead seals. 23. INSTALL TWO FUEL PIPES Torque: Inlet 250 kg-cm (18 ft-lb, 25 N m ) Outlet 225 kg-cm (16 ft-lb, 22 N m )
Page 232 NOTICE: Do not put the injection pump (with HAC, or for the 1 HD-T) at an angle more than 45° from the horizontal. (a) (1PZ and 1 HZ (M/T for Europe)) Place the cylinder block insulator in position. (b) Install a new O-ring to the pump.
Page 233 FU-94 FUEL SYSTEM - Injection Pump (h) Install a new O-ring to the injection pump drive gear. (i) Install the injection pump drive gear set nut. (j) Using SST, torque the nut. SST 09330-00021 Torque: 1,000 kg-cm (72 ft-lb, 98 Nm) CHECK INJECTION TIMING (See page EM-24) INSTALL INJECTION PIPES (See step 3 on page FU-15)
Page 234 FUEL SYSTEM - Power Control System (PCS) (HDB30 (w/ M/T) only) FU-95 15. FILL WITH ENGINE COOLANT (See page CO-5) 16. START ENGINE AND CHECK FOR FUEL LEAKS 17. CHECK IDLE SPEED AND MAXIMUM SPEED (See page EM-27) POWER CONTROL SYSTEM (PCS) (HDB30(w/ M/T) only) ON-VEHICLE INSPECTION INSPECT POWER CONTROL SYSTEM (PCS)
Page 235 FU-96 FUEL SYSTEM Power Control System (PCS) (HDB30 (w/ M/T) only) Inspect VSV operation (a) Check that air flows from pipes E to the filter. (b) Apply battery voltage across the terminals. (c) Check that air flows from pipe E to F. If operation is not as specified, replace the VSV.
Page 236 CO-1 COOLING SYSTEM Page DESCRIPTION CO-2 TROUBLESHOOTING CO-4 CHECK AND REPLACEMENT OF ENGINE COOLANT CO-4 WATER PUMP CO-6 THERMOSTAT CO-10 RADIATOR CO-12...
Page 237 CO-2 COOLING SYSTEM - Description DESCRIPTION This engine utilizes a pressurized water forced circulation cooling system which includes a thermostat equipped with a by-pass valve mounted on the inlet side. IPZ and 1HZ From Heater To Heater Thermostat Radiator 1HD-T From Heater To Heater Radiator...
Page 238 COOLING SYSTEM - Description CO-3 RESERVOIR TANK The cooling system is composed of the water jacket (inside the cylinder block and cylinder head), The reservoir tank is used to catch coolant which radiator, water pump, thermostat, cooling fan, overflows the cooling system as a result of volu- hoses and other components.
Page 239: Engine Coolant
CO-4 COOLING SYSTEM Troubleshooting, Check and Replacement of Engine Coolant TROUBLESHOOTING Engine overheats Fan belt loose or missing Adjust or replace belts CH-5 Dirt, leaves or insects on radiator or Clean radiator or condenser CO-12 condenser Hoses, water pump, thermostat housing, Repair as necessary radiator, heater, core plugs or head gasket leakage...
Page 240 COOLING SYSTEM - Check and Replacement of Engine Coolant CO-5 (d) Fill the system with coolant. Use a good brand of ethylene-glycol or TOYOTA radiator conditioner or equivalent anticorrosive, mixed according to the manufacturer's directions. Ethylene-glycol type: This type has an antifreeze and anticorrosive effect.
Page 241: Water Pump
CO-6 COOLING SYSTEM Water Pump WATER PUMP COMPONENTS Camshaft Oil Seal Retainer No.2 Turbo Water Pipe Alternator Adjusing Bar 200(14,20) 200(14,20) 400 (29, 39) Drive Belt Gasket Water Pump 200(14,20) Water Pump Pulley w/o Fluid Coupling w/ Fluid Coupling Fan Spacer 200 (14,20) Fluid Coupling 200(14,20)
Page 242 CO-7 COOLING SYSTEM - Water Pump REMOVAL OF WATER PUMP (See page CO-6) DRAIN ENGINE COOLANT (See page CO-5) REMOVE DRIVE BELT, FAN AND WATER PUMP PULLEY (a) Stretch the belt tight and loosen the four pump pulley set nuts. (b) Loosen the pivot bolt, lock bolt and adjusting bolt, CO0957 and remove the drive belt.
Page 243 CO-8 COOLING SYSTEM - Water Pump INSPECTION OF WATER PUMP INSPECT WATER PUMP Turn the pulley and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. CO0927 INSPECT FLUID COUPLING Check the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling.
Page 244 CO-9 COOLING SYSTEM - Water Pump INSTALL WATER PUMP PULLEY, FAN AND DRIVE BELT (a) Install the pump pulley, the fluid fan and coupling (fan spacer) assembly with the four nuts. (b) Place the drive belt on each pulley. (c) Stretch the belt tight and torque the four nuts. Torque: 200 kg-cm (14 ft-lb, 20 N-m) (d) Adjust the drive belt deflection.
Page 245 CO-10 COOLING SYSTEM - Thermostat THERMOSTAT REMOVAL OF THERMOSTAT DRAIN ENGINE COOLANT (See page CO-5) REMOVE WATER INLET Remove the three bolts and water inlet from the water inlet housing. REMOVE THERMOSTAT CO0948 INSPECTION OF THERMOSTAT INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve open- ing temperature.
Page 246 COOLING SYSTEM - Thermostat CO-11 INSTALLATION OF THERMOSTAT PLACE THERMOSTAT IN CYLINDER BLOCK (a) Install a new gasket to the thermostat. (b) Install the thermostat with the jiggle valve upward. INSTALL WATER INLET TO CYLINDER BLOCK Install the water inlet with the three bolts. Torque: 200 kg-cm (14 ft-lb, 20 N-m) NOTICE: Torque the two upper bolts first.
Page 247 CO-12 COOLING SYSTEM Radiator RADIATOR CLEANING OF RADIATOR 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. If the cleaner nozzle pressure is 30-35 kg/cm (427-498 psi, 2,942-3,432 kPa), keep a distance of at least...
Page 248 LU-1 LUBRICATION SYSTEM Page DESCRIPTION LU-2 TROUBLESHOOTING LU-4 OIL PRESSURE CHECK LU-5 REPLACEMENT OF ENGINE OIL AND OIL FILTER LU-6 OILPUMP LU-8 OIL COOLER, RELIEF VALVE AND CHECK VALVE LU-15 OIL NOZZLES AND CHECK VALVES LU-20...
Page 249 LU-2 LUBRICATION SYSTEM - Description DESCRIPTION A fully pressurized, fully filtered lubrication system has been adopted for this engine.
Page 250 LUBRICATION SYSTEM Description LU-3 A pressure feeding lubrication system has been OIL FILTER adopted to supply oil to the moving parts of this The oil filter is a full flow type filter with a built-in engine. The lubrication system consists of an oil paper filter element.
Page 251 LU-4 LUBRICATION SYSTEM - Troubleshooting TROUBLESHOOTING •...
Page 252: Oil Pressure Check
LUBRICATION SYSTEM Oil Pressure Check LU-5 OIL PRESSURE CHECK CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is poor, replace the oil. Use API grade CD or better and recommended viscosity oil. (Europe) Use API grade CC, CD or better and recommended viscos- ity oil.
Page 253 LU-6 LUBRICATION SYSTEM - Replacement of Engine Oil and Oil Filter REPLACEMENT OF ENGINE OIL AND OIL FILTER NOTICE: • Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harm- ful contaminants which may cause skin cancer.
Page 254 LUBRICATION SYSTEM Replacement of Engine Oil and Oil Filter LU-7 Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. Using SST, tighten it additional 3/4 turn. SST 09228-10001 FILL WITH ENGINE OIL Clean and install the oil drain plug with a new gasket.
Page 255: Oil Pump
LU-8 LUBRICATION SYSTEM - Oil Pump OIL PUMP COMPONENT...
Page 256 (See steps 1 to 12 on pages EM-43 to 45) REMOVE OIL PAN (a) Remove the twenty-three bolts (1PZ) or twenty- seven bolts (1 HZ and IHD-T) and three nuts. (b) Insert the blade of SST between the cylinder block and oil pan, cut off applied sealer and remove the oil pan.
Page 257: Disassembly Of Oil Pump
LU-10 LUBRICATION SYSTEM - Oil Pump (c) Remove the seven bolts, timing gear case and gasket. (d) Using a plastic-faced hammer, lightly tap out the timing gear case. (e) Remove the gasket. DISASSEMBLY OF OIL PUMP REMOVE DRIVEN ROTOR REMOVE RELIEF VALVE Remove the plug, gasket, spring and relief valve.
Page 258 LUBRICATION SYSTEM - Oil Pump LU-11 INSPECTION OF OIL PUMP INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve. If necessary, replace the oil pump assembly.
Page 259 LU-12 LUBRICATION SYSTEM - Oil Pump ASSEMBLY OF OIL PUMP (See page LU-8) INSTALL DRIVEN ROTOR INSTALL RELIEF VALVE (a) Insert the relief valve and spring into the installation hole of the timing gear case. (b) Install a new gasket and the plug. Torque: 425 kg-cm (31 ft-lb, 42 N-m) INSTALLATION OF OIL PUMP (See page LU-8)
Page 260 LUBRICATION SYSTEM - Oil Pump LU-13 (d) Install the timing gear case with the seven bolts. Torque: 200 kg-cm (14 ft-lb, 20 N-m) (e) Install the two nuts holding the injection pump to the timing gear case. Torque: 185 kg-cm (13 ft-lb, 18 N-m) Check that the injection pump period lines (or match- marks) are aligned.
Page 261 LU-14 LUBRICATION SYSTEM - Oil Pump INSTALL OIL STRAINER Install a new gasket and the oil strainer with the two bolts and two nuts. Torque: 90 kg-cm (78 in.-lb, 8.8 N m ) INSTALL OIL PAN (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and cylinder block.
Page 262: Check Valve
LUBRICATION SYSTEM Oil Cooler. Relief Valve and Check Valve LU-15 OIL COOLER, RELIEF VALVE AND CHECK VALVE COMPONENTS...
Page 263 LU-16 LUBRICATION SYSTEM - Oil Cooler, Relief Valve and Check Valve REMOVAL OF OIL COOLER, RELIEF VALVE AND CHECK VALVE (See page LU-15) DRAIN ENGINE COOLANT (See page CO-4) REMOVE OIL FILTER (Seepage LU-6) REMOVE INJECTION PUMP (See page FU-27) REMOVE OIL DIPSTICK AND GUIDE (a) Remove the two bolts, oil dipstick and guide.
Page 264 LUBRICATION SYSTEM Oil Cooler, Relief Valve and Check Valve LU-17 REMOVE ENGINE DRAIN COCK INSPECTION OF OIL COOLER, RELIEF VALVE AND CHECK VALVE INSPECT RELIEF VALVE Push the valve with a wooden stick to check if it is stuck. If stuck, replace the relief valve. INSPECT CHECK VALVE Push the valve with a wooden stick to check if it is stuck.
Page 265 LU-18 LUBRICATION SYSTEM - Oil Cooler, Relief Valve and Check Valve INSTALLATION COOLER, RELIEF VALVE AND CHECK VALVE (See page LU-15) INSTALL ENGINE DRAIN COCK (a) Apply adhesive to two or three threads of the drain cock. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (b) Install and torque the drain cock as shown.
Page 266 LUBRICATION SYSTEM - Oil Cooler, Relief Valve and Check Valve LU-19 INSTALL OIL COOLER AND OIL COOLER COVER ASSEMBLY Install a new gasket, the oil cooler and oil cooler cover assembly with the thirteen bolts and two nuts. Torque: 200 kg-cm (14 ft-lb, 20 N-m) INSTALL OIL DIPSTICK GUIDE AND DIPSTICK (a) Install a new O-ring to the oil dipstick guide.
Page 267 LU-20 LUBRICATION SYSTEM - Oil Nozzles and Check Valves OIL NOZZLES AND CHECK VALVES COMPONENTS REMOVAL OF OIL NOZZLES AND CHECK VALVES DRAIN ENGINE OIL (See page LU-6) REMOVE OIL PAN (See step 4 on page LU-9) REMOVE CHECK VALVE AND OIL NOZZLES Remove the five (1 PZ) or six (1 HZ and 1HD-T) check valves and oil nozzles.
Page 268 (a) Align the pin of the oil nozzle with the pin hole of the cylinder block. (b) Install the oil nozzle with the check valve. Install the five (1PZ) or six (1HZ and 1HD-T) oil nozzles and check valves. Torque: 275 kg-cm (20 ft-lb, 27 Nm)
Page 269 ST-1 STARTING SYSTEM Page PRE-HEATING SYSTEM ST-2 Super Glow Type (Europe and Australia) ST-2 Fixed Delay Type (HZJ80 and HDJ80) ex. (Europe and Australia) ST-9 Fixed Delay Type (PZJ, HZJ75, HZB and HDB) ex. (Europe and Australia) ST-11 TROUBLESHOOTING ST-13 STARTING SYSTEM CIRCUIT ST-13 STARTER...
Page 270 ST-2 STARTING SYSTEM - Pre-Heating System (Super Glow Type) PRE-HEATING SYSTEM Super Glow Type (Europe and Australia) SYSTEM CIRCUIT...
Page 271 STARTING SYSTEM - Pre-Heating System (Super Glow Type) ST-3 SYSTEM CIRCUIT (Cont'd) INSPECTION OF PRE-HEATING SYSTEM HINT: Refer to Diesel Electrical System Diagnosis inspection procedures. (See page EM-14) TIMER CHARACTERISTIC DIAGRAM...
Page 272 ST-4 STARTING SYSTEM - Pre-Heating System (Super Glow Type) TIMER CHARACTERISTIC DIAGRAM (Cont'd)
Page 273 STARTING SYSTEM - Pre-Heating System (Super Glow Type) ST-5 INSPECTION OF COMPONENTS Pre-Heating Timer LOCATION: PZJ, HZJ, HDJ Under the instrument panel on the pas- senger side. HZB, HDB Under the instrument panel center. INSPECT PREHEATING TIMER CIRCUIT Disconnect the connector from the pre-heating timer, and check the connector on the wire harness side as shown in the following chart.
Page 274 ST-6 STARTING SYSTEM - Pre-Heating System (Super Glow Type) INSPECT RELAY OPERATION (a) Apply battery voltage across terminals E and g. (b) Using an ohmmeter, check that there is continuity between terminals B and G. If operation is not as specified, replace the relay. No.2 Glow Plug Relay (PZJ, HZJ and HDJ) LOCATION: In the engine compartment on the left side.
Page 275 STARTING SYSTEM Pre-Heating System (Super Glow Type) ST-7 INSPECT RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals E and g. (b) Check that there is no continuity between terminals B and G. If continuity is not as specified, replace the relay. INSPECT RELAY OPERATION (a) Apply battery voltage across terminals E and g.
Page 276 ST-8 STARTING SYSTEM - Pre-Heating System (Super Glow Type) Water Temperature Sensor INSPECT TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the sensor terminals. Resistance: Refer to chart If the resistance is not as specified, replace the sensor.
Page 277 STARTING SYSTEM - Pre-Heating System (Fixed Delay Type) ST-9 Fixed Delay Type (HZJ80 and HDJ80) ex. (Europe and Australia) SYSTEM CIRCUIT INSPECTION OF PREHEATING SYSTEM INSPECT LIGHTING TIME OF GLOW INDICATOR LIGHT Turn the starter switch "ON", measure the lighting time. Light lighting time: Approx.
Page 278 ST-10 STARTING SYSTEM - Pre-Heating System (Fixed Delay Type) INSPECTION OF COMPONENTS Pre-Heating Timer INSPECT PREHEATING TIMER CIRCUIT LOCATION: Under the instrument panel on the passenger side. Disconnect the connector from the pre-heating timer, and check the connector on the wire harness side as shown in the following chart.
Page 279 STARTING SYSTEM Pre-Heating System (Fixed Delay Type) ST-11 Fixed Delay Type (PZJ, HZJ75, HZB and HDB) ex. (Europe and Australia) SYSTEM CIRCUIT...
Page 280: Glow Plug
ST-12 STARTING SYSTEM - Pre-Heating System (Fixed Delay Type) INSPECTION OF PREHEATING SYSTEM INSPECT LIGHTING TIME OF GLOW INDICATOR LIGHT Turn the starter switch "G", measure the lighting time. Light lighting time: 12V type Approx. 6 seconds 24 V type Approx. 5 seconds INSPECTION OF COMPONENTS Pre-Heating Timer INSPECT PREHEATING TIMER CIRCUIT...
Page 281 STARTING SYSTEM Troubleshooting, Starting System Circuit ST-13 TROUBLESHOOTING STARTING SYSTEM CIRCUIT...
Page 282 ST-14 STARTING SYSTEM - Starting System Circuit STARTING SYSTEM CIRCUIT (Cont'd)
Page 283 STARTING SYSTEM Starter ST-15 STARTER COMPONENTS DISASSEMBLY OF STARTER REMOVE FIELD FRAME AND ARMATURE (a) Remove the nut and spring washer, and disconnect the lead wire from the magnetic switch terminal. (b) Remove the two through bolts, spring washers, plate washers and O-rings.
Page 284 ST-16 STARTING SYSTEM - Starter (b) Remove the following parts from the magnetic switch: (1) Starter housing and clutch assembly (2) Return spring (3) Plate washer (4) Idler gear (5) Bearing REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole.
Page 285 STARTING SYSTEM - Starter ST-17 INSPECTION AND REPAIR OF STARTER Armature Coil INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity, replace the armature. INSPECT COMMUTATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the commutator and armature coil core.
Page 286 ST-18 STARTING SYSTEM Starter INSPECT UNDERCUT DEPTH Check that the undercut depth is clean and free of foreign material. Smooth out the edge. Standard undercut depth: 0.7-0.9 mm (0.028-0.035 in.) Minimum undercut depth: 0.2 mm (0.008 in.) If the undercut depth is less than minimum, correct it with a hacksaw blade.
Page 287 STARTING SYSTEM - Starter ST-19 Brush Holder INSPECT BRUSH HOLDER INSULATION Using an ohmmeter, check that there is no continuity between the positive ( + ) and negative (-) brush holders. If there is continuity, repair or replace the brush holder. Clutch and Gears INSPECT GEAR TEETH Check the gear teeth on the pinion gear, idler gear and the...
Page 288 ST-20 STARTING SYSTEM - Starter (d) Disassembly the following parts: (1) Stop collar (2) Pinion gear (3) Retainer (4) Compression spring (5) Starter housing (6) Starter clutch (7) Compression spring (8) Clutch shaft Assemble starter housing and clutch assembly (a) 1st, assemble the following parts: (1) Clutch shaft (2) Compression spring (3) Starter clutch...
Page 289 STARTING SYSTEM - Starter ST-21 (g) Using a plastic-faced hammer, tap the clutch shaft and install the stop collar onto the snap ring. Bearings INSPECT BEARINGS Turn each bearing by hand while applying inward force. If resistance is felt or if the bearing sticks, replace the bearing.
Page 290 ST-22 STARTING SYSTEM - Starter Magnetic Switch PERFORM PULL-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, replace the magnetic switch. PERFORM HOLD-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminal 50 and the switch body.
Page 291 STARTING SYSTEM - Starter ST-23 (c) Install the end cover with the two screws. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE (a) Apply grease to the steel ball. (b) Insert the steel ball into the clutch shaft hole. INSTALL GEAR, CLUTCH ASSEMBLY AND STARTER HOUSING (a) Apply grease to the return spring.
Page 292 ST-24 STARTING SYSTEM - Starter INSTALL FIELD FRAME AND ARMATURE ASSEMBLY (a) Install a new felt washer to the armature. (b) Install the lock plate to the cutout portion of the magnetic switch. (c) Align the lock plate with the cutout portion of the field frame.
Page 293 STARTING SYSTEM - Starter ST-25 PERFORMANCE TEST OF STARTER NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. PERFORM PULL-IN TEST (a) Disconnect the field coil lead wire from terminal C. (b) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward.
Page 294 ST-26 STARTING SYSTEM Starter Relay (PZJ, HZJ and HDJ) STARTER RELAY (PZJ, HZJ and HDJ) LOCATION: In the engine compartment on the left side. INSPECTION OF STARTER RELAY INSPECT RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals E and ST.
Page 295 STARTING SYSTEM Starter Relay (HZB and HDB) ST-27 STARTER RELAY (HZB and HDB) LOCATION: Inside wall adjacent to center door. INSPECTION OF STARTER RELAY INSPECT RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals E and ST. (b) Check that there is no continuity between terminals B and MG.
Page 296 ST-28 STARTING SYSTEM - Voltage Converter Timer VOLTAGE CONVERTER TIMER (HZJ80 and HDJ80) (w/ 24 V Starter) LOCATION: In the cowl on the passenger's side. INSPECTION OF VOLTAGE CONVERTER TIMER INSPECT VOLTAGE CONVERTER TIMER Disconnect the connector from the voltage converter timer, and check the connector on the wire harness side as shown in the following chart.
Page 297 STARTING SYSTEM - Voltage Converter Relay ST-29 VOLTAGE CONVERTER RELAY (HZJ80and HDJ80) (w/24 V Starter) LOCATION: In the engine compartment on the left side. INSPECTION OF VOLTAGE CONVERTER RELAY INSPECT RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals e and g.
Page 298 ST-30 STARTING SYSTEM - 24 V Hold Warning Relay 24 V HOLD WARNING RELAY (HZJ80and HDJ80) (w/ 24 V Starter) LOCATION: In the driver's cowl side. INSPECTION OF 24 V HOLD WARNING RELAY INSPECT RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 3.
Page 299 CH-1 CHARGING SYSTEM Page PRECAUTIONS CH-2 TROUBLESHOOTING CH-2 CHARGING SYSTEM CIRCUIT CH-3 ON-VEHICLE INSPECTION CH-5 ALTERNATOR CH-8...
Page 300 CH-2 CHARGING SYSTEM - Precautions, Troubleshooting PRECAUTIONS Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests w i t h a high voltage insulation resistance tester.
Page 301 CHARGING SYSTEM - Charging System Circuit CH-3 CHARGING SYSTEM CIRCUIT PZJ 70, 73, 75 and HZJ 70, 73, 75 Starter Switch Fuse ENGINE 1.25B (w/o Tachometer) (w/ Tachometer) Battery Stator Coil Fuse Battery (24 V Type) 7.5A Rotor Coil Alternator HZJ 80 and HDJ 80 Starter Switch Fuse...
Page 302 CH-4 CHARGING SYSTEM - Charging System Circuit CHARGING SYSTEM CIRCUIT (Cont'd) HZB 30 and HDB 30 Starter Switch Fuse ENGINE 1.0Y Fuse GAUGE 7.5A MAIN 2.0L Battery Stator Coil Fuse Battery 7.5A (24 V Type) Rotor Coil Alternator...
Page 303 CHARGING SYSTEM On-Vehicle Inspection CH-5 ON-VEHICLE INSPECTION Upper Level INSPECT BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL (a) Check the specific gravity of each cell. Standard specific gravity: When fully charged at 20°C (68°F) 1.25-1.27 (ex. (95D31 R and 95D31L)) Lower 1.27 -1.29 (95D31R and 95D31L) Level If not as specified, charge the battery.
Page 304 CHARGING SYSTEM - On-Vehicle Inspection CH-6 (c) (Reference) Using SST, measure the drive belt tension. SST 09216-00020 and 09216-00030 Drive belt tension: New belt 45-55 kg Used belt 20-35 kg If the belt tension is not as specified, adjust it. EC0003 EC0004 VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES...
Page 305 CHARGING SYSTEM - On-Vehicle Inspection CH-7 (b) Check the charging circuit as follows: With the engine running from idling to 2,000 rpm, 26.0 28.7 V 13.5 15.0V check the reading on the ammeter and voltmeter. 10 A Standard amperage: 10 A or less Standard voltage: 12 V type 14.0-15.0 V at 25°C (77°F)
Page 306 CH-8 CHARGING SYSTEM Alternator ALTERNATOR COMPONENTS Type A Retainer Drive End Frame (Stator) Pulley Alternator Washer Bearing cover Rear Bearing Rotor Rear End Cover Front Bearing Terminal Insulator Seal Plate Rectifier End Frame Brush Holder Cover Brush Holder IC Regulator Rectifier Holder Type B Rubber Insulator...
Page 307 CHARGING SYSTEM - Alternator CH-9 DISASSEMBLY OF ALTERNATOR (See page CH-8) REMOVE REAR END COVER (a) (PZJ, HZJ and HDJ) Remove the nut, condenser lead wire and terminal insulator. (b) (HZB and HDB) Remove the nut and terminal insulator. CH0846 (c) Remove the three nuts and end cover.
Page 308 CH-10 CHARGING SYSTEM - Alternator (b) Remove the four rubber insulator. CH0852 (c) (Type A) Type A Remove the seal plate. CH0854 REMOVE PULLEY (a) Hold SST (A) with a torque wrench, and tighten SST SST (B) (B) clockwise to the specified torque. SST 09820-63010 Torque: 400 kg-cm (29 ft-lb, 39 N-m) (b) Check that SST (A) is secured to the rotor shaft.
Page 309 CH-11 CHARGING SYSTEM - Alternator (c) Using SST, remove the rectifier end frame. SST 09286-46011 CH0870 (d) (Type A) Type A Remove the alternator washer. CH0879 REMOVE ROTOR FROM DRIVE END FRAME CH0851...
Page 310 CH-12 CHARGING SYSTEM - Alternator INSPECTION AND REPAIR OF ALTERNATOR Rotor INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between Ohmmeter the slip rings. Standard resistance (cold): 12VType 2.7-3.1 Q 24 V Type 1.0-1.4Q Continuity If there is no continuity, replace the rotor.
Page 311 CHARGING SYSTEM - Alternator CH-13 Brushes Type A INSPECT EXPOSED BRUSH LENGTH Using vernier calipers or scale, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brushes and brush holder assembly (Type A) or brushes (Type B).
Page 312 CHARGING SYSTEM - Alternator CH-14 (b) Reverse the polarity of the tester probes and repeat Ohmmeter step (a). (c) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. CH0466 INSPECT NEGATIVE SIDE RECTIFIER Ohmmeter...
Page 313 CH-15 CHARGING SYSTEM - Alternator (b) Using a press and socket wrench, press out the front Socket Wrench bearing. CH0856 (c) Using SST and a press, press in a new bearing. SST 09608-20012 (09608-00030) CH0880 (d) Install the bearing retainer with the four screws. CH0868 INSPECT REAR BEARING Check that the bearing is not rough or worn.
Page 314 CH-16 CHARGING SYSTEM - Alternator (b) Using SST and a press, press in a new bearing and bearing cover. SST 09285-76010 CH0201 ASSEMBLY OF ALTERNATOR (See page CH-8) INSTALL ROTOR TO DRIVE END FRAME Pulley (a) Place the rectifier end frame on the pulley. (b) Install the rotor to the rectifier end frame.
Page 315 CHARGING SYSTEM Alternator CH-17 INSTALL PULLEY (a) Install the pulley to the rotor shaft by tightening the pulley nut by hand. (b) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63010 Torque: 400 kg-cm (29 ft-lb, 39 Nm) (c) Check that SST (A) is secured to the pulley shaft.
Page 316 CHARGING SYSTEM - Alternator CH-18 INSTALL IC REGULATOR AND BRUSH HOLDER Type A (Type A) Upward (a) Place on the IC regulator and brush holder on the rectifier end frame. NOTICE: Be careful about the holder installation di- rection. (b) Install the five screws until there is a clearance of approx.
Page 317 CHARGING SYSTEM - Alternator CH-19 INSTALL REAR END COVER (a) Install the rear end cover with the three nuts. CH0845 (b) (PZJ, HZJ and HDJ) Install the terminal insulator, condenser lead wire with nut. (c) (HZB and HDB) Install the terminal insulator with the nut. CH0846 CHECK THAT ROTOR ROTATES SMOOTHLY CH0836...
Page 318: Service Specifications
SERVICE SPECIFICATIONS Page ENGINE MECHANICAL TURBOCHARGER SYSTEM FUEL SYSTEM COOLING SYSTEM A-21 LUBRICATION SYSTEM A-21 STARTING SYSTEM A-22 CHARGING SYSTEM A-22...
Page 319 SERVICE SPECIFICATIONS Engine Mechanical ENGINE MECHANICAL Specifications Engine tune-up Coolant capacity w/o Heater 9.6 liters 1O.1USqts 8.4 Imp. qts PZJ70, 73, 75 HZJ70, 73, 75 9.9 liters 10.5 US qts 8.7 Imp. qts 9.7 liters 10.3 US qts 8.5 Imp. qts HZJ80and HDJ80 10.4 liters 11.0 US qts...
Page 320 SERVICE SPECIFICATIONS - Engine Mechanical Specification (Cont'd) Engine tune-up 0.1 5 - 0.25 mm 0.006 - 0.010 in. Valve clearance Intake (cont'd) Exhaust 0.35 - 0.45 mm 0.014 - 0.018 in. New valve adjusting shim thickness 2.35 mm 0.0925 in. 2.40 mm 0.0945 in.
Page 321 SERVICE SPECIFICATIONS - Engine Mechanical Specifications (Cont'd) Cylinder head Warpage Limit 0.20 mm 0.0079 in. Valve seat Refacing angle Intake 25°, 45°, 70" Exhaust 25°, 45°, 60° Contacting angle 45° Contacting width Intake 1.5-1.9 mm 0.059 - 0.075 in. 1.8-2.2 mm 0.071 - 0 .
Page 322 SERVICE SPECIFICATIONS - Engine Mechanical Specifications (Cont'd) Camshaft Thrust clearance 0.10-0.20 mm 0.0039-0.0079 in. 0.30 mm 0.0118 in. Limit Journal oil clearance 0.022 - 0.074 mm 0.0009 0.0029 in. No.1 journal 0.10 mm 0.0039 in. Limit 0.030 - 0.066 mm 0.001 2 - 0.0026 in.
Page 323 SERVICE SPECIFICATIONS - Engine Mechanical Specification (Cont'd) Connecting rod Thrust clearance 0.10-0.20 mm 0.0039-0.0079 in. 0.30 mm 0.0118 in. Limit Connecting rod oil clearance 0.036 - 0.054 mm 0.0014 - 0.0021 in. U/S 0.25, U/S 0.50 0.037-0.077 mm 0.0015-0.0030 in. Limit 0.10 mm 0.0039 in.
Page 324 SERVICE SPECIFICATIONS - Engine Mechanical Torque Specifications kg-cm ft-lb Part tightened Injection pump x Timing gear case Injection pump x Injection pump stay Injection pump distributive head plug bolt IPZand 1HZ 1HD-T No.1 camshaft timing pulley x Camshaft 1,000 No.2 camshaft timing pulley x Injection pump drive gear Idler pulley bolt x Cylinder head Spring bolt x Cylinder head Injection pump drive gear x Injection pump...
Page 325 SERVICE SPECIFICATIONS - Turbocharger System TURBOCHARGER SYSTEM Specifications Turbocharger 0.50-0.65 kg/cn Turbocharging pressure (7.1 -9.2 psi, 4 9 - 6 4 kPa) Impeller wheel axial play 0.13 mm (0.0051 in.) or less Impeller wheel radial play 0.18 mm (0.0071 in.) or less Torque Specifications Part tightened kg-cm...
Page 326 SERVICE SPECIFICATIONS Fuel System FUEL SYSTEM Specifications Resistance at 20°C (68°F) Fuel heater 0 . 5 - 2.0 Q Injection DN20PD32 Nozzle type nozzles 145-155 kg/cm Nozzle opening pressure New nozzle ("IPZand 1HZ) (2,062 - 2,205 psi, 1 4,220 - 1 5,200 kP; 135-155 kg/cm Reused nozzle (1,920 - 2,205 psi, 1 3,239 - 1 5,200 kP;...
Page 327 A-10 SERVICE SPECIFICATIONS - Fuel System Specification (Cont'd) KBAL Injection Nozzle type 0.08 - 0.10 mm 0.0031 - 0.0039 in. nozzle Pre-lift dimension (1HD-T) Nozzle opening pressure 132-138 kg/cm No.2 (Inspection pressure) (1,877 - 1,963 psi, 1 2,945 - 13,533 kPa) 180-190 kg/cm No.1 (2,560-2,702 psi, 17,652-18,633 kPa)
Page 328 SERVICE SPECIFICATIONS - Fuel System A-11 Specification (Cont'd) Injection Pre-lift and nozzle opening pressure 1.610 mm 0.0634 in. nozzles adjusting shim thickness (cont'd) 1.620 mm 0.0638 in. 1.630 mm 0.0641 in. (1HD-T) 1.640 mm 0.0646 in. (cont'd) 1.650 mm 0.0650 in. 1.660 mm 0.0654 in.
Page 329 A-12 SERVICE SPECIFICATIONS - Fuel System Specification (Cont'd) Plunger adjusting shim thickness 1.90 mm 0.0748 in. Injection pump 1.95 mm 0.0768 in. (cont'd) 1HZ and 1HD-T (for pre-stroke) 2.00 mm 0.0787 in. 2.05 mm 0.0807 in. 2.10 mm 0.0827 in. 2.15 mm 0.0846 in.
Page 330 SERVICE SPECIFICATIONS Fuel System A-13 Injection Pump Adjustment Preparations of DN12SD12 Test nozzle type pump tester Test nozzle opening pressure 145-155 kg/cm (2,062 - 2,205 psi, 1 4,220 - 1 5,200 kPa) Injection pipe Outer diameter 6.0 mm 0.236 in. Inner diameter 2.0 mm 0.079 in.
Page 331 A-14 SERVICE SPECIFICATIONS - Fuel System Injection Pump Adjustment (Cont'd) Overflow Item Pump rpm Overflow volume cc/min. (cu in./min.) volume IPZand 1HZ 2,000 366-800 (22.3-48.8) 1HD-T 1,900 583-1,083 (35.6-66.1) Automatic timer Pump rpm Piston stroke mm (in.) Item 0.58 - 1.58 (0.0228 - 0.0622) 1,200 3.02 - 4.02 (0.1189 - 0.1583) 4.65-5.65 (0.1830-0.2224)
Page 332 SERVICE SPECIFICATIONS - Fuel System A-15 Injection Pump Adjustment (Cont'd) Maximum No. of Adjusting Injection volume Item Pump rpm speed measuring lever angle cc (cu in.) strokes 2,300 4.0-6.0 (0.24-0.37) Plus 21 -31° 2,500 1.0 (0.06) or less 2,300 3.0-5.0 (0.18-0.31) Plus 21 -31°...
Page 333 A-16 SERVICE SPECIFICATIONS - Fuel System Injection Pump Adjustment (Cont'd) Injection No. of Variation Adjusting Injection volume volume Item Pump rpm measuring limit cc lever angle cc (cu in.) (cu in.) (cont'd) strokes 11.70-12.90 1,100 (0.71 -0.79) (0.04) 11.60-16.40 (0.71 -1.00) (0.07) 1HD-T Plus 2 1 - 3 1 °...
Page 334 SERVICE SPECIFICATIONS - Fuel System A - 1 7 Injection Pump Adjustment (Cont'd) Injection Governor sleeve plug head thickness volume 5.9 mm 0.232 in. 1HD-T (cont'd) (cont'd) 6.0 mm 0.236 in. 6.1 mm 0.240 in. 6.2 mm 0.244 in. 6.3 mm 0.248 in.
Page 335 SERVICE SPECIFICATIONS - Fuel System A-18 Injection Pump Adjustment (Cont'd) Load sensing No. of Pump Injection volume Item Remark timer measuring cc (cu in.) (w/o HAC strokes only) Measured value at step (f) minus 1,600 1.4 (0.09) ± 0.3 (0.02) Measured value at step (f) minus 1,600 Set to...
Page 336 SERVICE SPECIFICATIONS - Fuel System A-19 Injection Pump Adjustment (Cont'd) Idle speed No. of Adjusting Injection volume Variation Pump rpm (cont'd) Item measuring limit lever angle cc (cu in.) cc (cu in.) strokes 9.32-11.72 Full position (0.57-0.72) 1HD-T q = 3.70-4.70 (Europe M/T) (0.02) (0.23-0.29)
Page 337 A-20 SERVICE SPECIFICATIONS - Fuel System Torque Specifications Part tightened ft-lb kg-cm Nozzle holder body * Nozzle holder retaining nut (IPZand 1HZ) Injection nozzle x Cylinder head (IPZand 1HZ) Nozzle leakage pipe * Injection nozzle (IPZand 1HZ) Injection pipe Injection nozzle (IPZand 1HZ) Injection pipe Injection pump...
Page 338 SERVICE SPECIFICATIONS - Cooling System, Lubrication System A-21 COOLING SYSTEM Specifications Engine coolant capacity See page A-2 Radiator cap Relief valve opening pressure 0.75-1.05 kg/cm (10.7-14.9 psi, 74-103 kPa) Limit 0.6 kg/cm (8.5 psi, 59 kPa) Thermostat Valve opening temperature 74-78°C 187-194T Valve lift...
Page 339 A-22 SERVICE SPECIFICATIONS - Starting System, Charging System STARTING SYSTEM Pre-heating Light lighting time See pages ST-3, 4 system Supper glow type Fixed delay type Approx. 5 seconds HZJ and HDJ ex. (Europe and Australia) PZJ, HZJ75, HZB and HDB Approx.
Page 340: Torque Specifications
STANDARD BOLT TORQUE SPECIFICATIONS Page STANDARD BOLT TORQUE SPECIFICATIONS...
Page 341 STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS HOW TO DETERMINE BOLT STRENGTH Mark Class Mark Class Hexagon Stud bolt head bolt Bolt head No. 7 No mark No mark Hexagon flange bolt No mark Grooved w/ washer hexagon bolt Hexagon head bolt protruding...
Page 342 STANDARD BOLT TORQUE SPECIFICATIONS SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Class Hexagon head bolt Hexagon flange bolt kg-cm ft-lb N - m kg-cm ft-lb N - m 48 in.-lb 52 in.-lb 1.25 12.5 1.25 1.25 1,150 56 i n . - l b 65 in.-lb 1.25 15.5...
Page 343 SSTAND SSM Page SST (SPECIAL SERVICE TOOLS) SSM (SPECIAL SERVICE MATERIALS)
Page 344 SST AND SSM - SST (Special Service Tools) SST (SPECIAL SERVICE TOOLS) Section Part Name EM TC FU CO LU ST CH Note Part No. Illustration 1 2 mm Socket Wrench 09011-38121 for 1 2 Pointed Head Oil Pan Seal 09032-00100 Cutter Valve Guide Bushing...
Page 345 (Remover & Replacer) (09222-05020) 1HD-T (Guide) (09222-05030) 1HD-T 1HD-T (Base) (09222-05040) Connecting Rod Bushing Remover 1PZ and 1HZ 09222-66010 & Replacer Cover & Seal 09223-00010 Timing gear Replacer Crankshaft Front Camshaft retainer oil seal 09223-46011 Oil Seal Replacer Crankshaft Rear...
Page 346 (Tweezers) / Governor Lever (09269-54040) \ Support Bolt Wrench / 2 Spring Nozzle 09268-17010 1HD-T Tool Set Injection Nozzle 09268-64010 1PZ and 1HZ Wrench Set Pre-stroke Mearing 0927517010 1HZ and 1HD-T Adapter (09751-19004) (O-Ring) 1HZ and 1HD-T Plunger Stroke 09275-54011...
Page 347 SST A N D S S M - SST (Special Service Tools) SST (SPECIAL SERVICE TOOLS) (Cont'd) Section Part Name E M T C FU CO LU S T C H Note Part No. Illustration Maximum Speed w/ HAC and 1HD-T 09275-54020 Adjusting Screw Lock Nut Wrench...
Page 348 SST AND SSM — SST (Special Service Tools), SSM (Special Service Materials) SST (SPECIAL SERVICE TOOLS) (Cont'd) Section Part Name EM TC FU CO LU ST CH Note Part No. Illustration (09992-00160) (No. 5 Attachment) (09992-00211) (Gauge Assy) Turbocharger 09992-00241 Pressure Gauge SSM (SPECIAL SERVICE MATERIALS) Part Name...

This manual is also suitable for:

1hz 1hd-t

Toyota 1PZ Repair Manual

Quick Links

Troubleshooting

Related Manuals for Toyota 1PZ

Summary of Contents for Toyota 1PZ

This manual is also suitable for:

Table of Contents