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.

IN-8 INTROOUCTION -A88REVIATIONS
USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL
__ M
, IN
A/C
Air Conditioner
ACV
Air Control V,lve
ACSO
Automatic Cold Stnt Device
Approx. Approximately
AfT
Automatic T'.n111niaaion
BACS Boo.t and "'tiudl Coml*'Ntion Stopper
BOC Bottom Deed C.nter
ECU
Engine Control Unit
EGR
Exhlu.t Gil Rlcireul.tion
FIPG Formed in Pl.e. Gllket
LHO Left Hand Driv.
LST Laid Sensing Tim.r
MP Multipurpou
MfT
Menu.l Tran'minion
OHC
Ova, He.d Camahaft
O/S Oversized
PCS POWI' Control SY5tlm
PCV po,itiva Cr.nke ••• Ventil.tion
PS
POWI, St •• ring
RHO Right-Hand Drive
SICS
Starting Injection Control Syttem
SSM
Special Service Mllerials
SST Special Sel"t/iCi Tool.
STO Stand.rd
SW Switch
TOC
Top o.,d Clntlr
TEMP. Tlmperalur.
U/S
Under,ill
VSV Vacuum SwitChing V.IIII
w/
With
wi. Without

INTRODUCTION -STANDARD BOLT TORQUE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS
IN-9
--.
HOW TO DETERMINE BOLT STRENGTH
---------------
Mark Class
---------
Mark Class
Hexagon 4-
4T
Stud bolt
head bolt
5- 5T
Bolt
6- 6T
rOr'head No. 7-
7T
~ No mark
B- BT
B- 9T
4T
'0-
lOT
11-
,n
0No mark
4T
Hexagon
o Nom,,'
flange bolt
wI washer
4T
~ Grooved
hexagon bolt v
6T
Hexagon
OJ
head bolt 2
protruding
5T
lines
Hexagon 0
flange bolt 2
wI washer protruding
6T Welded bolt
hexagon bolt lines
Hexagon 0
head bolt 3
~
protruding
7T
lines
4T
Hexagon 0
head bolt 4
protruding
BT
lines

IN-IO
INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS
IN
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
Class Diamete' Pitch Hexagon h.ad bot! Hexagon flange bolt
mm mm
N'm
kif-em ft·lbf
N'm
kgl'em ft·lbf
6 1 5 55 48 in.·lbf 6 60 52 in.·lbf
8,
.25
12.5 130
9
14 145 10
10
1.25 26 260 19 29 290 21
4T
12 1.25
47
480 35 53
540
39
14
1.5 74 760 55 84
850
61
16 1.5 115 1,150 83
---
61 6.5 65 56 in.-lbf 7.5 75 65 in.·lbf
8 1.25 15.5 160
12
17.5 175
13
10
1.25 32 330 24 36 360
26
5T
12 1.25
59 600 43 65 670 48
'4
1.5 91
930 67
100
1.050 76
16 1.5 140 1,400
101 ---
618 80 69 in.·lbf 9 90 78 in..lbf
81.25
19
195 14 21 210
'5
10
, .25
39 400 29
44 440
32
6T
12 1.25
71 730 53 80
810
59
14
1.5 110 1,100
80
125
1.250
90
16 1.5 170 1,750
127
- - -
6110.5 110 8 12 120 9
8,
.25
25
260
19 28
290
21
10 1.25
52 530 38 58 590
43
7T
12 1.25
95 970 70 105
1.050
76
14 1.5 145
1,500
108
'65
1,700 123
16
1.5 230 2,300 166
---
8 1.25
29 300 22 33 330
24
8T 10
1.25 61
620
45
68 690 50
12 1.25 110 1.100 80
120 1,250 90
8
1.25
34 340 25 37
380 27
9T 10 1.25
70 710 51 78
790
57
12
, .25
125
1.300
94
'40
1.450 105
8 1.25
38 390 28 42 430 31
,OT
10
1.25 78
600 58
88 890
64
12
1.25 140 1,450 105 155
1.600
116
8 1.25 42
430 31 47
480 35
11T
10
1.25 67
890
64
97
990
72
12 1.25 155
1,600 116 175
1,800
130

EG·'
ENGINE
ENGINE MECHANICAL EG- 1
PREPARATION EG- 2
TROUBLESHOOTING
EG- 6
AIR FILTER INSPECTION
AND
CLEANING EG - 11
COMPRESSION CHECK EG-12
VALVE CLEARANCE INSPECTION AND
ADJUSTMENT······································· EG-14
INJECTION TIMING INSPECTION AND
ADJUSTMENT······································· EG- 15
tOLE SPEED AND MAXIMUM SPEED
INSPECTION
AND ADJUSTMENT EG- 17
PS IDLE-UP SPEED INSPECTION AND
ADJUSTMENT (M/T)······························ EG- 19
Ale IDLE-UP SPEED INSPECTION AND
ADJUSTMENT·············· ..··..·..··· ···..···· EG- 20
TIMING BELT EG- 21
TIMING GEAR EG- 28
CYLINDER HEAD EG- 38
CYLINDER BLOCK EG- 64
SERVICE SPECiFiCATIONS.. ··················· ..· EG- 89
TURBOCHARGER SYSTEM EG- 93
PREPARATION EG- 93
PRECAUTION EG- 94
TROUBLESHOOTING EG- 95
TURBOCHARGER EG- 97
SERVICE SPECiFiCATIONS.. ······················ EG-103
FUEL SySTEM·········································· EG-I04
PREPARATION EG-l04
FUEL FILTER EG-l07
FUEL HEATER SYSTEM EG-l08
INJECTION NOZZLE EG-ll0
INJECTION PUMP EG-122
STARTING INJECTION CONTROL
SYSTEM (SICS)
EG-172
SERVICE SPECiFiCATIONS·· · ·..·..· EG-174
COOLING SYSTEM EG-117
PREPARATION EG-l77
COOLANT CHECK EG-178
COOLANT REPLACEMENT · · EG-178
WATER PUMP EG-laO
THERMOSTAT EG-l84
RADIATOR EG-l86
SERVICE SPECIFICATIONS EG-l9l
LUBRICATION SYSTEM EG-191
PREPARATION EG-l92
OIL PRESSURE CHECK EG-193
OIL AND FILTER REPLACEMENT EG-l93
OIL PUMP EG-195
OIL COOLER EG- 203
OIL NOZZLE EG- 208
SERVICE SPECiFICATIONS··············.. ······ .. EG- 209

EG-2 ENGINE -ENGINE MECHANICAL
ENGINE MECHANICAL
PREPARATION
SST (SPECIAL SERVICE TOOLS) _
....
:EG
~
09201
'0000
V,Iv, Guidi Bu.hinQ R.mover "
Repllcer Set
, .....
.
.............. .- .......... ........... -. ..........
~
(09201-01070)
v,tv, Guid, Buahing RIlTICIYer I:
Rlpllcer 7
~
09201-41020
V,tv, Stem Oil Seal Repl.e.,.
~~
09202-70020
V,Iv, Sprine Compressor
. . -----.-- ................
--- .............................. ,._-
...
~
(09202-00010) Attlchmll'll
{i)
-',
09213-58012
Crlnkah,ft PuM.., Holding Tool
-
~
-
..... ... .. -....... .........
... _ ...
.-- ..............
(90201-08131)
Wlth'r
@
." .......
........ . ........ ............. .
............................ _ ................
(91111-50845)
Bolt
~
09214-60010
C'lnhh,ft Puu,., &. G .. , Cranktt\.ft pulley
0
=1
R.plle ...
~
09214 76011
erlnkshaft Pull., Repllcer In)ection pump driv. S1 .. rbaaring
Illjeetion
pump drive gur oil
g.'
e:§3EJ
09222-11010
Connecting Rod Bu.hing Remoyer
§El
& Repl,eef
.....
-- -----.- ........- -
......... ...... _----_._.- ..-
.....
B(09222-05020)
RemO~f & Repl.e.,
... .....
.................. _ ..
........... ......... ...

ENGINE -ENGINE MECHANICAL EG-3
.. ........ .......... .. .................... .................. ......... .. ....... ..........
§(09222-05030) Guide
...... ................. -----------------------. ,-.,- .. .......................
fJ
(O9222-05040) Bm
0
09223 00010
Cover &: Seel Repl,ee. C'anklh,ft timing gear
Oil pump drive shaft ge8'
~
09223-46011 Cranklhaft Front
Oil Seal Cernlhafl oil .. ,I
Replacer
~
09223-56010
Cr.nk.hlft Re,r Oil Se.l
Replacer
09223-78010 Crankshaft
Oil Seal Replacer C"nk$hef1 front oil sui
~
(2a
~
09275-54011 Plunger Stroke
Menu.ing Tool
09308-10010
O~ Seal Puller C,anklh,ft front oil $811
~
09330
00021
Comp.nion FI.nge Holding Tool Crenk,heft pulley
~
09950-40010 Puller B Set
~-&~f~
~: ... ~~~
.... ....
, ........
........... ............. '
~
(09951-04010) Hang.r 150
No.1 camshaft timing pulley
Oil pump drive sheft gear
Crankshaft timing gear
Injection pump drive g98r bearing
.....
.............. , , .........
................. .............. .............
................................. ,
~~
(09952-0401 0) Slide Aim
No.1 camshaft liming pulley
O~ pump driv. shalt gear
Crankshaft timing gear
de <liil
Injection pump drive gear bearing
...
(09953-04010) Center Bolt 100 Oil pump drive shaft gear
~
Crankshaft timing g98r
....... ................... .............................. ....... ............. ................. ..... ........................... ........ ................. ...................... ...
(09953-04020) Center Bolt 150
No.1 camshaft timing pulla.,.
~
Oil pump drive shalt g98r
Crankshaft timing gaar
Injection pump drive gear bear,ng
... , ..... ........ ". ..... ...... .............. ...... .....

EG-4
<£Po!O'
~
'EG
@ ~ IJrn
.--...
-r- ... ~ '"".0 ir;fii'
. -::::--
~ """"""..,,
~
0000
~
~
~.."P'
a~
~
~
~
ENGINE -ENGINE MECHANICAL
(09954-04010) Arm 25
(09955-04060) Claw No.6
09950-50010 Puller CSe1
(09951-05010) Hanger 150
(09952-05010)
Slide Atm
(09953-05010) Center Boll 100
(09953-05020) Cenler 8011150
(09954-05020)
Claw No.2
09950-70010 Handle Set
(09951-07100) Handle 100
09960-10010 V'riebl,
Pin Wrench Set
(09962-01000) Variable Pin Wrench Arm Assy
No.1 cllmahalt timing pulley
Oil pump drive Ih.ft gear
Crankshalt timing gear
Injection pump drivll gear bearing
No.' umshaft timing pulley
Oil pump drive Illaflg'a,
Cranksh.ft timing ge,r
Injection pump drive gur be,ring
C •• nklhaft pulley
Injection pump drive gell'
Cr,nksh,ft pulley
Injection pump drive geer
Crtnkshaft pulley
Injection pump drive gear
Crankstlllft pulley
Crankstlaft pulley
Injection pump drive gear
Velve guide bustling
lrljection
pump drive ge.,
(09963-00700) Pin 7Injectiorl pump drive gear
09992 00024 Cylinder Compression Check
Ga ... ge
So<

ENGINE -ENGINE MECHANICAL EG-5
, .............
.. ...... .. ........ ........... . ....
(09992-0021l) G.UiI'
Any
~
09992-00400 Atuc:hment
No.7 Cylinder c:ompression c:tlec:lt
~
RECOMMENDED TOOLS
~~
09040-00010 Heugon
Wrenc:h Set.
~
=~ ..
09200 00010
Engine Adj ... tt Kit.
~ "A
~~
09904-00010 E .. pender Set.
-- .
EOUIPMENT
-- ..
Caliper gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dve penelrant
Engine tune up tester
Heater
Micrometer
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Soft brush
Spring tester
Vel", .pring
Steel square
V,I", .pring

EG-6
Thermometer
Torque wrench
Valve seat cutter
V-block
Vernier calipers
ENGINE - ENGINE MECHANICAL
SSM (SERVICE SPECIAL MATERIALS)
08826-00080 Seal Paeking Black
or equivalent Timing belt cover
(FIPG) Timing gear cove.
Camshaft oil sell reUlinar
Cylinder he.d lemi-circyla. plug
08826 00080
Seal Packing Black or equivel'nt Cylinder hflld cover
(FIPGj Main bearing
cover
R ... oil leal retainer
08826-00100 Seal Packing
12828. Water temperature sender gauge
THREE BONO 12828 or equivalerlt
(FIPGI
TROUBLESHOOTING
_-0'
Diesel Engine Diagnosis
GENERAL
1. Diesel engine problems are usually caused by the engine or fuel system. The injection pump is
very rarely the cause of fuel system problems.
2. Before beginning fuel system tests, first check that the engine compression. valve timing and
other major systems are within specifications.
PRELIMINARY CHECKS
1. Before performing fuel system checks, ensure that the engine is in good running condition. If
necessary, first check the compression. timing and major components or systems.
2. Check
the air filter, and clean or replace it if necessary.
3. Check that there is sufficient fuel in the tank.
4. Check
if the fuel is contaminated with gasoline or other foreign elements. Only good-quality
diesel fuel should be used.
5. Bleed air
from the system by pumping the priming.
6. Check
for water in the fuel filter and fuel tank. and drain as necessary.
7. If the engine will not crank or if it cranks slowly, first troubleshoot the electrical system.

ENGINE -ENGINE MECHANICAL EG-7
PRECAUTION,
1. The basic troubleshooting procedures for the diesel engine (velve clearance. compression.
bearings, vatves. pistons. etc.) are the same checks you would make for gasoline engine.
2. Repair of the injection pump requires considerable skill and use of 8special test bench.
N ~ '"
\\'- __ s_e_e_p_._9_. +'~"_. +~,'+,~'-t,~'-t-'~"' +~". +;"'-t,~'-t-,~,' +~". +-'+"~'-t-'-+-' +-' +-'+-,~,' +,~e' +-'+"~'-t-'-+
5
4
;;
,
~ ;;
o ,
z ~
.~
o
a
;;
,
~
6125
4
631
2
Symptom \ ~
~
'"
Suspect area
Engine does not crank
Engine cranks
normally
o
c
~rf__---------t___+-+-f__+-+_--t-+-t___+-+___t-+-t___+-+-t__+-t___+-+_j
00
,,"
2
32Engine cranks slowly
Engine cranks normally
~r
Bo
:E ;;;I--------+-il-+--+-I-+-I-t-+_j-+-+-I-+--+-t-+-I-t-+-I--I
'·0
".
rHigh engine idle speed
~
3
Rough idle with warm
engine
67 2 5
lack of power 9 6 12 5 8 1 2
Engine suddenly SlOPS 24 1 3
Engine does not shut
off with key 2
"
•
~
6
Excessive exhaust
smoke
Excessi .... efuel
consumption
4 3
8
10
2
5 7
Engine overheat 7
Low oil pressure
High oil pressure
Engine noise
when
warm
2
HINT: When inspecting a wire harness or circuit the Electrical Wiring Diagram repair manual should be
referred to and the circuits of related systems also should be checked.