Toyota 1KZ-TE Operating instructions

2000 TOYOTAMOTOR CORPORATION
All rightsreserved. This CD may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Jun. 28, 2000 01--000628--00
FOREWORD
ThisRepair Manual has been prepared to provide information covering general service repairs for the
1KZ-TE Engine equipped on the TOYOTA HILUX,4RUNNERandLAND CRUISER/ PRADO.
Applicablemodels:KZN165 series (HILUX)
KZN185series(4RUNNER)
KZJ90,KZJ95series(LAND CRUISER/LAND CRUISERPRADO)
Please note that the publications below have also been prepared as relevant service manuals for the
components and system inthisengine.
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.
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RM790E-D
1KZ-TE
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TOYOTAMOTOR CORPORATION
CAUTION
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.
SMust read this manual thoroughly. It is especially important to have good understanding all the
contents written in the PRECAUTION of ”IN” section.
SThe service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use toolsspe-
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.
SIf part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
SIt is important to note that this manual contains various ”Cautions” and ”Notices” that must be
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.
PAGES FROM SUPPLEMENT
S1KZ--T Engine Repair Manual
S1KZ--TE Engine Repair Manual
S1KZ--T, 1KZ--TE Engine Repair Manual Supplement RM522E
RM710E
RM353E
Pub.No.Manual Name

INTRODUCTION
PREPARATION
SERVICE SPECIFICATIONS
DIAGNOSTICS
ENGINE MECHANICAL
TURBOCHARGING
EMISSION CONTROL
ELECTRONIC CONTROL DIESEL
ENGINE FUEL
COOLING
LUBRICATION
STARTING
ALPHABETICAL INDEX
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Supplement: ENGINE 1KZ-TE: HILUX
MAIN INDEX
DECEMBER 2000
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INTRODUCTION
HOWTOUSETHISMANUALIN--1.............
GENERALINFORMATION IN--1/2..................
IDENTIFICATION INFORMATION IN--3..........
ENGINE SERIALNUMBER IN--3.................
REPAIRINSTRUCTIONS IN--4.................
GENERALINFORMATION IN--4/7..................
FOR ALL OF VEHICLES IN--8..................
PRECAUTION IN--8.............................
HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEMS IN--9..............
GENERALINFORMATION IN--9..................
HOW TO PROCEED WITH
TROUBLESHOOTING IN-10/19....................
HOW TO USE THE DIAGNOSTIC CHART AND
INSPECTION PROCEDURE IN--20/24...............
TERMSIN--25.................................
ABBREVIATIONS USED INTHISMANUAL IN--25/26....
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IN04V--05
B07996
B08237
N∙m (kgf∙cm, ft∙lbf) : Specified torque
zNon--reusable part
zCrankshaft Front Oil Seal
zGasket
Relief Valve
Spring
Plug
49 (500, 36)
Driven Rotor
--INTRODUCTION HOW TO USE THIS MANUAL
IN--1
1KZ--TE ENGINE SUP (RM790E)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. 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.
2. PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN--9.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:
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CONTINUED

Illustration:
what to do and where
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a)
Task heading : what to do
SST 09350--30020 (09350--06120)
Set part No. Component part No.
Detailed text : how to do task
(b)
Piston stroke: 1.40 —1.70 mm (0.0551 — 0.0669 in.)
Specification
Place SST and a dial indic ator ont o the ov erdr ive brake pis -
ton as shown in the illus tration.
Measur e the stroke apply ing and releas ing the compressed
air (392— 785 kPa, 4 — 8 kgf/cm
2or 57—114 psi) as shown
in the illus tration.
IN--2
--INTRODUCTION HOW TO USE THIS MANUAL
1KZ--TE ENGINE SUP (RM790E)
The procedur es are presented in a step --by--step format:
SThe illu st ration sh ows what to do and wh ere to do it.
SThe task headi ng tells what to do.
SThe detai led text tells how to perfor m the task and gives other infor mation such as specifications
and warnings .
Example:
This for mat provides the experienced techni cian with a FAST TRACK to the infor mation needed. The upper
casetask headi ng can beread at aglancewhen necessary,and the textbelow itprovides detai led infor ma-
tion. Important spec ifications and warnings alwaysstand out inbold type.
6. REFERENCES
References havebeen kept to aminimum.However,when they arerequired you aregiven the page to refer
to.
7. SPECIFICATIONS
Specifications arepresented inbold typethroughout the textwhere needed. Younever have toleavethe
procedure tolook up your specifications .They arealsofound inServiceSpecifications sectionfor quickref-
erence.
8. CAUTIONS, NOTICES, HINTS:
SCAUTIONS are presentedin boldtype,andindicatethereisapossibility ofinjurytoyouorother
people.
SNOTICESare also presentedin boldtype,andindicatethepossibility ofdamagetothecomponents
being repaired.
SHINTS areseparated from the textbut do not appear inbold. They provideadditional informati on to
help you perform the repairefficiently.
9. SI UNIT
TheUNITSgiven inthismanual areprimarilyexpressed accordingtothe SI UNIT(International System of
Unit),andalternatelyexpresse dinthemetric system andin the English System.
Example:
Torque: 30 N∙m (310 kgf∙cm, 22 ft∙lbf)
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B09246
IN00Q-- 35
--INTRODUCTION IDENTIFICATION INFORMATION
IN--3
1KZ--TE ENGINE SUP (RM790E)
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine block as
shown.
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PAGES FROM SUPPLEMENT1KZ-TE

IN0BX-- 12
FI1066
Z11554
Seal lock Adhesive
IN--4
--INTRODUCTION REPAIR INSTRUCTIONS
1KZ--TE ENGINE SUP (RM790E)
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
(c) Observe the following:
(1) Before performing electrical work, disconnect the
negative (--) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, first disconnect the negative (--)
terminal cable.
(3) When disconnecting the terminal cable, to prevent
damage to the battery terminal, loosen the cable
nut and raise the cable straight up without twisting
or prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape themwith a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals after
loosening the nut, and tighten the nut after installa-
tion. Do not use a hammer to tap the cable ends
onto the terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are secure and correct.
(e) Non--reusable parts
(1) Always replace cotter pins, gaskets, O--rings and oil
seals etc. with new ones.
(2) Non--reusable parts are indicated in the component
illustrations by the ”z” symbol.
(f) Precoated parts
Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) 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.
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CONTINUED

BE1367
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
V00076
AbbreviationPart NameSymbolIllustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKER
FUSE
M--FUSE
H--FUSE
FL
CB
--INTRODUCTION REPAIR INSTRUCTIONS
IN--5
1KZ--TE ENGINE SUP (RM790E)
(3) Precoated parts are indicated in the component il-
lustrations by the ”L” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
(h) Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in Preparation section in this
manual.
(j) When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.
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CONTINUED

IN0253
WRONG CORRECT
IN0252
WRONG CORRECT
IN--6
--INTRODUCTION REPAIR INSTRUCTIONS
1KZ--TE ENGINE SUP (RM790E)
(k) 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 & Body Repair Manual for each
vehicle).
SCancel the parking brake on the level place and
shift the transmission in Neutral (or N position).
SWhen jacking up the front wheels of the vehicle at
first place stoppers behind the rear wheels.
SWhen jacking up the rear wheels of the vehicle at
first place stoppers behind the front wheels.
SWhen either the front or rear wheels only should be
jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.
SAfter the vehicle is jacked up, be sure to support it
on rigid racks. It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull on the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) 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.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emissions--related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
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CONTINUED

IN0002
Example
--INTRODUCTION REPAIR INSTRUCTIONS
IN--7
1KZ--TE ENGINE SUP (RM790E)
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step--down
adapter for adjustment. Once the hose has been
stretched, it may leak.
(m) Tag hoses before disconnecting them:
(1) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20˚C(68˚F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.
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