Toyota 1HD-FT Operating instructions

@TOYOTA
1HD-FT
ENGINE
REPAIR MANUAL
Jan., 1995
.
..
Pub. No. RM437E

© 1995 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be
reproduced or copied, in whole or in part,
without the written permission of Toyota
Motor Corporation.
FOREWORD
This repair manual has been prepared to provide information
covering general service repairs for the 1HD-FT engine
equipped in the TQYOTA LAND CRUISER.
Applicable models:
HDJ80 series
Please
note that the publications below have also been pre-
pared as relevant service manuals
for the components and
system in this engine.
Manual Name Pub. No.
01HD·FT Engine Emission
Control Repair ERM111E
Manual
All information in this manual is based on the latest product in-
formation at the time of publication. However, specifications
and procedures are subject to change without notice.
TOYOTA MOTOR CORPORATION

INTRODUCTION
ENGINE
STARTING SYSTEM
~=
CHARGING SYSTEM

IN-1
INTRODUCTION
HOW TO USE THIS MANUAL IN- 2
IDENTIFICATION INFORMATION
IN- 4
GENERAL REPAIR INSTRUCTIONS IN- 5
ABBREVIATIONS USED
IN THIS
MANUAL IN- 8
STANDARD BOLT TORQUE
SPECIFICATIONS
.•..........................•....... IN- 9

IN-2
INTROOUCTION - HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
INDEX
__ n
IN
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.
GENERAL DESCRIPTION
At the beginning of each section. aGeneral Description is given that pertains to all repaIr
operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and
find the cause.
PREPARATION
Preparation lists the SST (Special Service Tools). recommended tools. equipment. lubricant and
SSM (Special Service Materials) which should be prepared before beginning the operation and
explains the purpose of each one.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and
shows how the parts fit together.
Example:
Plug 0' R
1 • Gasket riven otor
~J r"'""
~--
Timing Gear Case
•Non-reusable part

INTROOUCTION - HOW TO USE THIS MANUAL
IN-3
The procedures are presented in a step-by-step format:
•
The illustration shows what to do and where to do it.
• The task heading tells what to do.
•The detailed text tells how to perform the task and gives other information such as
specifications and warnings.
Example: N
Illustration:
what to do and where
Task heading: what to do
/
6_ INSTALL CRANKSHAFT PULLEY
(a) Using SST, install the bolt.
SST 0921 ~54015 (90119-~' 26)
Set part No. Component part No.
Detailed text: how to do task
(b) Install the b".
Torque: 30 N·m (310 kgf.cm. 22 ft.lbf)
"
Specification
This format provides the experienced technician with aFAST TRACK to the information needed.
The upper case task heading can be read at a glance when necessary, and the text below it
provides detailed information. Important specifications and warnings always stand out in bold
type.
REFERENCES
References have been kept to a minimum. However. when they are required you are given the
page to refer to.
SPECIFICA TlONS
Specifications are presented in bold type throughout the text where needed. You never have to
leave the procedure to look up your specifications. They are also found at the end of each section.
for quick reference.

IN-4
INTRODUCTION -IDENTIFICATION INFORMATION
IN
CAUTIONS, NOTICES, HINTS:
•CAUTIONS are presented in bold type. and indicate there is apossibility of injury to you or
other people.
•NOTICES are also presented in bold type, and indicate the possibility of damage to the
components being repaired.
•HINTS
are separated from the text but do not appear in bold. They provide additional
information to help you perform the repair efficiently.
SI UNIT
The UNITS given in this manual are primarily expressed according to the 51 UNIT(lnternational
System
of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N·m (310 kgf.cm. 22 ft·lbf)
The engine serial number is stamped on the engine
block
as shown.
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
_.-
"' ..

INTROOUCTION -GENERAL REPAIR INSTRUCTIONS
GENERAL REPAIR INSTRUCTIONS
IN-5
Seal lock Adhesive
INOO:Ml
1.
2.
3.
4.
5.
6.
7.
8.
--,
Use fender. seat and floor covers to keep the vehicle
clean and prevent damage.
During disassembly, keep parts in the appropriate
order to facilitate reassembly.
Observe the following:
(a) Before performing electrical work. disconnect
the negative cable from the battery terminal.
(b) If it is necessary to disconnect the battery for
inspection or repair. always disconnect the cable
from the negative (-) terminal which is grounded
to the vehicle body.
(c)
To prevent damage to the battery terminal post.
loosen the terminal nut and raise the cable strai-
ght up without twisting or prying it.
(d) Clean the battery terminal posts and cable termi-
nals with aclean shop rag. Do not scrape them
with a file or other abrasive objects.
(e) Install the cable terminal to the battery post with
the nut loose. and tighten the nut after installa·
tion. Do not use a hammer to tap the terminal
onto the post.
(f) Be sure the cover for the positive (+) terminal is
properly in place.
Check
hose and wiring connectors to make sure that
they are secure and correct.
Non-reusable parts
(a) Always replace cotter pins. gaskets. 0 -rings and
oil seals etc. with new ones.
(b) Non-reusable parts are indicated in the compo-
nent illustrations by the .... symbol.
Pre
coated parts
Pre coated parts are bolts and nuts. etc. that are
coated with aseal lock adhesive at the factory.
(a) If apre coated part is retightened. loosened or
caused to move in any way. it must be recoated
with the specified adhesive.
(b) When reusing precoated parts. clean off the old
adhesive and dry with
compressed air. Then
apply
the specified seal lock adhesive to the bolt.
nut
or threads.
(c) Precoated parts are indicated in the component
illustrations by the "'* .. symbol.
When necessary. use a sealer on gaskets to prevent
leaks.
Carefully observe
all specifications for bolt tightening
torques. Always
use a torque wrench.

IN
IN-6
INTRODUCTION -GENERAL REPAIR INSTRUCTIONS
9. Use of special service tools (SSn and special service
materials (SSM) may be required. depending on the
nature of the repair. Be sure to use SST and SSM
where specified and follow the proper work proce-
dure. Alist of SST and SSM can be found in the
preparation part at the front of each section in this
manual.
Fu",
EQual Amperage Rali~
10 )
10 )
10. When replacing fuses. be sure the new fuse has the
correct amperage rating. 00 NOT exceed the rating or
use one with alower rating.
illustration
Symbol Abbreviation
IE559-t
8£5517
tnSM
~ FUSE
.., ..
~ MEDIUM CURRENT FUSE
~ HIGH CURRENT FUSE
~ FUSIBLE LINK
-R- CIRCUIT BREAKER
..,..
FUSE
M.fUSE
H·FUSE
FL
CB
11. Care must be taken when jacking up and supporting
the vehicle. Be sure to lift and support the vehicle at
the proper locations.
(a) If the vehicle is to be jacked up only at the front
or rear end. be sure to block the wheels at the
opposite end in order to ensure safety.

INTROOUCTION -GENERAL REPAIR INSTRUCTIONS
IN.'
WRONG
WRONG
CORRECT
""'"
CORRECT
IH025'
(b) After the vehicle is jacked up. be sure to support
it on stands. It is extremely dangerous to do any
work
on a vehicle raised on a jack alone. even for
asmall
job that can be finished quickly.
12.
Observe the following precautions to avoid damage to
the parts:
(a) Do not open the cover or case of the EeU unless
absolutely necessary. (If the Ie terminals are tou-
ched. the Ie may be destroyed by static electric-
ity.)
(bl To disconnect vacuum hoses. pull on the end. not
the middle of the hose.
Ie) To pull apart electrical connectors. pull on the
connector itself. not the wires.
(d) Be careful not to drop electrical components.
such as sensors or relays. If they are dropped on
a hard floor. they should be replaced and not
reused.
(e) When steam cleaning an engine. protect the dis·
tributor. air filter. and VCV from water.
(f) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(g) When checking continuity at the wire connector.
insert the tester probe carefully to prevent termi·
nals from bending.
(h) When using a vacuum gauge. never force the
hose onto a connector that is too large. Use a
step-down adapter instead. Once the hose has
been stretched. it may leak.
Example
13. Tag hoses before disconnecting them:
(a) When disconnecting vacuum hoses. use tags to
identify how they should be reconnected.
(b) After completing ajob. double check that the
vacuum hoses are properly connected. Alabel
under the hood shows the proper layout.
14. Unless otherwise stated. all resistance is measured at
an ambient temperature of 20°C (68°F). Because the
resistance may be outside specifications if measured
at high temperatures immediately after the vehicle
has been running. measurements should be made
when the engine has cooled down.