Table Of Contents - Toyota 1HD-FT Repair Manual

Table of Contents

Identification Information7
Si Unit7
Engine Serial Number7
General Repair Instructions8
Abbreviations11
Standard Bolt Torque Specifications12
How To Determine Bolt Strength12
Specified Torque For Standard Bolts13
Engine14
Engine Mechanical15
Preparation15
Recommended Tools18
Equipment18
Troubleshooting19
Diesel Engine Diagnosis19
Diesel Electrical System Diagnosis (Engine Does Not Start Cold)22
Pre-Heating System22
Inspect Power Supply Section22
Inspect Control Section22
Air Filter Inspection And Cleaning24
Fuel Cut Solenoid Valve24
Compression Check25
Valve Clearance Inspection And Adjustment27
Injection Timing Inspection And Adjustment28
Install Sst And Dial Indicator29
Release Acsd Advance29
Idle Speed And Maximum Speed Inspection And Adjustment30
Ps Idle-Up Speed Inspection And Adjustment32
A/C Idle-Up Speed Inspection And Adjustment33
Timing Belt Components For Removal And Installation34
Timing Belt Removal35
Timing Belt Components Inspection36
Timing Belt Installation38
Timing Gear Components For Removal And Installation41
Timing Gears Removal43
Timing Gears Inspection45
Crankshaft Front Oil Seal Replacement47
Injection Pump Drive Gear Oil Seal Replacement47
Timing Gears Installation48
Cylinder Head Components For Removal And Installation51
Cylinder Head Removal55
Cylinder Head Disassembly58
Cylinder Head Components Inspection And Repair58
Camshaft Oil Seal Replacement68
Cylinder Head Assembly69
Cylinder Head Installation71
Cylinder Block Components For Preparation And After Assembly77
Preparation For Disassembly78
Components For Disassembly And Assembly79
Cylinder Block Disassembly80
Cylinder Block Inspection85
Piston And Connecting Rod Disassembly87
Piston And Connecting Rod Inspection88
Cylinder Boring93
Crankshaft Inspection And Repair94
Crankshaft Oil Seal Replacement95
Cylinder Block Assembly97
Post Assembly101
Service Specifications102
Service Data102
Turbocharger System106
Insufficient Acceleration, Lack Of Power Or Excessive Fuel Consumption108
Abnormal Noise109
Excessive Oil Consumption Or White Exhaust109
Turbocharger110
On-Vehicle Inspection110
Components For Removal And Installation111
Turbocharger Removal112
Turbocharger Inspection113
Turbocharger Installation114
Torque Specifications116
Fuel System Preparation117
Fuel Filter120
Fuel Heater System Components Inspection121
Injection Nozzle Components For Removal And Installation123
Injection Nozzles Removal124
Injection Nozzles Test125
Injection Nozzle Disassembly126
Injection Nozzles Cleaning And Inspection126
Injection Nozzles Assembly And Adjustment128
Injection Nozzles Installation133
Injection Pump Components For Removal And Installation135
Injection Pump Removal137
Injection Pump Components For Disassembly And Assembly139
Injection Pump Disassembly141
Injection Pump Components Inspection151
Injection Pump Assembly153
Injection Pump Adjustment167
Install Throttle Position Sensor/Bracket182
Install Fuel Pipes183
Injection Pump Installation184
Starting Injection Control System185
Sics Components Inspection186
Cooling System Preparation190
Coolant Check191
Coolant Replacement191
Water Pump Components For Removal And Installation193
Water Pump Removal194
Water Pump Inspection195
Water Pump Installation196
Thermostat Components For Removal And Installation197
Thermostat Inspection198
Thermostat Installation198
Radiator Cleaning199
Radiator Inspection199
Radiator Components For Disassembly And Assembly200
Radiator Disassembly200
Radiator Assembly201
Lubrication System Preparation205
Oil Pressure Check207
Oil And Filter Replacement207
Oil Pump Components For Removal And Installation209
Oil Pump Removal210
Oil Pump Disassembly212
Oil Pump Inspection212
Oil Pump Assembly213
Oil Pump Installation213
Oil Cooler Components For Removal And Installation216
Oil Cooler Removal218
Oil Cooler And Relief Valve Inspection218
Oil Cooler Installation219
Oil Nozzle Components For Removal And Installation221
Oil Nozzles Removal221
Oil Nozzles Inspection221
Oil Nozzles Installation222
Starting System224
Starting System Preparation225
Pre-Heating System On-Vehicle Inspection226
Pre-Heating Timer Or Emissions Ecu Inspection226
Intake Heater Relay Inspection228
Intake Heater Inspection229
Water Temperature Sensor230
Starter Component For Disassembly And Assembly231
Starter Disassembly231
Starter Inspection And Repair233
Armature Coil233
Commutator233
Field Frame234
Brushes234
Brush Springs235
Brush Holder235
Clutch And Gears235
Starter Assembly238
Magnetic Switch238
Starter Performance Test240
Starter Relay Inspection241
Voltage Converter Timer (W/ 24 V Starter) Inspection242
24 V Hold Warning Relay Inspection244
Charging System246
Charging System Precaution247
Charging System Preparation247
Charging System On-Vehicle Inspection248
Alternator Components For Disassembly And Assembly250
Alternator Disassembly250
Alternator Inspection And Repair253
Alternator Assembly256
Charging System Service Specifications259
Charging System Service Data259
Charging System Torque Specifications259