Toyota 1PZ Operating instructions

FOREWORD
Thisrepairmanualhasbeenpreparedtoprovideinformation
coveringgeneralservicerepairsforthe1 PZ,1 HZand1HD-T
enginesequippedontheTOYOTALANDCRUISERand
COASTER.
Applicablemodels:
PZJ70,73,75series
HZJ70,73,75,80series
HDJ80series
HZB30series
HDB30series
Pleasenotethatthepublicationsbelowhavealsobeenprepared
asrelevantservicemanualsforthecomponentsandsystemin
thisengine.
Allinformationinthismanualisbasedonthelatestproduct
informationatthetimeofpublication.However,specifications
andproceduresaresubjecttochangewithoutnotice.
TOYOTAMOTORCORPORATION
ManualName
LandCruiser(Wagon)NewCarFeatures
Pub.No.
NCF064E

CAUTION
Thismanualdoesnotincludeallthenecessaryitemsaboutrepairandservice,thismanualismade
forthepurposeoftheuseforthepersonswhohavespecialtechniquesandcertifications.Inthe
casesthatnon-specializedoruncertifiedtechniciansperformrepairorserviceonlyusingthismanu-
alorwithoutproperequipmentortool,thatmaycausesevereinjurytoyouorotherpeoplearound
andalsocausedamagetoyourcustomer'svehicle.
Inordertopreventdangerousoperation anddamagestoyourcustomer'svehicle,besuretofollow
theinstructionshownbelow.
Mustreadthismanualthoroughly.Itisespeciallyimportanttohavegoodunderstandingallthe
contentswritteninthePRECAUTIONof"IN"section.
Theservicemethodwritteninthismanualisveryeffectivetoperformrepairandservice.When
performingtheoperationsfollowingtheproceduresusingthismanual,besuretousetoolsspe-
cifiedandrecommended.Ifusingnon-specifiedorrecommendedtoolsandservicemethod,
besuretoconfirmsafetyofthetechniciansandanypossibilityofcausingpersonalinjuryor
damagetothecustomer'svehiclebeforestartingtheoperation.
Ifpartreplacementisnecessary,mustreplacethepartwiththesamepartnumberorequivalent
part.Donotreplaceitwithinferiorquality.
Itisimportanttonotethatthismanualcontainsvarious"Cautions"and"Notices"thatmustbe
carefullyobservedinordertoreducetheriskofpersonalinjuryduringserviceorrepair,orthe
possibilitythatimproperserviceorrepairmaydamagethevehicleorrenderitunsafe.Itisalso
importanttounderstandthatthese"Cautions"and"Notices"arenotexhaustive,becauseitis
importanttowarnofallthepossiblehazardousconsequencesthatmightresultfromfailureto
followtheseinstructions.

TOYOTA
1PZ,1HZ,1HD-TENGINE
REPAIRMANUAL
INTRODUCTION
ENGINEMECHANICAL
TURBOCHARGERSYSTEM
FUELSYSTEM
COOLINGSYSTEM
LUBRICATIONSYSTEM
STARTINGSYSTEM
CHARGINGSYSTEM
SERVICESPECIFICATIONS
STANDARDBOLTTORQUESPECIFICATIONS
SSTANDSSM
©2001TOYOTAMOTORCORPORATION
Allrightsreserved.Thisbookmaynotberepro-
ducedorcopied,inwholeorinpart,withoutthe
writtenpermissionofToyotaMotorCorporation.
FirstPrinting:Feb.8,199001-900208-00
34thPrinting:Aug.28,200134-010828-06-2

IN-1
INTRODUCTION
Page
HOWTOUSETHISMANUALIN-2
IDENTIFICATIONINFORMATIONIN-4
GENERALREPAIRINSTRUCTIONSIN-4
ABBREVIATIONSUSEDINTHISMANUALIN-7

IIM-2 INTRODUCTIONHowtoUseThisManual
HOWTOUSETHISMANUAL
Toassistyouinfindingyourwaythroughthismanual,the
SectionTitleandmajorheadingaregivenatthetopofevery
page.
AnINDEXisprovidedonthe1stpageofeachsectiontoguide
youtotheitemtoberepaired.
Atthebeginningofeachsection,PRECAUTIONSaregiventhat
pertaintoall repairoperationscontainedinthatsection.
Read these precautions before starting any repair task.
TROUBLESHOOTINGtablesareincludedforeachsystemto
helpyoudiagnosetheproblemandfindthecause.Therepairfor
eachpossiblecauseisreferencedintheremedycolumnto
quicklyleadyoutothesolution.
REPAIRPROCEDURES
Mostrepairoperationsbeginwithanoverviewillustration.It
identifiesthecomponentsandshowshowthepartsfittogether.
Example:

IN-3
INTRODUCTION- HowtoUseThisManual
Theproceduresarepresentedina step-by-stepformat:
•Theillustrationshowswhat todoandwhereto doit.
•Thetaskheadingtellswhat todo.
•Thedetailedtexttellshow toperformthetaskandgivesother
informationsuchasspecificationsandwarnings.
Example:
Thisformatprovidestheexperiencedtechnicianwitha
FASTTRACKtotheinformationneeded.Theuppercase
taskheadingcanbereadata glancewhennecessary,and
thetextbelowitprovidesdetailedinformation.Important
specificationsandwarningsalwaysstandoutinboldtype.
REFERENCES
Referenceshavebeenkepttoa minimum.However,whenthey
arerequired,youaregiventhepagetoreferto.
SPECIFICATIONS
Specificationsarepresentedinboldtypethroughoutthetext
whereneeded.Youneverhavetoleavetheproceduretolookup
yourspecifications.TheyarealsofoundinAppendixA forquick
reference.
CAUTIONS,NOTICES,HINTS:
•CAUTIONSarepresentedinboldtype,andindicatethereisa
possibilityofinjurytoyouorotherpeople.
•NOTICESarealsopresentedinboldtype,andindicatethe
possibilityofdamagetothecomponentsbeingrepaired.
•HINTSareseparatedfromthetextbutdonotappearinbold.
Theyprovideadditionalinformationtohelpyouefficiently
performtherepair.

IIM-4
INTRODUCTION- IdentificationInformation,GeneralRepairInstructions
IDENTIFICATIONINFORMATION
ENGINESERIALNUMBER
Theengineserialnumberisstampedontheleftsideofthe
cylinderblock.
GENERALREPAIRINSTRUCTIONS
1.Usefender,seatandfloorcoverstokeepthevehicleclean
andpreventdamage.
2.Duringdisassembly,keeppartsinordertofacilitatereas-
sembly.
3.Observethefollowing:
(a)Beforeperformingelectricalwork,disconnectthe
negative(—)cablefromthebatteryterminal.
(b)Ifitisnecessarytodisconnectthebatteryforinspec-
tionorrepair, alwaysdisconnectthecablefromthe
negative(—)terminalwhichisgroundedtothevehi-
clebody.
(c)Topreventdamagetothebatteryterminalpost,loosen
theterminalnutandraisethecablestraightupwith-
outtwistingorpryingit.
(d)Cleanthebatteryterminalpostsandcableterminals
witha shoprag.Donotscrapethemwitha fileor
otherabrasiveobject.
(e)Installthecableterminaltothebatterypostwiththe
nutloose,andtightenthenutafterinstallation.Donot
usea hammertotaptheterminalontothepost.
(f)Besurethecoverforthepositive(+) terminalis
properlyinplace.
4.Checkhoseandwiringconnectorstomakesurethatthey
aresecureandcorrect.
5.Non-reusableparts
(a)Alwaysreplacecotterpinsgaskets,O-rings,oilseals,
etc.withnewones.
(b)Non-reusablepartsareindicatedinthecomponent
illustrationsbythe"•"symbol.
6.PrecoatedParts
Precoatedpartsareboltsandnuts,etc.thatarecoatedwith
aseallockadhesiveatthefactory.
(a)Ifa precoatedpartisretightened,loosenedorcaused
tomoveinanyway,itmustberecoatedwiththe
specifiedadhesive.

IN-5
INTRODUCTION- GeneralRepairInstructions
(b)RecoatingofPrecoatedParts
(1)Cleanofftheoldadhesivefromthepart's
threads.
(2)Drywithcompressedair.
(3)Applythespecifiedseallockadhesive tothe
part'sthreads.
(c)Precoatedpartsareindicatedinthecomponentillus-
trationsbythe"*"symbol.
7.Whennecessary,usea sealerongasketstopreventleaks.
8.Carefullyobserveallspecificationsforbolttorques.Always
usea torquewrench.
9.Useofspecialservicetools(SST)andspecialservice
materials(SSM)mayberequired,dependingonthenature
oftherepair.BesuretouseSSTandSSMwherespecified
andfollowtheproperworkprocedure.A listofSSTand
SSMcanbefoundatthebackofthismanual.
10.Whenreplacingfuses,besurethenewfuseisthecorrect
amperage.DONOTexceedtheratingoruseoneofa lower
rating.
11.Caremustbetakenwhenjackingupandsupportingthe
vehicle.Besuretoliftandsupportthevehicleattheproper
locations.
(a)Ifthevehicleistobejackeduponlyatthefrontorrear
end,besuretoblockthewheelsinordertoensure
safety.
(b)Afterthevehicleisjackedup,besuretosupportiton
stands.Itisextremelydangeroustodoanyworkon
thevehicleraisedona jackalone,evenfora smalljob
thatcanbefinishedquickly.
12.Observethefollowingprecautionstoavoiddamagingthe
parts:
(a)Becarefulnottodropelectricalcomponents,suchas
sensorsorrelays.Iftheyaredroppedona hardfloor,
theyshouldbereplacedandnotreused.
(b)Topullapartelectricalconnectors,pullonthecon-
nectoritself,notthewires.
(c)Todisconnectvacuumhoses,pullontheend,notthe
middleofthehose.

IIM-6
INTRODUCTIONGeneralRepairInstructions
(d)Whensteamcleaninganengine,protecttheairfilter,
andinjectionpumpfromwater.
(e)Neveruseanimpactwrenchtoremoveorinstalltemp,
switchesortemp,sensors.
(f)Whencheckingcontinuityatthewireconnector,
insertthetesterprobecarefullytopreventterminals
frombending.
(g)Whenusinga vacuumgauge,neverforcethehose
ontoa connectorthatistoolarge.Usea step-down
adapterinstead.Oncethehosehasbeenstretched,it
mayleak.
13.Afterremovingandreinstallingtheinjectionpumpandfuel
hoses,cleanoffthefuelonenginecomponents.Inpartic-
ular,besuretochecktheradiatorhoseandby-passhose,
becausetheydeteriorateeasilyiftheycomeintocontact
withfuel.