1HD-T - 1 Land Cruiser Engine Service Manual
1HD-T - 1 Land Cruiser Engine Service Manual
1HD-T - 1 Land Cruiser Engine Service Manual
Applicable models:
PZJ70, 73, 75 series
HZJ70, 73, 75, 80 series
HDJ80 series
HZB30 series
HDB30 series
Please note that the publications below have also been prepared
as relevant service manuals for the components and system in
this engine.
In order to prevent dangerous operation and damages to your customer's vehicle, be sure to follow
the instruction shown below.
Must read this manual thoroughly. It is especially important to have good understanding all the
contents written in the PRECAUTION of "IN" section.
The 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 tools spe-
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.
If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
It 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.
TOYOTA
1PZ, 1HZ, 1HD-T ENGINE
REPAIR MANUAL
INTRODUCTION
ENGINE MECHANICAL
TURBOCHARGER SYSTEM
FUEL SYSTEM
COOLING SYSTEM
LUBRICATION SYSTEM
STARTING SYSTEM
CHARGING SYSTEM
SERVICE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS
SSTANDSSM
INTRODUCTION
Page
HOW TO USE THIS MANUAL IN-2
IDENTIFICATION INFORMATION IN-4
GENERAL REPAIR INSTRUCTIONS IN-4
ABBREVIATIONS USED IN THIS MANUAL IN-7
IIM-2 INTRODUCTION How to Use This Manual
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit together.
Example:
INTRODUCTION - How to Use This Manual IN-3
Example:
REFERENCES
References have been kept to a minimum. However, when they
are required, you are given the page to refer to.
SPECIFICATIONS
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 in Appendix A for quick
reference.
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the left side of the
cylinder block.
6. Precoated Parts
Precoated parts are bolts and nuts, etc. that are coated with
a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or caused
to move in any way, it must be recoated with the
specified adhesive.
INTRODUCTION - General Repair Instructions IN-5
ENGINE MECHANICAL
Page
DESCRIPTION EM-2
TROUBLESHOOTING EM-4
Diesel Engine Diagnosis EM-4
Diesel Electrical System Diagnosis EM -14
ENGINETUNE-UP EM-17
COMPRESSION CHECK EM-30
TIMING BELT EM-32
TIMINGGEARS EM-42
CYLINDER HEAD EM-54
CYLINDER BLOCK EM-84
EM-2 ENGINE MECHANICAL - Description
DESCRIPTION
The 1 PZ engine is an in-line 5-cylinder 3.5 liter OHC engine.
The 1 HZ and 1 HD-T engines are an in-line 6-cylinder 4.2 liter OHC engine.
1PZ
1HZ
1HD-T
EM8795 EM8792
EM8965 EM8793
EM8966 EM8794
ENGINE MECHANICAL Description EM-3
The 1 PZ engine is an in-line 5-cylinder engine Adjustment of the valve clearance is done by
with the cylinders numbered 1 - 2 - 3 - 4 - 5 from means of an outer shim type system, in which valve
the front. This engine's injection order is adjusting shims are located above the valve lifters.
1-2-4-5-3. This permits replacement of the shims without
The 1 HZ and 1HD-T engines are an in-line removal of the camshaft.
6-cylinder engine with the cylinders numbered Pistons are made of highly temperature-resistant
1 - 2 - 3 - 4 - 5 - 6 from the front. This engine's aluminum alloy. As the 1 HD-T engine is the direct
injection order is 1 - 4 - 2 - 6 - 3 - 5 . injection type, a deep combustion chamber has
The crankshaft is supported by 6 (1 PZ) or 7 (1 HZ been provided. The No.1 piston ring groove has
and 1HD-T) bearings on the inside of the crank- been strengthened using a fiber reinforced metal.
case. These bearings are made of aluminum alloy. Piston pins are the full-floating type, with the
The crankshaft is integrated with 10 weights (1 PZ) pins fastened to neither the connecting rods nor the
or 12 weights (1 HZ and 1HD-T) which are cast piston boss, but with a snap rings fitted to both
along with it for balancing. Oil holes are built into ends of the pin to prevent the pin from slipping out.
the crankshaft for supplying oil to the connecting The No.1 compression ring is made of steel and
rods, bearings and other components. the No.2 compression ring is made of cast iron. The
The crankshaft bearing cap is of ladder frame oil ring is made of steel. The outer diameter of each
construction and is incorporated into the crank piston ring is slightly larger than the diameter of the
case. piston and the flexibility of the rings allows them to
The cylinder head is made of cast iron with a hug the cylinder walls when they are mounted on
cross flow type intake and exhaust layout. The the piston. Compression rings No.1 and No.2 work
combustion chambers are swirl chamber type for to prevent the leakage of gas from the cylinder and
the 1 PZ and 1 HZ engines and direct injection type the oil ring works to scrape oil off the cylinder walls
for the 1 H D-T engine. The camshaft journal part of to prevent it from entering the combustion cham-
the cylinder head has camshaft caps made of alu- ber.
minum alloy and is made of cast iron on the cylinder The cylinder block is made of cast iron. It has 5
head side. The camshaft journal has no bearings cylinders (1 PZ) or 6 cylinders (1HZ and 1HD-T)
(with the exception of the No.1 journal). which are approximately 1.7 times the length of the
The 1 HZ and 1 HD-T engines has dual-type ex- piston stroke. The top of the cylinders is closed off
haust manifolds. by the cylinder head and the lower end of the
cylinders becomes the crankcase, in which the
Exhaust and intake valves are equipped with crankshaft is installed. In addition, the cylinder
irregular pitch springs which are capable of follow- block contains a water jacket, through which cool-
ing the valves even at high engine speeds. ant is pumped to cool the cylinders.
The camshaft is driven by the timing belt. The Plastic region tightening bolts are used for the
camshaft journal is supported at 6 places (1 PZ) or cylinder head bolts, crankshaft bearing cap bolts
7 places (1 HZ and 1HD-T). Lubrication of the and connecting rod cap bolts.
camshaft journal and cam is accomplished by oil
being supplied through the oiler port in the No.6 The oil pan is bolted onto the bottom of the
(1 PZ) or No.7 (1 HZ and 1 HD-T) of the camshaft crankshaft bearing cap with bolts and nuts. The oil
journal. pan is an oil reservoir made of pressed steel sheet.
EM-4 ENGINE MECHANICAL - Troubleshooting (Diesel Engine Diagnosis)
TROUBLESHOOTING
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 MECHANICAL - Troubleshooting (Diesel Engine Diagnosis) EM-5
PRECAUTION:
1. The basic troubleshooting procedures for the diesel engine (valve clearance, compression,
bearings, valves, pistons, etc.) are the same checks you would make for gasoline engine.
2. Repair of the injection pump requires considerable skill and use of a special test bench.
1. LOOSE OR CORRODED Check cables from battery to starter and make nec-
BATTERY CABLES essary repairs.
1. LOOSE OR CORRODED Check cables from battery to starter and make nec-
BATTERY CABLES essary repairs.
1. NO FUEL TO NOZZLE Loosen any one injection pipe union nut from its
nozzle holder.
Crank engine for about 5 seconds while confirming
that fuel is being discharged from pipe.
If fuel is coming out, begin diagnosis from item 4.
If not, begin from item 2.
2. NO FUEL CUT SOLENOID With starter switch turned ON, check for fuel cut
OPERATION solenoid operation noise (clicking sound) while re-
peatedly connecting and disconnecting fuel cut
solenoid.
If no noise, check if there is battery voltage to sole-
noid when starter switch is ON.
If battery voltage is confirmed, fuel cut solenoid is
faulty and should be replaced. If no voltage, refer to
ELECTRICAL DIAGNOSIS and make necessary re-
pairs.
3. NO FUEL INTO INJECTION Disconnect inlet hoses from fuel filter, and feed
PUMP clean fuel from separate container directly into fuel
pump.
HINT: When feeding fuel tank directly into pump,
keep container at same level as vehicle fuel tank.
If engine starts, either fuel filter or line between fuel
tank and filter is clogged and should be repaired
accordingly.
If engine still does not start (no fuel intake), check
fuel line between filter and pump.
If normal, pump is faulty and should be replaced.
5. INOPERATIVE PREHEATING With starter switch turned ON and glow plug indi-
OPERATION cator light illuminated, check that there is voltage
applied to glow plug.
If not, refer to ELECTRICAL DIAGNOSIS and repair
as necessary.
ENGINE MECHANICAL - Troubleshooting (Diesel Engine Diagnosis) EM-7
8. (w/ACSD) Check timer piston stroke and fast idle lever opening
IMPROPER COLD START angle with an injection pump tester when cold start
ADVANCE AND FAST IDLE advance is operated.
2. IDLE SPEED TOO LOW Check idle speed. (See page EM-27)
Idle speed:
1PZ 600-700 rpm
1HZM/T 600-700 rpm
1HZA/T 660-760 rpm
1HD-T M/T 600-700 rpm
1H D -T A/T 750 - 850 rpm
HINT: If less than standard, idling would normally
be rough.
If not as above, adjust with idle speed adjusting
screw.
1. ENGINE WILL NOT RE-START Check to see if engine re-starts according to pre-
scribed procedure.
If not, refer to ENGINE CRANKS NORMALLY BUT
WILL NOT START, above, and repair as necessary.
LACK OF POWER
HINT:
• First check that the air cleaner is not clogged or the engine overheating.
• Not applicable if the customer desires an output power higher than specified for that vehicle. For accuracy,
adjust with a chassis dynamo.
5. CLOGGED FUEL FILTER Disconnect inlet hose to fuel filter, and feed clean
fuel directly into pump.
HINT: When feeding fuel directly into pump, keep
container at same level as vehicle fuel tank.
If engine condition improves, fuel filter is clogged
and should be replaced. (See page FU-4)
If no increase in engine condition after replacing
fuel filter, check priming pump (hand pump) or per-
form other necessary repairs.
2. IDLE SPEED TOO HIGH After sufficiently warming up engine, check idle
speed. (See page EM-27)
Idle speed:
1PZ 600-700 rpm
1HZM/T 600-700 rpm
1HZA/T 660-760 rpm
1HD-T M/T 600-700 rpm
1H D -T A/T 750 - 850 rpm
If not as above, adjust with idle speed adjusting
screw.
3. MAXIMUM SPEED TOO HIGH Check maximum speed. (See page EM-27)
Maximum speed:
1PZ and 1 HZ 4,500 - 4,700 rpm
1H D -T 4,300 - 4,500 rpm
If not as above, adjust with maximum speed adjust-
ing screw.
IMPROPER FUEL CUT SOLENOID Disconnect connector of fuel cut solenoid, and
OPERATION check if engine stops.
If so, starter switch is faulty and should be repaired
as necessary or replaced.
If engine does not stop, either fuel cut solenoid is
faulty or there is interference by foreign particles.
Repair as necessary.
EM-14 ENGINE MECHANICAL - Troubleshooting (Diesel Electrical System Diagnosis)
Check if indicator light lights up Check fuse. Check for short circuit
with starter switch ON. No (See page ST-2) Fuse and repair if necessary.
Light on: 6 - 7 seconds Blown
Fuse OK
Yes
Voltage
*Check if voltage to terminal 1 of Start engine and check/if there is a voltage at terminal
pre-heating timer is terminated No 9 of pre-heating timer.
after engine is started. If faulty, repair charging system as necessary.
If okay, timer is faulty and should be replaced.
Yes
11 109 7
ST0049
ENGINE MECHANICAL - Troubleshooting (Diesel Electrical System Diagnosis) EM-15
OK
Voltage
*Place starter switch at ON and *Check for battery voltage at negative (-) side of glow
check for voltage to glow plug a plug resistor.
few seconds later. Thereafter, volt- If no voltage, No.1 glow plug relay is faulty and
No
age should drop about 1/2. should be replaced.
Voltage
at ALL
OK
Check glow plug for resistance. Glow plug is faulty and should be replaced.
Infinity
Approx. 0 Q
With starter switch turned ON, Fuel cut solenoid valve okay.
check for fuel cut solenoid valve Noise
operation noise (clicking sound)
while repeatedly connecting and
disconnecting fuel cut solenoid
valve.
No Noise
Apply battery voltage directly to Check wire harness from fuse to fuel cut solenoid.
solenoid, and check for noise. Noise
No Voltage