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1KZ-TE
Repair manual
Toyota 1KZ-TE Repair Manual
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Also See for 1KZ-TE
:
Repair manual
(341 pages)
,
Supplemental repair manual
(118 pages)
,
Repair manual
(284 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Introduction
Check Piston Stroke of Overdrive Brake
Identification Information
Engine Serial Number
Repair Instructions
Basic Repair Hint
If Vehicle Is Equipped with Mobile Communication System
For Using Hand-Held Tester
How to Troubleshoot ECU Controlled Systems
How to Proceed with Troubleshooting
Customer Problem Analysis
Symptom Confirmation and Diagnostic Trouble Code Check
Symptom Simulation
Heat Method
Water Sprinkling Method
Diagnostic Trouble Code Chart
Problem Symptoms Table
Circuit Inspection
Wiring Diagram
Inspection Procedure
How to Use the Diagnostic Chart and Inspection
Connector Connection and Terminal Inspection
Continuity Check (Open Circuit Check)
Resistance Check/Short Circuit Check
Visual Check and Contact Pressure Check
Connector Handling
Check Open Circuit
Check Short Circuit
Check and Replace ECU
Terms
Abbreviations
Preparation
Engine Mechanical Special Service Tools
Engine Mechanical Recommended Tools
Engine Mechanical Equipment
Engine Mechanical Special Service Materials
Turbocharging Special Service Tools
Turbocharging Recommended Tools
Turbocharging Equipment
Electronic Control Diesel Special Service Tools
Electronic Control Diesel Recommended Tools
Electronic Control Diesel Equipment
Engine Fuel Special Service Tools
Engine Fuel Recommended Tools
Engine Fuel Equipment
Cooling Special Service Tools
Cooling Equipment
Coolant
Coolant Special Service Materials
Lubricant
Lubricant Special Service Materials
Starting Special Service Tools
Starting Recommended Tools
Starting Equipment
Charging Special Service Tools
Charging Recommended Tools
Charging Equipment
Service Specifications
Standard Bolt
How to Determine Bolt Strength
Specified Torque for Standard Bolts
How to Determine Nute Strength
Engine Mechanical Service Data
Engine Mechanical Torque Specification
Turbocharging Service Data
Turbocharging Torque Specification
Electronic Control Diesel Service Data
Electronic Control Diesel Torque Specification
Engine Fuel Service Data
Engine Fuel Torque Specification
Cooling Service Data
Cooling Torque Specification
Lubrication Service Data
Lubrication Torque Specification
Starting Service Data
Starting Torque Specification
Charging Service Data
Charging Torque Specification
Diagnostics
Engine
Customer Problem Analysis Check
Pre-Check
Diagnosis System
Diagnosis Inspection (Normal Mode)
Fail-Safe Chart
Check for Intermittent Problems
Basic Inspection
Reference Value of Engine ECU Data
Engine Diagnostic Trouble Code Chart
Engine Parts Location
Terminals of ECU
Engine Problem Symptoms Table
Engine Speed Sensor Circuit Malfunction (TDC or G1 Circuit)
Engine Circuit Inspection
Engine Circuit Description
Engine Wiring Diagram
Engine Inspection Procedure
Engine Speed Sensor Circuit Malfunction (NE Circuit)
Timing Control System Malfunction
Water Temp. Sensor Circuit Malfunction
Intake Air Temp. Sensor Circuit Malfunction
Injection Pump Correction System Malfunction
Turbo Pressure Sensor Circuit Malfunction
Fuel Temp. Sensor Circuit Malfunction
Throttle Position Sensor Circuit Malfunction
Vehicle Speed Sensor Signal Circuit Malfunction
Starter Signal Circuit Malfunction
First Gear Position Switch Circuit Malfunction
Back up Power Source Circuit
Engine ECU Power Source Circuit
TE1, TE2 Terminal Circuit
Pre-Heating Control Circuit
Spill Control Valve Relay Circuit
Air Filter Inspection
Compression Inspection
Valve Clearance Inspection
Adjusting Shim Selection Using Chart
Injection Timing Inspection
Adjust Injection Timing
Idle Speed and Maximum Speed Inspection
Intake Construction Control Inspection
Connect Vacuum Gauges
Inspect Hot Engine Condition
Remove Vacuum Gauges
Timing Belt Components
Timing Belt Removal
Remove Timing Belt Cover
Set No.4 Cylinder to Tdc/Compression
If Re-Using Timing Belt, Mark Timing Belt
Remove Timing Belt Idler Pulley
Remove Timing Belt
Remove Intake Pipe
Remove Cylinder Head Cover
Remove No.1 Camshaft Timing Pulley
Inspect Timing Belt
Inspect Idler Pulley
Inspect Timing Belt Tensioner
Timing Belt Installation
Install No.1 Camshaft Timing Pulley
Install Cylinder Head Cover
Install Intake Pipe
Install No.2 Camshaft Timing Pulley
Install Timing Belt
Install Timing Belt Idler Pulley
Set Timing Belt Tensioner
Install Timing Belt Tensioner
Check Valve Timing
Install Timing Belt Cover
Timing Gear Components
Timing Gear Removal
Remove Camshaft Oil Seal Retainer
Remove Vacuum Pump
Remove Crankshaft Pulley
Remove Timing Gear Cover
Check Thrust Clearance of Idler Gear
Remove Timing Gears
Disassembly Idler Gear
Timing Gear Inspection
Inspect Idler Gear
Inspect Injection Pump Drive Gear Bearing
Check Backlash of Timing Gears
Timing Gear Replacement
Replace Crankshaft Front Oil Seal
Replace Injection Pump Drive Gear Oil Seal
Replace Injection Pump Drive Gear Bearing
Timing Gear Installation
Assemble Idler Gear
Install Timing Gear
Install Timing Gear Cover
Check Injection Pump Drive Shaft Thrust Clearance
Install Crankshaft Pulley
Install Vacuum Pump
Cylinder Head Components
Cylinder Head Removal
Drain Engine Coolant
Remove Water Outlet
Remove Intake Manifold
Remove Nozzle Leakage Pipe
Remove Injection Nozzles
Cylinder Head Disassembly
Cylinder Head Inspection
Clean Top Surfaces of Pistons and Cylinder Block
Remove Gasket Material
Clean Combustion Chambers
Clean Cylinder Head
Inspect for Flatness
Inspect for Cracks
Clean Valves
Inspect Valve Stems and Guide Bushings
Inspect and Grind Valves
Inspect and Clean Valve Seats
Inspect Valve Springs
Inspect Camshaft for Runout
Inspect Cam Lobes
Inspect Camshaft Journals
Inspect Camshaft Bearings
Inspect Camshaft Journal Oil Clearance
Inspect Camshaft Thrust Clearance
Inspect Valve Lifters and Lifter Bores
Inspect Intake and Exhaust Manifolds
Inspect Cylinder Head Bolts
Cylinder Head Replacement
Replace Valve Guide Bushings
Replace Camshaft Oil Seal
Cylinder Head Reassembly
Select Combination Chamber Shim
Install Combustion Chambers
Install Valves
Install Valve Lifters and Shims
Install Semi Circular Plug
Install Heater Water Inlet Pipe
Install Front Engine Hanger
Cylinder Head Installation
Check Piston Protrusion and Select Cylinder Head Gasket
Place Cylinder Head on Cylinder Block
Install Cylinder Head Bolts
Install Camshaft
Install Camshaft Oil Seal Retainer
Cylinder Block Components
Cylinder Block Disassembly
Remove Piston Rings
Disconnect Connecting Rod from Piston
Cylinder Block Inspection
Cylinder Block Replacement
Replace Oversized (O/S) Pistons
Cylinder Block Reassembly
Turbocharging
Turbocharging Troubleshooting
Turbocharging Maintenance Precaution
Turbocharger On-Vehicle Inspection
Inspect Intake Air System
Inspect Exhaust System
Turbocharger Components
Turbocharger Removal
Turbocharger Disassembly
Turbocharger Inspection
Clean Compressor Housing
Turbocharger Reassembly
Turbocharger Installation
Emission Control System
Positive Crankcase Ventilation (PCV) System Inspection
Electronic Control Diesel
ECD System Precaution
Throttle Body On-Vehicle Inspection
Inspect Throttle Body Operation
Throttle Body Components
Throttle Body Removal
Throttle Body Inspection
Throttle Body Installation
Timing Control Valve Inspection
Spill Control Valve Inspection
ECD Main Relay Inspection
Spill Control Valve Relay Components
Spill Control Valve Relay Inspection
VSV for Intake Constructor Control Components
VSV for Intake Constructor Control Inspection
Water Temperature Sensor Inspection
Fuel Temperature Sensor Inspection
Intake Air Temperature Sensor Inspection
Turbo Pressure Sensor Inspection
Engine Speed Sensor Inspection
Crankshaft Position Sensor Inspection
First Gear Position Switch Inspection
First Gear Position Switch Replacement
Injection Pump Correction Resistor Inspection
Engine ECU Components
Engine ECU Inspection
Engine Fuel
Fuel Filter Replacement
Injection Nozzle Components
Injection Nozzle Removal
Injection Nozzle Disassembly
Injection Nozzle Inspection
Injection Nozzle Reassembly
Injection Nozzle Test
Injection Pressure Test
Leakage Test
Spray Pattern Test
Injection Nozzle Installation
Injection Pump On-Vehicle Inspection
Injection Pump Components
Injection Pump Removal
Injection Pump Disassembly
Injection Pump Inspection
Injection Pump Reassembly
Injection Pump Installation
Cooling
Coolant Inspection
Coolant Replacement
Fill Engine Coolant
Water Pump Components
Water Pump Removal
Water Pump Inspection
Water Pump Installation
Install Water Pump Assembly
Thermostat Components
Thermostat Removal
Thermostat Inspection
Thermostat Installation
Radiator On-Vehicle Cleaning
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Quick Links
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Wiring Diagram
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Table of Contents
Troubleshooting
How to Proceed with Troubleshooting
14
Turbocharging Troubleshooting
250
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