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Toyota 1KZ-TE Repair Manual

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BACK TO ENGINE INDEX
RM790E-D
This
Repair Manual
1KZ-TE Engine
Applicable models:
Please note that the publications below have also been prepared as relevant service manuals for the
components and system in this engine.
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1KZ- -T Engine Repair Manual
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1KZ- -TE Engine Repair Manual
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1KZ- -T, 1KZ- -TE Engine Repair Manual Supplement
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that non--specialized or uncertified technicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer's vehicle.
In order to prevent dangerous operation and damages to your customer's vehicle, be sure to follow
the instruction shown below.
Must read this manual thoroughly. It is especially important to have good understanding all the
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contents written in the PRECAUTION of "IN" section.
The service method written in this manual is very effective to perform repair and service. When
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performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using non--specified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer's vehicle before starting the operation.
If part replacement is necessary, must replace the part with the same part number or equivalent
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part. Do not replace it with inferior quality.
It is important to note that this manual contains various "Cautions" and "Notices" that must be
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carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these "Cautions" and "Notices" are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
FOREWORD
TOY OTA MOTOR C ORP ORATION
has been prepared to provide information covering general service repairs for the
TOYOTA HILUX
equipped on the
KZN165 series
K Z N1 8 5 se rie s (4 RUNNE R)
K Z J9 0 , K Z J9 5 s e rie s (L A ND CRUI S E R/ L A ND CRUI S E R P RA DO )
Manual Name
, 4 RUNNE R a n d L A ND CRUI S E R/ P RA DO .
(HILUX)
2000
A ll r ight s r es er v ed. T his CD m ay not be r epr o-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Jun. 28, 2000 01--000628--00
CAUTION
1KZ-TE
VIEW THE MAIN INDEX
PAGES FROM SUPPLEMENT
TO MODEL INDEX
TOYOTA MOTOR CORPORATION
Pub.No.
RM353E
RM710E
RM522E

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Summary of Contents for Toyota 1KZ-TE

  • Page 1 A ll r ight s r es er v ed. T his CD m ay not be r epr o- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: Jun. 28, 2000 01--000628--00 Manual Name Pub.No.
  • Page 2 BACK TO MAIN FOREWORD & To Engine Index 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX MAIN INDEX HILUX ENGINE 1KZ-TE: Supplement: DECEMBER 2000 INTRODUCTION PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS ENGINE MECHANICAL TURBOCHARGING EMISSION CONTROL ELECTRONIC CONTROL DIESEL ENGINE FUEL COOLING...
  • Page 3 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX INTRODUCTION HOW TO USE THIS MANUAL ... . . IN--1 GENERAL INFORMATION ....
  • Page 4 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -1 INTRODUCTION HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN04V- -05 GENERAL INFORMATION INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page.
  • Page 5 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -2 INTRODUCTION HOW TO USE THIS MANUAL The procedur es are presented in a step --by--step for mat: The illu st ration sh ows what to do and wh ere to do it.
  • Page 6 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -3 INTRODUCTION IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION IN00Q- -35 ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown. B09246 1KZ- -TE ENGINE SUP (RM790E)
  • Page 7 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -4 INTRODUCTION REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS IN0BX- -12 GENERAL INFORMATION BASIC REPAIR HINT Use fender, seat and floor covers to keep the vehicle clean and prevent damage.
  • Page 8 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -5 INTRODUCTION REPAIR INSTRUCTIONS Precoated parts are indicated in the component il- lustrations by the ”L” symbol. When necessary, use a sealer on gaskets to prevent leaks.
  • Page 9 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -6 INTRODUCTION REPAIR INSTRUCTIONS Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the prop- er locations (As for vehicle lift and support location, please refer to Chassis &...
  • Page 10 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -7 INTRODUCTION REPAIR INSTRUCTIONS When checking continuity at the wire connector, in- sert the tester probe carefully to prevent terminals from bending. When using a vacuum gauge, never force the hose onto a connector that is too large.
  • Page 11 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -8 INTRODUCTION FOR ALL OF VEHICLES FOR ALL OF VEHICLES IN00R- -14 PRECAUTION FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire haz- ard.
  • Page 12 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -9 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN005- -34 GENERAL INFORMATION A large number of ECU controlled systems are used in the HILUX, 4RUNNER and LAND CRUISER/LAND CRUISER PRADO.
  • Page 13 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -10 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN006- -37 HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro- cedure is shown.
  • Page 14 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -11 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred.
  • Page 15 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -12 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the HILUX, 4RUNNER and LAND CRUISER/LAND CRUISER PRADO fulfills vari- ous functions.
  • Page 16 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -13 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshoot- ing using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnos- tic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table.
  • Page 17 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -14 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle.
  • Page 18 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -15 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction with a hair dryer or similar object.
  • Page 19 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -16 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot- ing using the diagnostic trouble codes displayed in the diagnostic trouble code check.
  • Page 20 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -17 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a ”Normal”...
  • Page 21 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -18 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CIRCUIT INSPECTION How to read and use each page is shown below. D Diagnostic Trouble Code No. and Detection Item Circuit Description The major role and operation, etc.
  • Page 22 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -19 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS D Indicates the position of the ignition switch during the check. Inspection Procedure Use the inspection procedure to determine...
  • Page 23 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -20 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN0GK- -02 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE CONNECTOR CONNECTION AND TERMINAL IN- SPECTION For troubleshooting, diagnostic trouble code charts or problem symptom charts are provided for each circuit with detailed inspection procedures on the following pages.
  • Page 24 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -21 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads.
  • Page 25 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -22 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Prepare a test male terminal and insert it in the female ter- minal, then pull it out. NOTICE: When testing a gold- -plated female terminal, always use a gold- -plated male terminal.
  • Page 26 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -23 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check the voltage. Fig. 4 In a circuit in which voltage is applied (to the ECU connec- tor terminal), an open circuit can be checked for by con- ducting a voltage check.
  • Page 27 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -24 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Disconnect connector ”B” and measure the resis- Fig. 7 tance between terminal 1 of connector ”A” and body ground, and terminal 1 of connector ”B2” and body ground.
  • Page 28 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX IN- -25 INTRODUCTION TERMS TERMS IN00S- -13 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning Air Conditioning Alternating Current Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device...
  • Page 29 Special Service Materials Special Service Tools Standard Switch TACH Tachometer Top Dead Center TEMP. Temperature Transmission TOYOTA Motor Corporation Three- -Way Catalyst Underdrive Vacuum Control Valve Vehicle Identification Number Vacuum Switching Valve With Wire Harness Without WU- -TWC Warm Up Three- -Way Catalytic Converter...
  • Page 30 BACK TO BACK INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PREPARATION E NG I NE M E CHA NI CA L ....
  • Page 31 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -1 PREPARATION ENGINE MECHANICAL ENGINE MECHANICAL PP3F2- -01 S S T (S peci al S ervi ce Tool s) 09843- -18040 Diagnosis Check Wire No.2 CONTINUED 1KZ- -TE ENGINE SUP (RM790E)
  • Page 32 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -2 PREPARATION ENGINE MECHANICAL PP1TO- -03 EQUIPMENT Carbide cutter Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune- -up tester Micrometer Piston ring compressor Piston ring expander...
  • Page 33 BACK TO MODEL INDEX PP- -3 PREPARATION TURBOCHARGING TURBOCHARGING PP3F3- -01 S S T (S peci al S ervi ce Tool s) 09350- -32014 TOYOTA Automatic Transmission Tool Set (09351- -32070) No.2 Piston Spring Compressor Bearing housing 09992- -00242 Turbocharger Pressure Gauge CONTINUED...
  • Page 34 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -4 PREPARATION TURBOCHARGING PP3F4- -01 RECOMMENDED TOOLS 09905- -00013 Snap Ring Pliers . CONTINUED 1KZ- -TE ENGINE SUP (RM790E)
  • Page 35 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -5 PREPARATION TURBOCHARGING PP1TR- -04 EQUIPMENT Dial indicator Impeller wheel Torque wrench 1KZ- -TE ENGINE SUP (RM790E)
  • Page 36 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -6 PREPARATION EMISSION CONTROL EMISSION CONTROL PP1SX- -02 RECOMMENDED TOOLS 09082- -00040 TOYOTA Electrical Tester. 1KZ- -TE ENGINE SUP (RM790E)
  • Page 37 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -7 PREPARATION EMISSION CONTROL PP1SY- -02 EQUIPMENT MITYVAC (Hand- -held vacuum tester) Torque wrench Vacuum gauge 1KZ- -TE ENGINE SUP (RM790E)
  • Page 38 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -8 PREPARATION ELECTRONIC CONTROL DIESEL ELECTRONIC CONTROL DIESEL PP1T5- -02 S S T (S peci al S ervi ce Tool s) 09992- -00242 Turbocharger Pressure Gauge Turbo pressure sensor...
  • Page 39 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -9 PREPARATION ELECTRONIC CONTROL DIESEL PP3F5- -01 RECOMMENDED TOOLS 09082- -00040 TOYOTA Electrical Tester. CONTINUED 1KZ- -TE ENGINE SUP (RM790E)
  • Page 40 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -10 PREPARATION ELECTRONIC CONTROL DIESEL PP15E- -04 EQUIPMENT Thermometer Torque wrench Torx socket (E8) Vacuum gauge 19 mm deep socket wrench 1KZ- -TE ENGINE SUP (RM790E)
  • Page 41 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -11 PREPARATION ENGINE FUEL ENGINE FUEL PP3F6- -02 S S T (S peci al S ervi ce Tool s) 09241- -76022 Injection Pump Stand Set 09245- -54010...
  • Page 42 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -12 PREPARATION ENGINE FUEL PP3F7- -01 RECOMMENDED TOOLS 09040- -00011 Hexagon Wrench Set . 09082- -00040 TOYOTA Electrical Tester. CONTINUED 1KZ- -TE ENGINE SUP (RM790E)
  • Page 43 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -13 PREPARATION ENGINE FUEL PP1FL- -04 EQUIPMENT Injection nozzle tester Injection pump tester Torque wrench 19 mm deep socket wrench Fuel temperature sensor 1KZ- -TE ENGINE SUP (RM790E)
  • Page 44 PP1TK- -03 COOLANT Item Capacity Classification Engine coolant ”Toyota Long Life Coolant” or equivalent 4Runner, Land Cruiser/Land Cruiser Prado M/T w/ Rear heater 10.5 liters (11.1 US qts, 9.2 Imp. qts) w/o Rear heater 9.5 liters (10.0 US qts, 8.4 Imp. qts) A/T w/ Rear heater 11 liters (11.6 US qts, 9.7 Imp.
  • Page 45 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -15 PREPARATION LUBRICATION LUBRICATION PP3F8- -01 S S T (S peci al S ervi ce Tool s) 09228- -10002 Oil Filter Wrench CONTINUED 1KZ- -TE ENGINE SUP (RM790E)
  • Page 46 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX PP- -16 PREPARATION LUBRICATION PP1T2- -02 LUBRICANT Item Capacity Classification Engine oil API grade CF- -4 or CF 4Runner, Land Cruiser/Land Cruiser (You may also use API CE or CD)
  • Page 47 BACK TO BACK INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SERVICE SPECIFICATIONS STANDARD BO LT ......
  • Page 48 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -1 SERVICE SPECIFICATIONS STANDARD BOLT STANDARD BOLT SS0ZS- -01 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Class Stud Bolt Weld Bolt Normal Recess Bolt...
  • Page 49 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -2 SERVICE SPECIFICATIONS STANDARD BOLT SS0ZT- -01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Hexagon head bolt Hexagon flange bolt Class Class N∙m kgf∙cm ft∙lbf N∙m...
  • Page 50 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -3 SERVICE SPECIFICATIONS STANDARD BOLT SS0ZU- -01 HOW TO DETERMINE NUT STRENGTH Nut Type Old Standard Hexagon Nut Present Standard Class Hexagon Nut Cold Forging Nut Cutting Processed Nut...
  • Page 51 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -4 SERVICE SPECIFICATIONS ENGINE MECHANICAL ENGINE MECHANICAL SS0ZE- -04 SERVICE DATA Idle speed 650 - - 750 rpm Maximum speed 4,450 - - 4,750 rpm Cylinder head...
  • Page 52 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -5 SERVICE SPECIFICATIONS ENGINE MECHANICAL SS0ZF- -04 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Intercooler x Bracket w/ Intercooler Intake air connector x Inter cooler w/ Intercooler...
  • Page 53 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -6 SERVICE SPECIFICATIONS TURBOCHARGING TURBOCHARGING SS0ZG- -02 SERVICE DATA Turbocharger Turbocharging pressure 51 - - 67 kPa (0.52 - - 0.68 kgf/cm , 7.4 - - 9.7 psi)
  • Page 54 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -7 SERVICE SPECIFICATIONS TURBOCHARGING SS0ZH- -02 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf V- -band x Bearing housing 42 in.∙lbf Actuator x Compressor housing 19.1 Bearing housing side plate x Bearing housing...
  • Page 55 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -8 SERVICE SPECIFICATIONS EMISSION CONTROL EMISSION CONTROL SS0YM- -03 SERVICE DATA EGR valve lift sen- Resistance (at 20˚C (68˚F)) Between terminals 1 and 2 at 20˚C (68˚F) 2.6 Ω...
  • Page 56 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -9 SERVICE SPECIFICATIONS EMISSION CONTROL SS0YN- -03 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf EGR valve x EGR pipe w/ EGR 19.6 EGR pipe x Exhaust manifold w/ EGR 39.2...
  • Page 57 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -10 SERVICE SPECIFICATIONS ELECTRONIC CONTROL DIESEL ELECTRONIC CONTROL DIESEL SS0L2- -04 SERVICE DATA Throttle control Resistance (2 and 1/3, 5 and 4/3) at hot 23 - - 33 Ω...
  • Page 58 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -11 SERVICE SPECIFICATIONS ELECTRONIC CONTROL DIESEL SS0YQ- -03 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Throttle body x Intake manifold Fuel temperature sensor x Fuel pump 21.6...
  • Page 59 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -12 SERVICE SPECIFICATIONS ENGINE FUEL ENGINE FUEL SS0QX- -05 SERVICE DATA Injection nozzle Nozzle opening pressure New nozzle 15,298 - - 16,083 kPa (156 - - 164 kgf/cm...
  • Page 60 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -13 SERVICE SPECIFICATIONS ENGINE FUEL SS0QY- -05 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Fuel inlet hollow screw x Injection pump body 36.8 Delivery valve holder x Distributive head 58.85...
  • Page 61 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -14 SERVICE SPECIFICATIONS LUBRICATION LUBRICATION SS0YP- -02 TORQUE SPECIFICATION Part tightened N∙m kgf∙cm ft∙lbf Oil pan x Drain plug Relief valve x Oil pump Oil pump x Cylinder block...
  • Page 62 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX SS- -15 SERVICE SPECIFICATIONS STARTING STARTING SS0YU- -04 SERVICE DATA Pre- -heating Light lighting time at 30˚C (86˚F) Approx. 0.5 seconds system 1KZ- -TE ENGINE SUP (RM790E)
  • Page 63 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DIAGNOSTICS ENGINE ......
  • Page 64 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -1 DIAGNOSTICS ENGINE ENGINE DI31H- -06 HOW TO PROCEED WITH TROUBLESHOOTING When using hand--held tester, troubleshoot in accordance with the procedure on the following pages. Titles inside...
  • Page 65 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -2 DIAGNOSTICS ENGINE When not using hand--held tester, troubleshoot in accordance with the procedure on the following pages. Titles inside are titles of pages in Vehicle Brought to Workshop this manual, with the page number indicated in the bottom portion.
  • Page 66 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -3 DIAGNOSTICS ENGINE DI31I- -04 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s ENG I NE CO NT RO L SYST EM Ch eck Sh eet Name Model and Model Customer’s Name...
  • Page 67 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -4 DIAGNOSTICS ENGINE DI8FD- -01 PRE- -CHECK DIAGNOSIS SYSTEM (a ) De scrip tio n When troubleshooting Multiplex OBD (M--OBD) ve- hicles, the only difference from the usual trouble-...
  • Page 68 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -5 DIAGNOSTICS ENGINE *2 trip detection logic: When a logic malfunction is first detected, the mal- function is temporarily stored in the engine ECU memory. If the same malfunction is detected again during the second drive test, this second detection causes the check engine warn- ing light to light up.
  • Page 69 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -6 DIAGNOSTICS ENGINE Normal Mode: INSPECT DIAGNOSIS Check the check engine warning light. The check engine warning light comes on when the ignition switch is turned ON and the engine is not running.
  • Page 70 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -7 DIAGNOSTICS ENGINE Read the DTC from the check engine warning light. Normal As an example, the blinking patterns for codes; nor- mal, 12 and 31 are as shown in the illustration.
  • Page 71 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -8 DIAGNOSTICS ENGINE After simulating the malfunction conditions, use the hand--held tester diagnosis selector to check the DTCs and freeze frame data, etc. HI NT: Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from the check (test) mode to the normal mode, so all the diagnostic codes, etc.
  • Page 72 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -9 DIAGNOSTICS ENGINE Accelerator pedal closed position SW ON : Accelerator pedal position is fixed at 0 % 19( 1) +B OFF Accelerator pedal closed position SW OFF :...
  • Page 73 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -10 DIAGNOSTICS ENGINE Is en g in e cran ked ? Proceed to problem symptoms table on page DI - - Ch eck air f ilter. P a pe r fi l te r ty pe : PREPARATION: Remove the air filter.
  • Page 74 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -11 DIAGNOSTICS ENGINE Ch eck fu el q u ality. CHE CK: Check that only diesel fuel is used. Check that the fuel does not contain any impurity.
  • Page 75 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -12 DIAGNOSTICS ENGINE Check diagnostic connector (DLC3) circuit (See page DI - - 98). Repair or replace. Ch eck vacu u m p u mp ( See p ag e EC - - 3).
  • Page 76 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -13 DIAGNOSTICS ENGINE 80 - - 100 kPa E ngine at idling (683- -833 mmHg, 26.9- -32.8 in.Hg) E ngine r ac ing at 2, 000 r pm...
  • Page 77 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -14 DIAGNOSTICS ENGINE DI31K- -06 DI AGNOS T I C T ROUBL E CODE CHART HINT: Parameters listed in the chart may not be exactly the same as your readings due to the type of instrument or other factors.
  • Page 78 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -15 DIAGNOSTICS ENGINE S Open or short in injection pump correction unit cuicuit Injection Pump Correction Sys- S Injection pump correction unit OFF/N.A. (DI- -69) tem Malfunction...
  • Page 79 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -16 DIAGNOSTICS ENGINE DI8FF- -01 PA R T S L O C AT I O N Land Cruiser/Land Cruiser Prado, 4Runner Glow Plug Combination Meter Engine ECU...
  • Page 80 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -17 DIAGNOSTICS ENGINE Hilux Starter Relay ECD Main Relay (Marking: ECD) (Marking: ST) Combination Meter Glow Plug Relay (Marking: SUB GLW RLY) Turbo Pressure Sensor Engine ECU...
  • Page 81 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -18 DIAGNOSTICS ENGINE DI8FE- -01 T E RM I NAL S O F E CU 4Runner Engine ECU Terminals 30 29 17 16 A10774 Symbols (Terminals No.)
  • Page 82 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -19 DIAGNOSTICS ENGINE TACH (E17- -2) - - E1 (E15- -22) LG - - BR Idling Pulse generation TC (E18- -18) - - E1 (E15- -22) GR - - BR...
  • Page 83 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -20 DIAGNOSTICS ENGINE Hilux Engine ECU Terminals 30 29 17 16 A10774 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) BATT (E7- -2) - - E1 (E4- -22)
  • Page 84 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -21 DIAGNOSTICS ENGINE Accelerator pedal fully closed 9 - - 14 PDL (E6 9) PDL (E6- -9) - - E1 (E4- -22) E1 (E4 22) L - - BR...
  • Page 85 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -22 DIAGNOSTICS ENGINE Land Cruiser/Land Cruiser Prado Engine ECU Terminals 30 29 17 16 A10774 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) BATT (E8- -2) - - E1 (E5- -22)
  • Page 86 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -23 DIAGNOSTICS ENGINE IG switch ON 9 - - 14 ACT (E7- -13) - - E1 (E5- -22) L- -B - - BR At A/C cut controlled (Driving below 30 km/h, accelerator pedal 0 - - 3 fully opened for 5 sec.)
  • Page 87 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -24 DIAGNOSTICS ENGINE DI31N- -06 PROBLEM SYMPTOMS TABLE When the malfunction code is not confirmed the DTC check and the problem still can not be confirmed in the basic inspection, then proceed to this step and perform a troubleshooting according to the numbered order given in the table below.
  • Page 88 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -25 DIAGNOSTICS ENGINE 1. Injection nozzle FU- -3 2. ECU power source circuit DI- -92 3. Compression Hunting at hot engine (Poor idling) 4. Fuel line (Air beed) 5.
  • Page 89 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX Circuit Inspection. 1. DTC-12: Crankshaft position sensor circuit malfunction: Pg DI-26 / DI-28 2. DTC-13: Engine speed sensor circuit malfunction (NE circuit): Pg DI-29 / DI-30 3. DTC-14 Timing control system malfunction: Pg DI-31 / DI-33 4.
  • Page 90 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -26 DIAGNOSTICS ENGINE DI31O- -05 CI RCUI T I NS P E CT I O N Crankshaft P osi ti o n S ensor Ci rcui t...
  • Page 91 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -27 DIAGNOSTICS ENGINE WIRING DIAGRAM Engine ECU Crankshaft Position Sensor TDC+ TDC-- Engine Speed Sensor (inside the Injection Pump) NE-- E4 (Hilux), C15 (Hilux), E5 (Land Cruiser/Land Cruiser Prado),...
  • Page 92 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -28 DIAGNOSTICS ENGINE Ch eck resistan ce o f cran ksh aft p o sitio n sen so r ( T DC) (See Pu b . No . RM710E, ED...
  • Page 93 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -29 DIAGNOSTICS ENGINE DI31P- -06 E ngine Speed Sensor Ci rcuit M alfuncti on (NE Ci r cu i t) CIRCUIT DESCRIPTION Refer to DTC12 on page DI -- 26.
  • Page 94 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -30 DIAGNOSTICS ENGINE Check and replace engine ECU (See page IN - - 20). 1KZ- -TE ENGINE SUP (RM790E)
  • Page 95 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -31 DIAGNOSTICS ENGINE DI8FG- -01 Tim ing Control S ystem Malfuncti on CIRCUIT DESCRIPTION The engine ECU controls the injection timing by actuating the timing control valve. The timing control valve is mounted on the injection pump and delay one by duty control of pump internal fuel pressure.
  • Page 96 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -32 DIAGNOSTICS ENGINE Land Cruiser/Land Cruiser Prado Engine ECU From Terminal 3 of ECD Relay Timing Control Valve ( S ee page DI -- 92) B--R B--R...
  • Page 97 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -33 DIAGNOSTICS ENGINE Check for open or short in harness and connector between timing control valve and engine ECU, and timing c ontrol valve and ECD ma in re lay (Ma rk ing: ECD) (See pa ge IN - - 20).
  • Page 98 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -34 DIAGNOSTICS ENGINE DI8FH- -01 Throttl e Control M otor Ci rcuit M alfuncti on CIRCUIT DESCRIPTION Throttle control motor is operated by the engine ECU and it opens and closes the throttle valve.
  • Page 99 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -35 DIAGNOSTICS ENGINE 4Runner Engine ECU Throttle Control Motor R--Y LU+A R--L LU--A G--Y LU+B LU--B Throttle Full Switch W--B L--B THOP A15430 A09824 Land Cruiser/Land Cruiser Prado...
  • Page 100 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -36 DIAGNOSTICS ENGINE INSPECTION PROCEDURE HI NT: Read freeze frame data using hand--held tester, as freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air--fuel ratio was lean or rich, etc.
  • Page 101 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -37 DIAGNOSTICS ENGINE Repair or replace harness or connector. Check and replace engine ECU. 1KZ- -TE ENGINE SUP (RM790E)
  • Page 102 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -38 DIAGNOSTICS ENGINE DI6K5- -02 S pill Control Valve Ci rcuit CIRCUIT DESCRIPTION The engine ECU controls the fuel injection volume by operating the spill control valve. The spill control valve is mounted on the injection pump, and open or close the injection pressure releasing port by the solenoid valve in the spill control valve (During injection;...
  • Page 103 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -39 DIAGNOSTICS ENGINE 4Runner Engine ECU Spill Control Valve SPV+ R--B SPV-- A12069 Land Cruiser/Land Cruiser Prado Engine ECU Magnetic Spill Valve SPV+ SPV-- A12069 INSPECTION PROCEDURE...
  • Page 104 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -40 DIAGNOSTICS ENGINE Check voltage between terminal SPV of engine ECU connector and body ground. PREPARATION: Remove the glove compartment. E4, E5 or E15 Connector Disconnect the E4 (Hilux), E5 (Land Cruiser/Land Cruiser Prado) or E15 (4Runner) connector from the engine ECU.
  • Page 105 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -41 DIAGNOSTICS ENGINE Check and replace engine ECU (See page IN - - 20). 1KZ- -TE ENGINE SUP (RM790E)
  • Page 106 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -42 DIAGNOSTICS ENGINE DI8FI- -01 19 (1) Accel erator P edal P osi ti o n S ensor ci r cui t Malfuncti on (Open/Short) CIRCUIT DESCRIPTION The accelerator pedal position sensor is mounted in the accelerator pedal and detects the accelerator pedal opening angle.
  • Page 107 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -43 DIAGNOSTICS ENGINE WIRING DIAGRAM Hilux Engine ECU Accelerator Pedal Position Sensor R--W B--L B--R Accelerator Pedal Closed Position Switch W--B W--B L--W A15078 CONTINUED 1KZ- -TE ENGINE SUP (RM790E)
  • Page 108 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -44 DIAGNOSTICS ENGINE 4Runner Engine ECU Accelerator Pedal Position Sensor B--R Y--R V--W LG--R BR--B Accelerator Pedal Closed Position Switch W--B L--W L--W W--B W--B A15412 CONTINUED...
  • Page 109 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -45 DIAGNOSTICS ENGINE Land Cruiser/Land Cruiser Prado Engine ECU A59 Accelerator Pedal Position Sensor G--Y Y--R G--W BR--W Accelerator Pedal Closed Position Switch W--B W--B A15413 INSPECTION PROCEDURE...
  • Page 110 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -46 DIAGNOSTICS ENGINE Accelerator pedal opening position Accelerator pedal expressed as percentage Fully released Approx. 65 % Fully depressed Approx. 18 % Check for intermittent problems (S e e pa ge DI - - 9 Check voltage between terminal 4 of wire harness side connector and body ground.
  • Page 111 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -47 DIAGNOSTICS ENGINE Ch eck fo r o p en an d sh o rt in h arn ess an d co n n ecto r in VA o r VAS b etween en - g in e ECU an d accelerato r p ed al p o sitio n sen so r ( See p ag e IN - - 20).
  • Page 112 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -48 DIAGNOSTICS ENGINE W hen not using hand - - held tester : Check voltage between terminal 4 of wire harness side connector and body ground. PREPARATION: Disconnect the accelerator pedal position sensor con- nector.
  • Page 113 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -49 DIAGNOSTICS ENGINE Replace accelerator pedal. Check voltage between terminals VCC and E2C of engine ECU connector. PREPARATION: VCC E2C Remove the glove compartment door. Turn the ignition switch ON.
  • Page 114 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -50 DIAGNOSTICS ENGINE DI31T- -05 19 (2) Accel erator P edal P osi ti o n S ensor Ci r cui t Malfuncti on (I DL Switch/Range) CIRCUIT DESCRIPTION Refer to DTC 19 (1) on page DI -- 42.
  • Page 115 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -51 DIAGNOSTICS ENGINE Ch eck vo ltag e b etween termin als IDL an d E2C o f en g in e ECU co n n ecto r.
  • Page 116 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -52 DIAGNOSTICS ENGINE Check voltage between terminal VCC of wire harness side connector and body ground (See page DI - - 42, step 2). Go to step 8.
  • Page 117 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -53 DIAGNOSTICS ENGINE W hen not using hand - - held tester : Ch eck vo ltag e b etween termin als IDL an d E2C o f en g in e ECU co n n ecto r.
  • Page 118 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -54 DIAGNOSTICS ENGINE Ch eck vo ltag e b etween termin als VA, VAS an d E2C o f en g in e ECU co n n ecto r (See p ag e DI - - 42, step 3).
  • Page 119 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -55 DIAGNOSTICS ENGINE DI8FJ- -01 19 (3) Accel erator P edal Cl o sed P o si ti on S w i tch Ci rcuit M alfuncti on (S hort)
  • Page 120 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -56 DIAGNOSTICS ENGINE Check voltage between terminal PDL of engine ECU connector and body ground. PREPARATION: Remove the glove compartment door. Turn the ignition switch ON. Measure the voltage between terminal PDL of the engine ECU conector and the body ground.
  • Page 121 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -57 DIAGNOSTICS ENGINE DI8FK- -01 Water Tem p . S ensor Ci rcui t M al functi on CIRCUIT DESCRIPTION The water temperature sensor senses the coolant temperature.
  • Page 122 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -58 DIAGNOSTICS ENGINE WIRING DIAGRAM Hilux Engine ECU Water Temp. Sensor G--R A10940 4Runner Engine ECU Water Temp. Sensor A10940 Land Cruiser/Land Cruiser Prado Engine ECU Water Temp. Sensor...
  • Page 123 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -59 DIAGNOSTICS ENGINE INSPECTION PROCEDURE HI NT: If DTC22, 24 and 39 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using hand--held tester, as freeze frame data records the engine conditions when a malfunction is detected.
  • Page 124 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -60 DIAGNOSTICS ENGINE Check for open in harness or engine ECU. PREPARATION: Remove the glove compartment door. Connect terminals THW and E2 of the engine ECU con-...
  • Page 125 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -61 DIAGNOSTICS ENGINE Check for short in harness or engine ECU. PREPARATION: Remove the glove compartment door. Disconnect the E5 (Hilux), E6 (Land Cruiser/Land Cruiser Prado) or E16 (4Runner) connector of the engine ECU.
  • Page 126 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -62 DIAGNOSTICS ENGINE Ch eck water t emp eratu re sen so r ( See Pu b . No . RM710E, ED sectio n ) . Replace water temperature sensor.
  • Page 127 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -63 DIAGNOSTICS ENGINE DI8FL- -01 DT C I ntake Ai r Tem p. Sensor Ci rcuit M alfuncti on CIRCUIT DESCRIPTION The intake air temperature sensor is built in the intake manifold and senses the intake air temperature.
  • Page 128 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -64 DIAGNOSTICS ENGINE WIRING DIAGRAM Hilux, Land Cruiser/Land Cruiser Prado Engine ECU I21 (Hilux), I8 (Land Cruiser/Land Cruiser Prado) Intake Air Temp. Sensor P--L (Hilux) L--Y (Land Cruiser/Land Cruiser Prado)
  • Page 129 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -65 DIAGNOSTICS ENGINE Same value as the actual intake air temperature. HI NT: If there is open circuit, hand--held tester indicates --40˚C (--40˚F). If there is short circuit, hand---held tester indicates 140˚C (284˚F) or more.
  • Page 130 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -66 DIAGNOSTICS ENGINE Check for open in harness or engine ECU. PREPARATION: Remove the glove compartment door. Intake Air Engine ECU Connect between terminals THA and E2 of the engine Temp.
  • Page 131 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -67 DIAGNOSTICS ENGINE Check for short in harness or engine ECU. PREPARATION: Remove the glove compartment door. Disconnect the E5 (Hilux), E6 (Land Cruiser/Land Cruiser Prado) or E16 (4Runner) connector of the engine ECU.
  • Page 132 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -68 DIAGNOSTICS ENGINE Ch eck in take air t emp eratu re sen so r ( See p ag e ED - - 13). Replace intake air temperature sensor.
  • Page 133 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -69 DIAGNOSTICS ENGINE DI31X- -04 I nj ecti o n P um p Correcti o n S ystem M al func - ti o n CIRCUIT DESCRIPTION The correction system is the one to correct a small change between each injection pumps.
  • Page 134 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -70 DIAGNOSTICS ENGINE Try to change injection pump correction unit to another one. PREPARATION: Remove the injection pump correction unit from the injection pump. Install another injection pump correction unit.
  • Page 135 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -71 DIAGNOSTICS ENGINE DI31Z- -04 Turbo P ressure S ensor Ci rcui t M al functi on CIRCUIT DESCRIPTION The turbo pressure sensor is connected to the intake manifold.
  • Page 136 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -72 DIAGNOSTICS ENGINE WIRING DIAGRAM Hilux Engine ECU Turbo Pressure Sensor B--Y G--R A05611 4Runner Engine ECU Turbo Pressure Sensor L--B B--Y A05611 CONTINUED 1KZ- -TE ENGINE SUP (RM790E)
  • Page 137 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -73 DIAGNOSTICS ENGINE Land Cruiser/Land Cruiser Prado Engine ECU Turbo Pressure Sensor B--Y A05611 INSPECTION PROCEDURE HI NT: If DTC22, 24, 35 and 39 are output simultaneously, E2 (sensor ground) may be open.
  • Page 138 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -74 DIAGNOSTICS ENGINE Ch eck tu rb o p ressu re sen so r ( See p ag e ED - - 14). Replace turbo pressure sensor.
  • Page 139 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -75 DIAGNOSTICS ENGINE Ch eck co n n ectio n o f vacu u m h o se b etween tu rb o p ressu re sen so r an d in take ma n i f o l d .
  • Page 140 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -76 DIAGNOSTICS ENGINE Check voltage between terminals PIM and E2 of engine ECU connector. PREPARATION: Remove the glove compartment door. Turn the ignition switch ON. CHE CK: Measure the voltage between terminals PIM and E2 of the en- gine ECU connector.
  • Page 141 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -77 DIAGNOSTICS ENGINE Check and replace engine ECU. 1KZ- -TE ENGINE SUP (RM790E)
  • Page 142 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -78 DIAGNOSTICS ENGINE DI8FM- -01 DT C Fuel Tem p. Sensor Ci rcuit M alfuncti on CIRCUIT DESCRIPTION The fuel temperature sensor senses the fuel temperature. A thermistor built in the sensor changes the resistance value ac- cording to the fuel temperature.
  • Page 143 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -79 DIAGNOSTICS ENGINE WIRING DIAGRAM Hilux Engine ECU Fuel Temp. Sensor LG--B G--R A10940 4Runner Engine ECU Fuel Temp. Sensor A10940 Land Cruiser/Land Cruiser Prado Engine ECU Fuel Temp.
  • Page 144 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -80 DIAGNOSTICS ENGINE INSPECTION PROCEDURE HI NT: If DTC22, 24, 35 and 39 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using hand--held tester, as freeze frame data records the engine conditions when a malfunction is detected.
  • Page 145 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -81 DIAGNOSTICS ENGINE Check for open in harness or engine ECU. PREPARATION: Remove the glove compartment door. Connect terminals THF and E2 of the engine ECU con-...
  • Page 146 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -82 DIAGNOSTICS ENGINE Check for short in harness or engine ECU. PREPARATION: Remove the glove compartment door. Disconnect the E5 (Hilux), E6 (Land Cruiser/Land Cruiser Prado) or E16 (4Runner) connector of the engine ECU.
  • Page 147 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -83 DIAGNOSTICS ENGINE Ch eck fu el temp eratu re sen so r ( See p ag e ED - - 12). Replace fuel temperature sensor. Check for open and short in harness and connector between engine ECU and fu el temp eratu re sen so r ( See p ag e IN - - 20).
  • Page 148 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -84 DIAGNOSTICS ENGINE DI8FN- -01 Vehicle Speed Sensor Signal Circuit Malfuncti on CIRCUIT DESCRIPTION The vehicle speed sensor outputs a 4--pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear.
  • Page 149 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -85 DIAGNOSTICS ENGINE WIRING DIAGRAM Hilux Combination Meter Engine ECU G--O A15415 4Runner Combination Meter Engine ECU G--O A15415 Land Cruiser/Land Cruiser Prado Combination Meter Engine ECU...
  • Page 150 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -86 DIAGNOSTICS ENGINE INSPECTION PROCEDURE HINT: Read freeze frame data using hand--held tester, as freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air--fuel ratio was lean or rich, etc.
  • Page 151 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -87 DIAGNOSTICS ENGINE DI8FO- -01 EGR Valve Lift Sensor Circuit Malfuncti on CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area S Open or short in EGR valve lift sensor circuit No EGLS signal to engine ECU for 1.0 sec.
  • Page 152 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -88 DIAGNOSTICS ENGINE Check voltage between terminal EGLS of engine ECU connector and body ground (See page EC - - 6). PREPARATION: EGLS Remove the glove compartment door.
  • Page 153 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -89 DIAGNOSTICS ENGINE DI8FQ- -01 Back Up P o wer S ource Ci rcui t CIRCUIT DESCRIPTION Battery positive voltage is applied to terminal +BF of the engine ECU even when the ignition switch is OFF for the use of the DTC memory, air--fuel ratio adaptive control value memory and etc.
  • Page 154 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -90 DIAGNOSTICS ENGINE Land Cruiser/Land Cruiser Prado Engine ECU Engine Room R/B B--R B--Y B--Y Battery A15418 INSPECTION PROCEDURE Check voltage between terminal +BF of engine ECU connector and body ground.
  • Page 155 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -91 DIAGNOSTICS ENGINE Ch eck ECD f u se. PREPARATION: Hilux, 4Runner Remove the ECD fuse from the engine room R/B. CHE CK: Check the continuity of the ECD fuse.
  • Page 156 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -92 DIAGNOSTICS ENGINE DI8FV- -01 ECU P ower Source Ci rcuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the ECD main relay (Marking: ECD) and supplying power to the terminal +B of the engine ECU.
  • Page 157 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -93 DIAGNOSTICS ENGINE 4Runner Engine ECU Driver Side J/B Ignition Switch IGSW B--R GR--B W--R L--R Engine Room J/B L--O MREL L--O Relay W--R W--R W--B W--B...
  • Page 158 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -94 DIAGNOSTICS ENGINE Land Cruiser/Land Cruiser Prado Engine ECU Driver Side J/B Center J/B Ignition Switch IGSW B--R B--W B--W W--R Engine Room J/B L--O MREL L--O...
  • Page 159 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -95 DIAGNOSTICS ENGINE Proceed to next circuit inspection shown on probl e m s y m ptoms ta bl e (S e e pa ge DI - - 2 4 ).
  • Page 160 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -96 DIAGNOSTICS ENGINE Check voltage between terminal IGSW of engine ECU connector and body ground. PREPARATION: IGSW Remove the glove compartment door. Turn the ignition switch ON.
  • Page 161 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -97 DIAGNOSTICS ENGINE Check voltage between terminal MREL of engine ECU connector and body ground. PREPARATION: MREL Remove the glove compartment door. Turn the ignition switch ON.
  • Page 162 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -98 DIAGNOSTICS ENGINE DI8FU- -01 Di agnosti c Connector (DLC3) Ci rcuit CIRCUIT DESCRIPTION Terminals TC and CG are located in the DLC3. The DLC3 is located under the finish lower panel. When terminals TC and CG are connected, a DTC in the normal mode or test mode can be read from the check engine warning light in the combination meter.
  • Page 163 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -99 DIAGNOSTICS ENGINE 4Runner Engine ECU Combination Meter CHK ENG GAUGE B--Y R--W B--Y Ignition Switch Engine Room R/B DLC3 BATT W--B Check Connector Battery A15421 CONTINUED...
  • Page 164 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -100 DIAGNOSTICS ENGINE Land Cruiser/Land Cruiser Prado Combination Meter Ignition Switch GAUGE B--Y CHK ENG SHORT CONNECTOR Engine ECU W--L Y--R E J29 DLC3 Y--R GR--L B--W...
  • Page 165 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -101 DIAGNOSTICS ENGINE HI NT: If this inspection is OK and there is no hand--held tester, the fol- lowing steps are unnecessary because this circuit is OK. Pro-...
  • Page 166 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -102 DIAGNOSTICS ENGINE Check and replace engine ECU. Check voltage between terminal W of engine ECU connector and body ground. PREPARATION: Remove the glove compartment door. Disconnect the E7 (Hilux), E8 (Land Cruiser/Land Cruiser Prado) or E18 (4Runner) connector of the engine ECU.
  • Page 167 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -103 DIAGNOSTICS ENGINE Check voltage between terminal BATT of DLC3 and body ground. CHE CK: DLC3 Measure the voltage between terminal BATT of the DLC3 and the body ground.
  • Page 168 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -104 DIAGNOSTICS ENGINE DI8FP- -01 S tarter S i gnal Ci rcui t CIRCUIT DESCRIPTION While the engine is cranking, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve a good start ability.
  • Page 169 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -105 DIAGNOSTICS ENGINE 4Runner Engine ECU Engine Room R/B G--B B--W B--W Ignition Switch B--W W--R B--W Engine Room R/B No.2 B--W B--R W--B B--W Battery Starter...
  • Page 170 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -106 DIAGNOSTICS ENGINE Land Cruiser/Land Cruiser Prado Engine ECU Engine Room R/B R--W R--W B--W W--R Ignition Switch W--L Engine Room R/B No.2 B--R B--W W--B B--R...
  • Page 171 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -107 DIAGNOSTICS ENGINE INSPECTION PROCEDURE HI NT: This diagnostic chart is based on the premise that the engine is being cranked under the normal conditions. If the engine does not crank, proceed to the problem symptoms table on page DI -- 24.
  • Page 172 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -108 DIAGNOSTICS ENGINE W hen not using hand - - held tester : Check voltage between terminal STA of engine ECU connector and body ground. PREPARATION: START Remove the glove compartment door.
  • Page 173 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -109 DIAGNOSTICS ENGINE DI3SC- -03 EGR Control Circuit CIRCUIT DESCRIPTION The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving condi- tions into the intake air mixture to slow down combustion, reduce the combustion temperature and reduce NOx emissions.
  • Page 174 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -110 DIAGNOSTICS ENGINE Land Cruiser/Land Cruiser Prado Engine ECU From Terminal 3 of ECD Main Relay (Marking: ECD) E--VRV for EGR ( S ee page DI -- 92)
  • Page 175 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -111 DIAGNOSTICS ENGINE Check and replace engine ECU (See page IN - - 20). Check operation of E - - VRV for EGR. PREPARATION: Disconnect the vacuum hoses from the E--VRV.
  • Page 176 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -112 DIAGNOSTICS ENGINE Ch eck EGR valve (See p ag e EC - - 3). Replace EGR valve. Check and replace engine ECU (See page IN - - 20).
  • Page 177 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -113 DIAGNOSTICS ENGINE Check operation of E - - VRV for EGR. PREPARATION: Remove the glove compartment door. Disconnect the E4 (Hilu x), E 5 (Land Cruiser Land Cruiser Prado) or E15 (4Runner) connector of the engine ECU.
  • Page 178 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -114 DIAGNOSTICS ENGINE Ch eck EGR valve (See p ag e EC - - 3). Replace EGR valve. Check and replace engine ECU (See page IN - - 20).
  • Page 179 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -115 DIAGNOSTICS ENGINE DI8FW- -01 P re - - h eati n g Control Ci rcui t CIRCUIT DESCRIPTION When the ignition switch is turned ON, the engine ECU calculates the glow indicator lighting time/heating corresponding to the coolant temperature at that time and turns on the glow indicator light/glow plug relay.
  • Page 180 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -116 DIAGNOSTICS ENGINE WIRING DIAGRAM Hilux Engine ECU Center J/B Driver Side J/B Combination meter GLOW GIND GAUGE R--L R--L R--W J12 J/C SREL B--R B--R IJ1 14...
  • Page 181 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -117 DIAGNOSTICS ENGINE 4Runner Engine ECU Driver Side J/B Combination meter GLOW GIND GAUGE B--Y B--Y SREL IG1 19 B--R Engine Engine Room Room R/B R/B No.2...
  • Page 182 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -118 DIAGNOSTICS ENGINE Land Cruiser/Land Cruiser Prado Engine ECU Driver Side J/B Combination meter GLOW GIND GAUGE B--Y SREL G--R W--R IM2 19 G--R Engine Engine Room Room R/B R/B No.2...
  • Page 183 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -119 DIAGNOSTICS ENGINE Check voltage between terminal GIND of engine ECU connector and body ground. PREPARATION: GIND Remove the glove compartment. Disconnect the E7 (Hilux), E8 (Land Cruiser/Land Cruis- er/Prado) or E18 (4Runner) connector from the engine ECU.
  • Page 184 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -120 DIAGNOSTICS ENGINE Check for open in harness and connector between combination meter and engine ECU, and com- bi na ti on me te r a nd G AUG E fus e (S e e pa ge I N - - 2 0 ).
  • Page 185 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -121 DIAGNOSTICS ENGINE Check and replace engine ECU (See page IN - - 20). Check for open and short in harness and connector between glow plug relay and engine ECU, and glow plug relay and body ground (See page IN - - 20).
  • Page 186 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -122 DIAGNOSTICS ENGINE Proceed to next circuit inspection shown on probl e m s y m ptoms ta bl e (S e e pa ge DI - - 24).
  • Page 187 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -123 DIAGNOSTICS ENGINE DI8FR- -01 1st Gear Positi on Switch Ci rcuit (only for M/T) CIRCUIT DESCRIPTION The shift position switch on the side of transmission detects the 1st gear and limits the engine output when high load is applied during the vehicle running in the 1st gear.
  • Page 188 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -124 DIAGNOSTICS ENGINE Check voltage between terminal FSW of engine ECU connector and body ground. PREPARATION: Remove the glove compartment door. Turn the ignition switch ON. CHE CK:...
  • Page 189 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -125 DIAGNOSTICS ENGINE DI8FT- -01 A/ C S ignal Circuit CIRCUIT DESCRIPTION When the A/C compressor is on, the A/C amplifier sends an A/C signal to the engine ECU, then engine ECU increases the fuel injection volume to improve the driveability during the engine idling.
  • Page 190 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -126 DIAGNOSTICS ENGINE INSPECTION PROCEDURE W hen using hand - - held tester : Connect hand - - held tester, and check A/C signal. PREPARATION: Connect the hand--held tester to the DLC3.
  • Page 191 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -127 DIAGNOSTICS ENGINE Check and replace A/C amplifier. W hen not using hand - - held tester : Check voltage between terminal AC1 of engine ECU connector and body ground.
  • Page 192 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -128 DIAGNOSTICS ENGINE DI8FS- -01 A/ C Cut Control Circuit CIRCUIT DESCRIPTION This circuit cuts the air conditioning operation during the vehicle acceleration in order to increase an accel- eration performance.
  • Page 193 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -129 DIAGNOSTICS ENGINE INSPECTION PROCEDURE W hen using hand - - held tester : Connect hand - - held tester, and check operation of air conditioning cut control.
  • Page 194 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX DI- -130 DIAGNOSTICS ENGINE A/C Switch Condition Voltage 9 - - 14 V 0 - - 3 V Check and replace A/C amplifier. Check and replace engine ECU (See page IN - - 20).
  • Page 195 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ENGINE MECHANICAL IDLE SPEED AND MAXIMUM SPEED ..EM--1 CYLINDER HEAD ......
  • Page 196 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -1 ENGINE MECHANICAL IDLE SPEED AND MAXIMUM SPEED IDLE SPEED AND MAXIMUM SPEED EM0QL- -03 INSPECTION INITIAL CONDITIONS Engine at normal operating temperature. Air cleaner installed. All pipes and hoses of air induction system connected.
  • Page 197 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -2 Page 1 of 6 ENGINE MECHANICAL CYLINDER HEAD CYLINDER HEAD EM1LQ- -01 COM P ONE NT S w/ Intercooler (Land Cruiser/Land Cruiser Prado for Australia) z Gasket...
  • Page 198 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -3 Page 2 of 6 ENGINE MECHANICAL CYLINDER HEAD Turbocharger Heat Insulator Exhaust manifold Heat Insulator w/ EGR 19 (190, 14) z Gasket 20 (200, 14) Turbine Outlet Elbow...
  • Page 199 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -4 Page 3 of 6 ENGINE MECHANICAL CYLINDER HEAD Injection Pipe 9 (90, 78 in.∙lbf) 15 (150, 11) Clamp 15 (150, 11) Oil Filler Cap x 10...
  • Page 200 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -5 Page 4 of 6 ENGINE MECHANICAL CYLINDER HEAD Adjusting Shim Valve Lifter Keeper Spring Retainer Valve Spring Spring Seat Engine Hanger Heater Water Inlet Pipe z Oil Seal...
  • Page 201 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -6 Page 5 of 6 ENGINE MECHANICAL CYLINDER HEAD EM1LR- -01 INSPECTION INSPECT AND GRIND VALVES Grind the valve enough to remove pits and carbon. Check that the valve is ground to the correct valve face angle.
  • Page 202 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -7 Page 6 of 6 ENGINE MECHANICAL CYLINDER HEAD Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve.
  • Page 203 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -8 Page 1 of 9 ENGINE MECHANICAL CYLINDER BLOCK CYLINDER BLOCK EM1LS- -01 DI SASSEMBLY RE MO V E CO NNE CTI NG RO D CAP S AND CHE CK O I L...
  • Page 204 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -9 Page 2 of 9 ENGINE MECHANICAL CYLINDER BLOCK HI NT: Mark 2, 3, 4, 5 or 6 If using a standard bearing, replace it with one having the same number.
  • Page 205 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -10 Page 3 of 9 ENGINE MECHANICAL CYLINDER BLOCK Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust washers (No.5...
  • Page 206 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -11 Page 4 of 9 ENGINE MECHANICAL CYLINDER BLOCK HI NT: No. 2 If replacing the cylinder block subassembly, the bearing stan- No. 5 No. 1 dard clearance will be: No.
  • Page 207 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -12 Page 5 of 9 ENGINE MECHANICAL CYLINDER BLOCK EM1LT- -01 INSPECTION INSPECT CYLINDER BORE DIAMETER Front HI NT: There are 3 sizes of the standard cylinder bore diameter, marked ”1”, ”2”...
  • Page 208 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -13 Page 6 of 9 ENGINE MECHANICAL CYLINDER BLOCK Subtract the piston diameter measurement from the cylinder bore diameter measurement. Front Standard oil clearance: 0.050 - - 0.070 mm (0.0020 - - 0.0028 in.) Maximum oil clearance: 0.14 mm (0.0055 in.)
  • Page 209 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -14 Page 7 of 9 ENGINE MECHANICAL CYLINDER BLOCK EM1LU- -01 REPLACEMENT REPLACE OVERSIZED (O/S) PISTONS HI NT: Bore all the 4 cylinders to the O/S piston outside diameter.
  • Page 210 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -15 Page 8 of 9 ENGINE MECHANICAL CYLINDER BLOCK EM1LV- -01 RE AS S E M BLY HI NT: Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all slid- ing and rotating surfaces.
  • Page 211 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EM- -16 Page 9 of 9 ENGINE MECHANICAL CYLINDER BLOCK Using a piston ring expander, install the 2 compression Piston Ring Expander rings with the code mark facing upward.
  • Page 212 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX TURBOCHARGING T URB O CHA RG E R ..... . .
  • Page 213 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX Turbocharger. On-vehicle inspection. 1. Inspect intake air system: Pg TC-1 2. Inspect exhaust system: Pg TC-1 3. Check turbocharger pressure: Pg TC-1 4. Inspect impeller wheel rotation: Pg TC-1 5.
  • Page 214 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX TC- -1 TURBOCHARGING TURBOCHARGER TURBOCHARGER TC01P- -03 ON - - V E HI CL E I NS P E CT I O N INSPECT INTAKE AIR SYSTEM Check for leakage or clogging between the air cleaner housing and turbocharger inlet and between the turbocharger outlet and cylinder head.
  • Page 215 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX TC- -2 TURBOCHARGING TURBOCHARGER TC038- -01 COM P ONE NT S Turbine Housing V--Band Snap Ring E--Ring Bearing Housing z O--Ring Compressor Housing 4.8 (49, 42 in.∙lbf) Bearing Housing...
  • Page 216 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX TC- -3 TURBOCHARGING TURBOCHARGER TC033- -02 DI SASSEMBLY INSPECT TURBI NE S HAFT RO TAT I O N Grasp the edge of the turbine shaft, and turn it. Check that the turbine shaft turns smoothly.
  • Page 217 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX TC- -4 TURBOCHARGING TURBOCHARGER RE MO V E ACTUATO R Actuator Disconnect the actuator hose form the compressor hous- ing. Using SST, apply pressure to the actuator. 09992 -- 00242 NOTICE: Never apply more than 147 kPa (1.50 kgf/cm...
  • Page 218 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX TC- -5 TURBOCHARGING TURBOCHARGER Using a plastic--faced hammer, tap out the bearing hous- Bearing ing. Housing NOTICE: Remove the bearing housing as straight as possible and so not make the turbine wheel interfere with the turbine hous- ing.
  • Page 219 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX TC- -6 TURBOCHARGING TURBOCHARGER TC035- -02 RE AS S E M BLY I NS TALL BE ARI NG HO US I NG Install the snap ring to the turbocharger.
  • Page 220 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX TC- -7 TURBOCHARGING TURBOCHARGER Align the matchmarks on the V--band, turbine housing and bearing housing, and temporarily tighten a new nut. New V--Band Torque: 4.8 N∙m (49 kgf∙cm, 42 in.∙lbf)
  • Page 221 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX TC- -8 TURBOCHARGING TURBOCHARGER Remove the SST. ADJ US T ACTUATO R P US H RO D S T RO KE Stroke NOTICE: Never apply more than 147 kPa (1.50 kgf/cm , 21.3 psi) of...
  • Page 222 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX TC- -9 TURBOCHARGING TURBOCHARGER Using SST, apply approx. 119 kPa (1.21 kgf/cm , 17.2 psi) Selected of pressure to the actuator, and install the selected plate Plate Washer washers between the actuator and compressor housing with the 2 bolts.
  • Page 223 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX TC- -10 TURBOCHARGING INTERCOOLER I NT E RCOOL ER TC039- -01 COM P ONE NT S w/ Intercooler (Land Cruiser/Land Cruiser Prado for Australia) 10 (100, 7) Gasket...
  • Page 224 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EMISSION CONTROL PARTS LAYOUT AND SCHEMATIC DRAWING ... EC--1/2 EXHAUST GAS RECIRCULATION (EGR) SYSTEM (w/ EGR) .....
  • Page 225 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EC- -1 EMISSION CONTROL PARTS LAYOUT AND SCHEMATIC DRAWING PARTS L AY OUT AND SCHEMATIC DRAWING EC0IQ- -01 LOCATION Turbo Pressure Sensor Engine ECU Intake Air Temp. Sensor...
  • Page 226 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EC- -2 EMISSION CONTROL PARTS LAYOUT AND SCHEMATIC DRAWING EC09B- -03 DRAWI NG Vacuum Pump Throttle Body Vacuum Damper *EGR Valve *E--VRV for EGR *EGR Valve Lift Sensor...
  • Page 227 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EC- -3 EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM (w/ EGR) EXHAUST GAS RECIRCULAT ION (EGR) SYSTEM (w/ EGR) EC0IN- -01 ON - - V E HI CL E I NS P E CT I O N...
  • Page 228 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EC- -4 EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM (w/ EGR) CHE CK O UTP UT VACUUM WI TH VACUUM G AUG E Vacuum Gauge Connect a vacuum gauge to the output pipe.
  • Page 229 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EC- -5 EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM (w/ EGR) EC0IO- -01 COM P ONE NT S EGR Valve z Gasket 19 (195, 14) Lift Sensor Connector...
  • Page 230 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EC- -6 EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM (w/ EGR) EC0IP- -01 INSPECTION INSPECT EGR VALVE Remove the EGR valve. Under the condition of applying the vacuum to the dia- phragm chamber, check the valve operation.
  • Page 231 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX EC- -7 EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM (w/ EGR) INSPECT WATER TEMPERATURE SENSOR (See Pub. No. RM710E, page ED - - 15) INSPECT TURBO P RESSURE SENSOR...
  • Page 232 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ELECTRONIC CONTROL DIESEL THROTTLE BODY ..... . .
  • Page 233 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -1 Page 1 of 7 ELECTRONIC CONTROL DIESEL THROTTLE BODY THROTTLE BODY ED02R- -02 ON - - V E HI CL E I NS P E CT I O N...
  • Page 234 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -2 Page 2 of 7 ELECTRONIC CONTROL DIESEL THROTTLE BODY ED02S- -02 COM P ONE NT S w/ Intercooler (Land Cruiser/Land Cruiser Prado for Australia) 10 (100, 7)
  • Page 235 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -3 Page 3 of 7 ELECTRONIC CONTROL DIESEL THROTTLE BODY w/o Intercooler Wire Clamp Hilux PCV Hose Engine Wire 4Runner, Land Cruiser/Land Cruiser Prado PCV Hose Wire Clamp...
  • Page 236 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -4 Page 4 of 7 ELECTRONIC CONTROL DIESEL THROTTLE BODY ED03T- -01 RE M O VAL w/ Inte rcooler: REMOVE INTERCOOLER ASSEMBLY Disconnect the turbo pressure sensor connector.
  • Page 237 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -5 Page 5 of 7 ELECTRONIC CONTROL DIESEL THROTTLE BODY w/o Intercooler: w/o Intercooler Using a torx socket wrench (E8), remove the 4 stud bolts for the throttle body.
  • Page 238 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -6 Page 6 of 7 ELECTRONIC CONTROL DIESEL THROTTLE BODY ED03U- -01 INSTALLATION I NS TALL T HRO TTLE BO DY w/ Intercooler: Install a new gasket and the throttle body with the 4 bolts.
  • Page 239 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -7 Page 7 of 7 ELECTRONIC CONTROL DIESEL THROTTLE BODY Connect the air hose to the turbocharger, and place the w/o Intercooler clamp lock together with the pliers and press down the tip of the lock plate.
  • Page 240 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -8 ELECTRONIC CONTROL DIESEL TIMING CONTROL VALVE TIMING CONTROL VALVE ED03V- -01 INSPECTION Ohmmeter INSPECT TIMING CONTROL VALV E Disconnect the valve connector. Using an ohmmeter, measure the resistance between the terminals.
  • Page 241 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -9 ELECTRONIC CONTROL DIESEL SPILL CONTROL VALVE SPILL CONTROL VALVE Ohmmeter ED02U- -02 INSPECTION INSPECT SPILL CONTROL VALVE Disconnect the valve connector. Using an ohmmeter, measure the resistance between the terminals.
  • Page 242 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -10 Page 1 of 2 ELECTRONIC CONTROL DIESEL E- -VRV FOR EGR (w/ EGR) E - - V RV F OR E GR (w/ E GR) ED03W- -01 COM P ONE NT S 5.4 (55, 48 in.∙lbf)
  • Page 243 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -11 Page 2 of 2 ELECTRONIC CONTROL DIESEL E- -VRV FOR EGR (w/ EGR) ED03X- -01 INSPECTION Ohmmeter INSPECT E - - VRV Inspect the E--VRV for open circuit.
  • Page 244 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -12 ELECTRONIC CONTROL DIESEL FUEL TEMPERATURE SENSOR FUEL TEMPERAT URE SENSOR ED040- -01 INSPECTION REMOVE FUEL TEMPERATURE SENSOR Disconnect the sensor connector. Using a 19 mm deep socket wrench, remove the sensor and O--ring.
  • Page 245 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -13 ELECTRONIC CONTROL DIESEL INTAKE AIR TEMPERATURE SENSOR INTAKE AIR T EMPERAT URE w/ Intercooler SENSOR ED041- -01 INSPECTION w/ Inte rcooler: REMOVE INTAKE AIR TEMPERATURE SENSOR Disconnect the sensor connector.
  • Page 246 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -14 Page 1 of 3 ELECTRONIC CONTROL DIESEL TURBO PRESSURE SENSOR TURBO PRESSURE SENSOR ED042- -01 COM P ONE NT S w/ Intercooler (Land Cruiser/Land Cruiser Prado for Australia)
  • Page 247 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -15 Page 2 of 3 ELECTRONIC CONTROL DIESEL TURBO PRESSURE SENSOR ED033- -02 INSPECTION Voltmeter INSPECT POWER SOURCE V O LTAG E O F TURBO Disconnect PRESSURE SENSOR Disconnect the sensor connector.
  • Page 248 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -16 Page 3 of 3 ELECTRONIC CONTROL DIESEL TURBO PRESSURE SENSOR Using SST (turbocharger pressure gauge), apply pres- Engine ECU sure to the sensor in 19.6 kPa (0.20 kgf/cm , 2.84 psi)
  • Page 249 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -17 ELECTRONIC CONTROL DIESEL ENGINE SPEED SENSOR ENGINE SPEED SENSOR Ohmmeter ED03F- -02 INSPECTION INSPECT ENGINE SPEED SENSOR Disconnect the sensor connector. Using an ohmmeter, measure the resistance between the terminals.
  • Page 250 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -18 Page 1 of 2 ELECTRONIC CONTROL DIESEL ACCELERATOR PEDAL POSITION SENSOR ACCELERATOR PEDAL POSITION SENSOR ED043- -01 COM P ONE NT S Accelerator Pedal Position Sensor...
  • Page 251 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -19 Page 2 of 2 ELEC TR O N IC C O N TR O L D IESEL AC C ELER ATO R PED AL PO SITIO N SEN SO R...
  • Page 252 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -20 ELECTRONIC CONTROL DIESEL ACCELERATOR PEDAL CLOSED POSITION SWITCH ACCELERATOR PEDAL CLOSED Ohmmeter POSITION SWITCH ED038- -02 INSPECTION INSPECT ACCE LE RATO R P E DAL CLO S E D P O S I TI O N SWITCH Disconnect the switch connector.
  • Page 253 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -21 Page 1 of 2 ELECTRONIC CONTROL DIESEL FIRST GEAR POSITION SWITCH (M/T) FIRST GEAR POSITION SWITCH (M/T) ED03Y- -01 INSPECTION INSPECT FIRST GEAR POSITION SWITCH Disconnect the switch connector.
  • Page 254 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -22 Page 2 of 2 ELECTRONIC CONTROL DIESEL FIRST GEAR POSITION SWITCH (M/T) ED03Z- -01 REPLACEMENT RE MO V E TRANS MI S S I O N REMOVE FIRST GEAR POSITION SWITCH Using SST, remove the switch and gasket.
  • Page 255 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ED- -23 ELECTRONIC CONTROL DIESEL INJECTION PUMP CORRECTION UNIT INJ E CTION P UMP CORRECTION UNIT ED03B- -02 INSPECTION INSPECT INJ ECTION PUMP CORRECTION UNIT (See page DI - - 69)
  • Page 256 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ENGINE FUEL FUEL HEATER ......
  • Page 257 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -1 Page 1 of 2 ENGINE FUEL FUEL HEATER FUEL HEAT ER FU08L- -01 COM P ONE NT S 1.96 (20, 17 in.∙lbf) Fuel Heater (with Vacuum switch)
  • Page 258 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -2 Page 2 of 2 ENGINE FUEL FUEL HEATER FU065- -02 INSPECTION REMOVE FUEL HEATER Disconnect the fuel heater connector. Remove the 2 screws and fuel heater.
  • Page 259 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -3 Page 1 of 2 ENGINE FUEL INJECTION NOZZLE INJECTION NOZZLE FU06W- -02 TEST INJECTION PRESSURE TEST Install the injection nozzle to the injection nozzle hand tester and bleed air from the union nut.
  • Page 260 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -4 Page 2 of 2 ENGINE FUEL INJECTION NOZZLE Adjusting s him thickness: mm (in.) mm (in.) mm (in.) 0.900 (0.0354) 1.275 (0.0502) 1.650 (0.0650) 0.925 (0.0364) 1.300 (0.0512)
  • Page 261 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -5 ENGINE FUEL INJECTION PUMP INJECTION PUMP FU06Y- -02 ON - - VEHICLE INSPECTION INSPECT ENGINE SPEED SENSOR (See page ED - - 17) INSPECT SPILL CONTROL VALVE...
  • Page 262 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -6 Page 1 of 2 ENGINE FUEL INJECTION PUMP FU03P- -03 COM P ONE NT S Clamp Turbo Pressure Sensor Connector Engine Wire Throttle Control Motor Connector...
  • Page 263 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -7 Page 2 of 2 ENGINE FUEL INJECTION PUMP Fuel Inlet Hollow Screw 36.8 (375, 27) 24.5 (250, 18) Cap Nut z Gasket Fuel Inlet Pipe 24.5 (250, 18)
  • Page 264 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -8 ENGINE FUEL INJECTION PUMP FU06Z- -02 RE M O VAL w/ Inte rcooler: RE MO V E I NTE R CO O L E R (S e e pa ge E M - - 2 )
  • Page 265 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -9 ENGINE FUEL INJECTION PUMP Loosen the 2 nuts holding the injection pump to the timing gear case. Remove the 3 bolts and injection pump stay. B12970 Using SST, disconnect the injection pump from the timing gear case.
  • Page 266 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -10 Page 1 of 2 ENGINE FUEL INJECTION PUMP FU08M- -01 DI SASSEMBLY MOUNT PUMP ASSEMBLY TO SST (STAND) 09241 -- 76022, 09245 -- 54010 RE MO V E S E T KE Y O F DRI V E P ULLE Y F RO M DRI V E...
  • Page 267 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -11 Page 2 of 2 ENGINE FUEL INJECTION PUMP REMOVE DELIVERY VALVE HOLDERS Using SST, remove the 4 delivery valve holders and springs. 09260 -- 54012 (09269 -- 54020) Remove the 4 delivery valves and gaskets.
  • Page 268 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -12 ENGINE FUEL INJECTION PUMP FU03S- -03 INSPECTION NOTICE: Do not touch the sliding surfaces of the delivery valves. INSPECT DELIVERY VALVES Pull up the valve, release it.
  • Page 269 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -13 Page 1 of 2 ENGINE FUEL INJECTION PUMP FU08N- -01 RE AS S E M BLY MO UNT P UMP BO DY TO S S T (S TAND)
  • Page 270 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -14 Page 2 of 2 ENGINE FUEL INJECTION PUMP I NS TALL F UE L I NLE T HO LLO W S CRE WS FUE L PIPES Install a new gasket and the hollow screw.
  • Page 271 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -15 Page 1 of 2 ENGINE FUEL INJECTION PUMP FU070- -02 INSTALLATION INSTALL INJ ECTION PUMP Install a new O--ring to the pump. Apply a light coat of engine oil on the O--ring.
  • Page 272 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX FU- -16 Page 2 of 2 ENGINE FUEL INJECTION PUMP CHE CK I NJ E CTI O N P UMP DRI V E S HAFT T HRUS T CLE ARANCE Move the No.
  • Page 273 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX COOLING COOLANT Replacement ... CO -1 Drain Engine Coolant, Fill Engine Coolant, Check for Coolant leaks & Check Specific...
  • Page 274 Drain Plug ing system. B09314 Use ”Toyota Long Life Coolant” or equivalent and mix it with plan water according to the manufactur- er’s directions. Using of coolant which includes more than 50 % [freezing protection down to --35˚C (--31˚F)] or 60 % [freezing protection down to --50˚C (--58˚F)] of...
  • Page 275 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX LUBRICATION OIL AND FILTER ......
  • Page 276 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX LU- -1 Page 1 of 2 LUBRICATION OIL AND FILTER OIL AND FILT ER LU0HW- -02 REPLACEMENT CAUTION: Prolonged and repeated contact with mineral oil will S S S S result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis.
  • Page 277 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX LU- -2 Page 2 of 2 LUBRICATION OIL AND FILTER Tighten the oil filter by hand until the rubber gasket con- tacts the seat of the filter mounting.
  • Page 278 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX LU- -3 Page 1 of 3 LUBRICATION OIL PUMP OI L P UMP LU0HX- -02 COM P ONE NT S Clamp Turbo Pressure Sensor Connector Engine Wire 9 (90, 78 in.∙lbf)
  • Page 279 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX LU- -4 Page 2 of 3 LUBRICATION OIL PUMP Alternator Camshaft Oil Seal Retainer 21 (216, 15) Alternator Bracket 62 (620, 45) 21 (216, 15) Water Pump 9 (90, 78 in.∙lbf)
  • Page 280 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX LU- -5 Page 3 of 3 LUBRICATION OIL PUMP L Taper Screw Plug z O--Ring 16 (160, 12) 42 (425, 31) Driven Rotor Spring z Gasket Relief Valve...
  • Page 281 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX STARTING PRE--HEATING SYSTEM ....ST--1...
  • Page 282 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT BACK TO MODEL INDEX ST- -1 STARTING PRE- -HEATING SYSTEM PRE - - HEATING SYSTEM ST0ML- -01 INSPECTION INSPECT LIGHTING TIME OF GLOW INDICATOR LIGHT Turn the ignition switch ON, measure the lighting time.
  • Page 283 BACK TO MAIN INDEX 1KZ-TE PAGES FROM SUPPLEMENT ALPHABETICAL INDEX BACK TO MODEL INDEX ID - - 1 Page 1 of 2 ALPHABETICAL INDEX (A - - T) Page Page ABBREVIATIONS USED IN THIS MANUAL HOW TO PROCEED WITH TROUBLESHOOTING (TERMS) .
  • Page 284 BACK TO CHAPTER INDEX 1KZ-TE PAGES FROM SUPPLEMENT ALPHABETICAL INDEX BACK TO MODEL INDEX ID - - 2 Page 2 of 2 ALPHABETICAL INDEX (T - - T) TERMINALS OF ECU (ENGINE) (DIAGNOSTICS) ......