Toyota 1KZ-TE - Repair Manual

1999
TOYOTA MOTOR CORPORATION
A ll r ight s r es er v ed. This CD may not be repro-
duced or copied, in whole or in part, without the
writtenpermission of Toyota Motor Corporation.
First Printing; Jun. 11, 1999 01--990611--00--2
FOREWORD
This REPAIR MANUAL has been prepared to provide information covering general service repairs
for the
1KZ-TE ENGINE equipped on the TOYOTA HILUX.
Applicable models:
KZN165 series
Please note that the publications below have also been prepared as relevant service manuals for the compo-
nents and system in this engine.
Manual Name Pub. No.
S
HILUX Electrical Wiring Diagram
EWD307F
All information inthis manualis basedon the latest product information at the timeof publication.However,
specifications and procedures are subject to change without notice.
Thismanualdoesnotincludeallthenecessaryitemsaboutrepairandservice.T hismanualismade
for the purpose of the use for the persons who have special techniques and certifications. In the
casesthatnon --specializedoruncertifiedtechniciansperformrepairorserviceonlyusingthismanu-
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’svehicle, be sure tofollow
the instruction shown below.
S
Mustreadthismanualthoroughly.Itisespeciallyimportanttohave goodunderstanding allthe
contents written in the PRECAUTION of ”IN” section.
S
Theservicemethodwritteninthismanualisveryeffectivetoperform repairandservice.When
performingtheoperationsfollowingtheproceduresusingthismanual,besuretousetoolsspe-
cified and recommended. If using non--specified or r ecommended 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.
S
Ifpartreplacementisnecessary,mustreplacethepartwiththesamepartnumberorequivalent
part. Do not replace it with inferior quality.
S
It is important to note that this manual contains various ”Cautions” and ”Notices”that must be
carefullyobserved in order to reduce the riskof personal injury during service or repair, or the
possibilitythatimproperserviceorrepairmaydamagethevehicleo r r ender it unsafe.Itisalso
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warnof all the possiblehazardous consequences that might result from failureto
follow these instructions.
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RM710E-D
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CAUTION
TOYOTA MOTOR CORPORATION
1KZ-TE
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Summary

INTRODUCTION

HOW TO USE THIS MANUAL

Explains how to navigate and utilize the repair manual effectively.

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

Guide on diagnosing and resolving issues within ECU controlled systems.

PREPARATION

SERVICE SPECIFICATIONS

ENGINE MECHANICAL

Service data and specifications for engine mechanical components.

TURBOCHARGING

Service data and specifications for the turbocharging system.

ELECTRONIC CONTROL DIESEL

Service data for electronic control diesel system components.

ENGINE FUEL

Service data for engine fuel system components.

COOLING

Service data for cooling system components.

LUBRICATION

Service data for lubrication system components.

STARTING

Service data for starting system components.

CHARGING

Service data for charging system components.

ENGINE MECHANICAL

COMPRESSION

Steps for inspecting engine compression pressure.

VALVE CLEARANCE

Procedures for checking and adjusting engine valve clearance.

INJECTION TIMING

Steps for inspecting and adjusting engine injection timing.

IDLE SPEED AND MAXIMUM SPEED

Procedures for checking and adjusting idle and maximum engine speeds.

TIMING BELT

Components, removal, inspection, and installation of the timing belt.

TURBOCHARGING

TROUBLESHOOTING

Guide for diagnosing and resolving turbocharger problems.

ENGINE FUEL

FUEL FILTER

INJECTION NOZZLE

INJECTION PUMP

COOLING

COOLANT

WATER PUMP

LUBRICATION

OIL AND FILTER

OIL PUMP

OIL COOLER

OIL NOZZLE

STARTING

PRE-HEATING SYSTEM

STARTER

STARTER RELAY

CHARGING

CHARGING SYSTEM

ALTERNATOR

Toyota 1KZ-TE Specifications

General

Displacement	2982 cc
Bore x Stroke	96.0 mm x 103.0 mm
Compression Ratio	21.2:1
Fuel Type	Diesel
Fuel System	Direct Injection
Number of Cylinders	4
Valvetrain	SOHC, 2 valves per cylinder
Turbocharger	Yes
Intercooler	Yes
Engine Type	Inline-4, Turbocharged