Toyota 1hd 1hz 1pz T Engine

Full download: http://manualplace.com/download/toyota-1hd-1hz-1pz-t-engine/

This is the cut pages sample. Download all 348 page(s) at: ManualPlace.com
FOREWORD

This repair manual has been prepared to provide information

covering general service repairs for the 1 PZ, 1 HZ and 1HD-T
engines equipped on the TOYOTA LAND CRUISER and
COASTER.

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.

Manual Name Pub. No.

Land Cruiser (Wagon) New Car Features NCF064E

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.

TOYOTA MOTOR 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.

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

©2001 TOYOTA MOTOR CORPORATION

All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Feb. 8,1990 01-900208-00
34th Printing: Aug. 28,2001 34-010828-06-2
 IN-1

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

HOW TO USE THIS MANUAL

To assist you in finding your way through this manual, the
Section Title and major heading are given at the top of every
page.
An INDEX is provided on the 1st page of each section to guide
you to the item to be repaired.
At the beginning of each section, PRECAUTIONS are given that
pertain to all repair operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING tables are included for each system to
help you diagnose the problem and find the cause. The repair for
each possible cause is referenced in the remedy column to
quickly lead you to the solution.

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

The procedures are presented in a step-by-step format:

• The illustration shows what to do and whereto 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:

This format provides the experienced technician with a

FAST 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.

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.

CAUTIONS, NOTICES, HINTS:

• CAUTIONS are presented in bold type, and indicate there is a
possibility 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 efficiently
perform the repair.
IIM-4 INTRODUCTION - Identification Information, General Repair Instructions

IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the left side of the
cylinder block.

GENERAL REPAIR INSTRUCTIONS

1. Use fender, seat and floor covers to keep the vehicle clean
and prevent damage.
2. During disassembly, keep parts in order to facilitate reas-
sembly.
3. 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 inspec-
tion or repair, always disconnect the cable from the
negative ( —) terminal which is grounded to the vehi-
cle body.
(c) To prevent damage to the battery terminal post, loosen
the terminal nut and raise the cable straight up with-
out twisting or prying it.
(d) Clean the battery terminal posts and cable terminals
with a shop rag. Do not scrape them with a file or
other abrasive object.
(e) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. 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.
4. Check hose and wiring connectors to make sure that they
are secure and correct.
5. Non-reusable parts
(a) Always replace cotter pins gaskets, O-rings, oil seals,
etc. with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the " • " symbol.

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

(b) Recoating of Precoated Parts

(1) Clean off the old adhesive from the part's
threads.
(2) Dry with compressed air.
(3) Apply the specified seal lock adhesive to the
part's threads.
(c) Precoated parts are indicated in the component illus-
trations by the " * " symbol.
7. When necessary, use a sealer on gaskets to prevent leaks.
8. Carefully observe all specifications for bolt torques. Always
use a torque wrench.
9. Use of special service tools (SST) 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 procedure. A list of SST and
SSM can be found at the back of this manual.
10. When replacing fuses, be sure the new fuse is the correct
amperage. DO NOT exceed the rating or use one of a lower
rating.
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 in order to ensure
safety.
(b) After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on
the vehicle raised on a jack alone, even for a small job
that can be finished quickly.

12. Observe the following precautions to avoid damaging the

parts:
(a) 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.
(b) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.

(c) To disconnect vacuum hoses, pull on the end, not the

middle of the hose.
IIM-6 INTRODUCTION General Repair Instructions

(d) When steam cleaning an engine, protect the air filter,

and injection pump from water.
(e) Never use an impact wrench to remove or install temp,
switches or temp, sensors.
(f) When checking continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
(g) 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.
13. After removing and reinstalling the injection pump and fuel
hoses, clean off the fuel on engine components. In partic-
ular, be sure to check the radiator hose and by-pass hose,
because they deteriorate easily if they come into contact
with fuel.
INTRODUCTION - Abbreviations Used in This Manual IN-7

ABBREVIATIONS USED IN THIS MANUAL

A/C Air Conditioner
ACV Air Control Valve
ACSD Automatic Cold Start Device
Approx. Approximately
A/T Automatic Transmission
BACS Boost and Altitude Compensation Stopper
BDC Bottom Dead Center
Ex. Except
FL Fusible Link
FIPG Formed in Place Gasket
HAC High Altitude Compensator
LH Left-Hand
LHD Left-Hand Drive
LST Load Sensing Timer
MP Multipurpose
M/T Manual Transmission
OHC Over Head Cam
O/S Oversized
PCS Power Control System
PCV Positive Crankcase Ventilation
RH Right-Hand
RHD Right-Hand Drive
SSM Special Service Materials
SST Special Service Tools
STD Standard
SW Switch
TDC Top Dead Center
U/S Undersize
w/ With
w/o Without
 EM-1

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.

(Possible Cause) (Check Procedure and Correction Method)

1. LOOSE OR CORRODED Check cables from battery to starter and make nec-
BATTERY CABLES essary repairs.

2. DISCHARGED BATTERY Check alternator output and drive belt.

If necessary, repair. (See page CH-5)

3. INOPERATIVE STARTER Check for battery voltage at starter terminals 30 and

50.
If Okay, see STARTING SYSTEM for repair proce-
dure, (see page ST-15)

ENGINE CRANKS SLOWLY-WILL NOT START

HINT: Minimum cranking speed:
Cold HZJ80 (A/T) and HDJ80 (A/T) 110 rpm
Others 100 rpm
Hot 150 rpm

(Possible Cause) (Check Procedure and Correction Method)

1. LOOSE OR CORRODED Check cables from battery to starter and make nec-
BATTERY CABLES essary repairs.

2. DISCHARGED BATTERY Check alternator output and drive belt.

If necessary, repair. (See page CH-5)

3. IMPROPER ENGINE OIL Check engine oil.

If improper viscosity, drain and refill with oil of vis-
cosity recommended by manufacturer.
(See page LU-6)
EM-6 ENGINE MECHANICAL Troubleshooting (Diesel Engine Diagnosis)

ENGINE CRANKS NORMALLY BUT WILL NOT START

(Possible Cause) (Check Procedure and Correction Method)

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.

4. FUEL LEAKAGE FROM Check for loose unions or cracks.

INJECTION PIPES If leaking, tighten to standard torque or, if necessary,
replace pipe(s).

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

6. FAULTY GLOW PLUG Check glow plug for continuity.

OPERATION If no continuity, a broken wire is indicated and glow
plug should be replaced.

7. IMPROPER INJECTION TIMING Check injection timing. (See page EM-27)

Plunger stroke: 1PZ 0.82 —0.88 mm
(0.0323-0.0346 in.)
1HZ 1.03-1.09 mm
(0.0406-0.0429 in.)
1HD-T 1.29-1.35 mm
(0.0508-0.0531 in.)
If not as above, injection pump is improperly
adjusted.

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.

9. FAULTY INJECTION NOZZLES Check injection pressure with a nozzle tester.

(See page FU-10 or 20)
Opening pressure:
1PZand1HZ 135-155 kg/cm2
(1,920-2,205 psi)
(13,239-15,200 kPa)
1HD-T
No.1 opening pressure
180-190 kg/cm2
(2,560-2,702 psi)
(17,652 - 18,633 kPa)
No.2 opening pressure
(Inspection pressure)
132-138 kg/cm2
(1,877-1,963 psi)
(12,945-13,533 kPa)
If not as above, nozzle adjustment is improper and
pressure should be readjusted.
If pressure cannot be adjusted to specification, re-
place injection nozzle.
EM-8 ENGINE MECHANICAL Troubleshooting (Diesel Engine Diagnosis)

ROUGH IDLE WITH WARM ENGINE

(Possible Cause) (Check Procedure and Correction Method)

1. IMPROPER ADJUSTMENT OF With accelerator pedal released, check that adjusting

ACCELERATOR CABLE lever is in contact with idle speed adjusting screw.
Also check if accelerator cable or linkage is catching
on something.
If necessary, adjust so that lever is in contact with
screw, or make other required repairs.

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.

3. FUEL LEAKAGE Check for leaks at injection pump connections,

pump distributive head bolts, injection nozzles and
delivery valve holders.
Tighten any loose connections to specified torque or
replace parts as necessary.

4. IMPROPER INJECTION TIMING Refer to step 7 of ENGINE CRANKS NORMALLY

BUT WILL NOT START, above.
Toyota 1hd 1hz 1pz T Engine
ENGINE MECHANICAL - Troubleshooting (Diesel Engine Diagnosis)
Full download: http://manualplace.com/download/toyota-1hd-1hz-1pz-t-engine/ EM-9

5. IMPROPER OPERATION OF With engine idling, loosen injection pipe to each

INJECTION NOZZLES OR cylinder in order, and check if idle speed changes.
DELIVERY VALVES If no change, a faulty cylinder is indicated.
Check according to following procedure.
• Faulty injection nozzle
Check injection nozzle with a nozzle tester.
(See page FU-10 or 20)
Opening pressure:
IPZandiHZ 135-155 kg/cm2
(1,920-2,205 psi)
(13,239-15,200 kPa)
1HD-T
No.1 opening pressure
180-190 kg/cm2
(2,560-2,702 psi)
(17,652 - 18,633 kPa)
No.2 opening pressure
(Inspection pressure)
132-138 kg/cm2
(1,877-1,963 psi)
(12,945-13,533 kPa)
If not as above, nozzle adjustment is improper and
pressure should be readjusted.
If pressure cannot be adjusted to specification, re-
place injection nozzle.
• Faulty delivery valve
If injection pressure is as specified, delivery vale is
defective and should be replaced.

This is the cut pages sample. Download all 348 page(s) at: ManualPlace.com