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 operations (1) Before performing electrical work, disconnect the negative (-) terminal cable from the battery. (2) If it is necessary to disconnect the battery for inspection or repair, always disconnect the negative (-) terminal cable which is grounded to the vehicle body. (3) To prevent damage to the...

V

Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. When the problem symptoms do not appear during confirmation, use the symptom simulation method described later on.) Circuit Inspection or Parts Inspection Check the results obtained in Step 2, then confirm the inspection procedure for the system or the part which should be checked using the diagnostic trouble code chart or the problem symptoms table. Check and repair the affected system or part in...

Toyota Kzte Injector Pump

Hilux 2004 Timing Belt

N-m kgf-cm, ft-lbf Specified torque N-m kgf-cm, ft-lbf Specified torque When removing the crankshaft pulley and timing gear as the timing belt is off and the valve interferes with the piston, never,turn the crankshaft to the right beyond the dead point above the No.4 cylinder. j 1. REMOVE TIMING BELT AND PULLEYS . 2. REMOVE DRIVE BELT, FAN AND WATER PUMP amp ' PULLEY See page CO-5

Accelerator Pedal Sensor For Toyota Hilux

1kz Ecu Vehicle Speed

All conditions below are detected continuously for 8 sec. or more a Vehicle speed signal 0 km h 0 mph b Engine speed 1,800 - 3,200 rpm c Engine coolant temp. 60C 176F or more d Accelerator pedal opening angle 32 or more Combination meter ' lt 5- Open or short in vehicle speed sensor circuit

1kzte Engine Compression In

1kz Injector Pump Sensor

If there is lack of power, excessive oil consumption or poor fuel lt leiii eri economy, measure the compression pressure. Allow the engine to warm up to normal operating temperature. 2. DISCONNECT INJECTION PUMP SPILL CONTROL VALVE CONNECTOR gt 3. DISCONNECT GLOW PLUG WIRE FROM GLOW w PLUG CONNECTOR v el NOTICE v v In order not to short the glow plug wire, apply vinyl tape around the terminal. ' i 4. REMOVE INTAKE PIPE See page EM-44 3X9 ion 3i it 1i 5. , REMOVE INJECTION PIPES See page FU-18f...

1kz Idler Gear Removal

1kzte Idler Gear

CHECK THRUST CLEARANCE OF IDLER GEAR Using-a dial indicator, measure the thrust clearance. Standard thrust clearance 0.06 - 0.11 mm 0.0024 - 0.0043 In. Maximum thrust clearance 0.30 mm 0.0118 in. If the thrust clearance is greater than maximum, replace the thrust plate. If necessary, replace the idler gear and or idler gear shaft. The matchmark on each gear laces the front of the en-t - gine. Take care not to damage the gear teeth when removing and installing the gears. Do not use parts that...

Sub Glw Rly Was Ist

1kz Glow Plug Relay

INSPECT ENGINE ECU See page DM5 a Remove the glow plug relay. Marking SUB GLW RLY b Inspect the glow plug relay continuity. 1 Using an ohmmeter, check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay. 2 Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay.

Toyota Engine Oil 5w30 Hilux 2011

Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade API CF-4 or CF You may also use API CE or CD If you use SAE 10W-30 or higher viscosity oil in extremely low temperatures, the engine may become difficult to start, so SAE 5W-30 engine oil is recommended. After warming up the engine and then 5 minutes after the engine stops, oil level should be between the L and F marks of the dipstick. If low, check for leakage...

Circuit Description

1kz Diesel Pump Spill Solenoid

The engine ECU controls the fuel injection volume by operating the spill control valve. The spill control valve is mounted on the injection pump, and open or close the injection pressure releasing port by the solenoid valve in the spill control valve During injection valve is close ON . The engine ECU decides the basic fuel injection volume by the engine rpm and throttle valve opening angle, and calculates the final fuel injection angle to add the various corrections on the basic fuel injection...

Toyota 1kz Throttle Position

The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, the IDL contacts in the throttle position sensor are on, so the voltage at the terminal IDL of the engine ECU becomes 0 V. At this time, a voltage of approximately 0.3 - 0.8 V is applied to terminal VA of the engine ECU. When the throttle valve is opened, the IDL contacts go off and thus the power source voltage of approximately 12 V in the engine...

Correct Battery Voltage For Toyota Hilux 1kzte

Maintenance-Free Battery CHECK BATTERY VOLTAGE a After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system headlight, blower motor, rear defogger etc. for 60 seconds to remove the surface charge. b Turn the ignition switch OFF and turn off the electrical systems. c Measure the battery voltage between the negative - and positive terminals of the battery. Standard voltage 12.5...

Toyota 1kzte Head Gasket Thinknes Difference

b Select a new cylinder head gasket. HINT There are 5 types of cylinder head gasket hole number 1 to 5 installed at factory, but only 3 types for supply parts hole number 1, 3 and 5 , so when replacing the gasket select from one of 3 types above. Installed cylinder head gasket thickness 0.80 - 0.90 mm 0.0315 - 0.0354 in. Select the largest piston protrusion value from the measurements made, then select the appropriate cylinder head gasket according to the table below. 2. SET NO.4 CYLINDER TO...

Vsv Constictor Intake Controls For Hilux Surf 1kzte

Vsv No1 Vsv No2

VSV for No.1 Intake Constrictor Control VSV for No.1 Intake VSV for No.2 Intake Constrictor Control Cons dt Control Vacuum Hose Connector Connector VSV for No.1 Intake Constrictor Control VSV for No.1 Intake VSV for No.2 Intake Constrictor Control Cons dt Control Vacuum Hose Connector Connector No.2 Camshaft Timing Pulley No.2 Camshaft Timing Pulley Flange N-m kgf-cm, ft-lbf Specified torque

Toyota 1kz Coolant Sensor

The water temperature sensor senses the coolant temperature. A thermistor built into the sensor changes the resistance value according to the coolant temperature. The lower the coolant temperature, the greater the thermistor resistance value, and the higher the coolant temperature, the lower the thermistor resistance value See Fig. 1 . The water temperature sensor is connected to the engine ECU See below . The 5 V power source voltage in the engine ECU is applied to the water temperature sensor...

1 Kz-te Replace Correction Resistor

REMOVE FIRST GEAR POSITION SWITCH a Using SST, remove the switch and gasket. SST 09817-16011 b Remove the gasket from the switch, j. ts 3. REINSTALL NEW FIRST GEAR POSITION SWITCH a Install a new gasket to the switch. u lt b Using SST, install the switch. r Torque 30 N-m 306 kgf cm, 22.1 ft lbf t SST 09817-16011 INJECTION PUMP CORRECTION RESISTOR

How To Set The Timing Mark Of 1kz-te Engine

Injection Pump 1kz

Using SST, align the holes of the idler gear and No.1 idler sub-gear by turning the No.1 idler sub-gear clockwise, and install a service bolt. v SST 09960-10010 09962-01000, 09963-0060 INSTALL TIMING GEAR NOTICE The matchmark on each gear faces the front of the en gine. Take care not to damage the gear teeth when removing and installing the gears. Do not use parts that are scratched or damaged, they cause noise. Install the crankshaft timing gear. T With the crankshaft key groove facing upward,...

Inspect Axial Play Of Turbine Shaft

Dial Indicator Turbine Shaft End Play

a Using a dial indicator, insert the needle of the dial indicator into the exhaust side. b Move the turbine shaft in an axial direction, measure the axial play of the turbine shaft. Maximum axial play 0.15 mm 0.0063 in. If the axial play is greater than maximum, replace the turbocharger. -luorl nidiu ,bned-V a bnsd-V bnr 3. INSPECT RADIAL PLAY OF TURBINE SHAFT a Using a dial indicator, insert the needle of the dial indicator into the oil outlet hole, and set it in the center of the turbine b...

Inspect Rh And Lh Balance Shaft

Balance Shaft

a Using cylinder gauge, measure the inside diameter of the balance shaft bearing. Bearing inside diameter from front side 42.000 - 42.020 mm 1.6535 -1.6543 in. 41.000 - 41.020 mm 1.6142 - 1.6150 in. 32.000 - 32.020 mm 1.2598 - 1.2606 in. b Using a micrometer, measure the diameter of the balance sTraft main journals. Main journal diameter from front side 41.941 - 41.960 mm 1.6512 -1.6520 in. 40.931 -40.950 mm 1.6115-1.6122 in. 31.941 - 31.960 mm 1.2575 -1.2583 in. c Subtract the balance shaft...

O

In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to...

97 Hilux 1kz-te Turbo Presure Sensor

The turbo pressure sensor is connected to the intake manifold. The engine ECU detects the intake manifold pressure as a voltage by the sensor. The engine ECU uses the intake manifold pressure signal for correction of injection volume control and injection timing control. j j The turbo pressure sensor monitors both the atmospneric pressure and intake manifold pressure and transmits the output voltage to the engine ECU, and the engine ECU uses this atmospheric pressure value for correcting the...

1kz-te Injection Pump Crankshaft Position Sensor

INSPECT ENGINE SPE rf NSdfc r a Disconnect the sensor connector. b Using an ohmmeter, measure the resistance between terminals. Resistance 205-255 ft at 20 C 68 F If the resistance is not specified, replace the injection pump assembly see page FU-16 . c Reconnect the sensor connector

Check Valve Timing

Nozzle Holes

Turn the crankshaft pulley clockwise and check that each pulley aligns with the timing marks TDC mark as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. a Remove any old packing FIPG material. b Apply seal packing to the camshaft oil seal retainer and timing gear cover a shown in the illustration. Seal packing Part No. 08826-00080 or equivalent c Install the gasket to the timing belt cover. ,, j d Install the timing belt cover with the 4 seal...

Intake Constrictor Control

Intake Constrictor Control

VSVforNo.2 Intake Constrictor Control VSVforNo.2 Intake Constrictor Control VSV for No. 1 Intake Constrictor Control VSV for No. 1 Intake Constrictor Control Connector VSVforNo.2 Intake Constrictor Control Connector VSV for No. 1 Intake Constrictor Control VSV for No. 1 Intake Constrictor Control Connector

Inspect Timing Control Valve

a Disconnect the valve connector. b Using an ohmmeter, measure the resistance between the terminals. Resistance 10 -14 Q at 20 C 68 F If the resistance is not as specified, replace the valve. c Inspect the valve solenoid operation. 1 Connect the battery positive the terminal to the valve terminal B. 2 Connect the battery negative terminal to the valve terminal TCV. 3 Check that the solenoid makes a clicks sound. If operation is not as specified, replace the valve. NOTICE Do not apply voltage...

Diagnosis System

The engine ECU contains a built-in self-diagnosis system by which troubles with the engine signal network are detected and a check engine warning light in the combination meter lights up. j By analyzing various signals as shown in the later table See page Dl 12 the engine ECU detects system malfunctions relating to the sensors or actuators. In the normal mode, the self-diagnosis system monitors 9 items, indicated by code No. as shown in Dl 12. A check engine warning light informs the driver...

Install Timing Belt

Timing Belt Toyota Tercel

If re-using the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution. 12. SET TIMING BELT TENSIONER Tr-rr a Using a press, slowly press in the push rod using 981 -9,807 N 100 - 1,000 kgf, 220 - 2,205 Ibf of force. b Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the set- c Release the press. V.,'

Install Injection Pump

Injection Toyota Hilux

a Install a new O-ring to the pump. _ b Apply a light coat of engine oil on the O-ring. c Align the set key on the drive shaft and groove of the injection pump drive gear. v y d Hold the injection pump with hands and press the injection pump drive gear to the backward and weld it with the injection pump drive shaft. e Align the punching line of the injection pump flange and the upper processing surface of the timing gear case, and then temporarily install the 2 nuts. f Tighten the 2 nuts...

Remove Fuel Filter

1kz Hand Pump

SST 09228-64040 a Check and clean the fuel filter installation surface. b Apply fuel to the gasket of a new fuel filter. c Lightly screw the fuel filter into place, and tighten rt until the gasket comes into contact with the seat. d Tighten it additional 3 4 turn by hand. 6. INSTALL FUEL FILTER WARNING SWITCH TO NEW FUEL FILTER a Install a new O-ring to the warning switch. b Apply fuel to the O-ring of the warning switch. c Install the warning switch to a new...

Check For Intermittent Problems

As previously described on page DI-3, abnormality detection ability in the test mode is increased compared to that in the normal mode, so that when intermittent problems occur in the engine ECU signal circuits TDC, NE, THW, THA, VRP, VRT, PIM, THF, VA shown in the table opposite, the appropriate DTC is output. Accordingly, when the DTC shown in the table left 12, 13, 22, 24, 32, 35, 39, 41 are output during the DTC check, and inspection of the appropriate circuits reveals no abnormality, check...

Diagnostic Trouble Code Chart

1kz Trouble Code Toyota

The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example The suspect circuits or parts for each problem symptSTn are shown in the...

Diagnostic Trouble Code Check Procedure

Diagnostic Trouble Code Check Make a note of and then clear Same diagnostic trouble code is displayed Problem is still occurring in the diagnostic circuit The problem is still occurring in a place other than in the diagnostic circuit The diagnostic trouble code displayed first is either for a past problem or it is a secondary problem The problem occurred in the diagnostic circuit in the past The problem is still occurring in a place other than in the diagnostic circuit The problem occurred in a...

Timing Gear Components

Toyota Cruiser Pcv Hose

VSV for No.1 Intake Constrictor Control VSV for No.1 Intake VSV for No.2 Intake Constrictor Control Constrictor Control Vacuum Hose Connector Connector y VSV for No.1 Intake VSV for No.2 Intake Constrictor Control Constrictor Control Vacuum Hose Connector Connector y No.2 Camshaft Timing Pulley No.2 Camshaft Timing Pulley Flange N-m kgf-cm,ft-lbf Specified torque Y Non-reusable part

Inspect Injection Pump Drive Gear Bearing

1kz Balance Gears

Check that bearing is not rough or worn. If necessary, replace the bearing. See page EM-31 _engine reertanrcal - timing-eeair 4ji 3. CHECK BACKLASH OF TIMING GEARS Using3t dial indicator, measure the backlash. P Standard gear backlash 0.02 - 0.15 mm 0.0008 - 0.0060 in. Maximum gear backlash 0.20 mm 0.0079 in. If the gear backlash is greater than maximum, replace the gears as a set.

Gap Piston Rings

1992 Toyota Tercel Piston Rings Assembly

If the clearance is greater than maximum, replace the piston. c Inspect the pistoh ring end gap. 1 Insert the piston ring into the cylinder bore. 2 Using a piston, push the piston ring a little beyond -j the bottom of the ring travel, 120 mm 4.72 in. from 3 Using a feeler gauge, measure the end gap. -Standard end gap 0.400 - 0.600 mm 0.0157 - 0.0236 in. 0.200 - 0.500 mm 0.0079 - 0.0197 in. If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum,...

Crankshaft Position Sensor Inspection

Cold and Hot in these sentences express the temperature of the sensors themselves. Cold is from -10 C 14 F to 50 C 122 F and Hot Is from 50 C 122 F to 100 C 212 F . INSPECT CRANKSHAFT POSITION SENSOR - a Disconnect the sensor connector. b Using an ohmmeter, measure the resistance between terminals. If the resistance is not as specified, replace the sensor. Torque 5 N-m 51 kgf-cm, 44 in.-lbf Apply engine oil to a new O-ring. NOTICE Be careful not drop and shock the sensor.

Install Oil Pressure Sender Gauge

. a Apply adhesive to 2 or 3 threads of the oil pressure sender gauge. Adhesive Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b Install the oil pressure sender gauge. 5. INSTALL OIL COOLER AND OIL COOLER COVER ASSEMBLY Install a new gasket, the oil cooler and oil cooler cover assembly with the 13 bolts. Torque 13 N-m 130 kgf-cm, 9 ft-lbf 6. INSTALL OIL FILTER See page LU-2

Components

2000 1kz Accelerator Position Sensor

VSVfor No.1 Intake Constrictor Control VSVfor No.1 Intake Constrictor Control VSV for No.2 Intake Constrictor Control N-m kgf-cm, ft-lbf Specified torque VSVfor No.1 Intake Constrictor Control Connector VSV for No.2 Intake Constrictor Control Connector VSV for No.2 Intake Constrictor Control N-m kgf-cm, ft-lbf Specified torque

Remove Injection Pipes

Injection Toyota Hilux

a Remove the 2 nuts holding the clamps a to the intake b Using a screwdriver, pry out the clamp B . c Loosen the 8 union nuts of the injection pipes. d Remove the 4 injection pipes and 2 clamps A . a Disconnect the fuel hose from the return pipe. b Remove the 4 nuts, leakage pipe and 4 gaskets. Using-SST, remove the 4 injection nozzles, gaskets and seats. SST 09268-64010 09268-64020 Arrange the injection nozzle in correct order. x

Remove Intake Pipe

1kz Injector Pipes

Disconnect the VSV for the No.1 and No.2 intake constrictor control connectors. Disconnect the vacuum hose from the actuator of the chamber A Disconnect the vacuum hose from the actuator of the chamber B Disconnect the vacuum hose from the 3-way from vacuum pump vo Remove the 4 nuts and 4 seal washers. Use pliers to pinch the ends of the clamp together until the lock plate engages the catch. Make sure the lock plate and catch are engaged securely. Remove the intake pipe, PCV hose and gasket....

Corolla Check Connector

Celica Te1 And Port

To confirm that the test mode is operating, check that the check engine warning light flashes when the ignition If the check engine warning light does not flash, refer to DTC chart for the TE2 terminal circuit on page DI-53. 6 Simulate the conditions of the malfunction described by the customer. 7 After the road test, using SST, connect terminals TE1 and E1 of the check connector. 8 Read the DTC on check engine warning light in the combination meter See page DI-3 . 9 After completing the check,...

Install Cylinder Head Bolts

Toyota 1kz Head Torque

The cylinder head bolts are tightened in 3 progressive steps steps b , d and e . - If any bolts is broken or deformed, replace it. a Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. b Install and uniformly tighten the 18 cylinder head bolts, in several passes, in the sequence shown. Torque 39 N-m 400 kgf-cm, 29 ft-lbf cj Mark the front of the cylinder head bolt with paint. d Retighten the cylinder head bolts 90 in the numerical order shown. e...

1kz-te Spill Valve Relay Wiring

Inspect the relay continuity. 1 Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2 Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 1 Apply battery voltage across terminals 1 and 2. 2 Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL SPILL CONTROL VALVE RELAY ELECffiCTftC CONTROL...

Hilux Ecu Connector

Spill Control Valve Relay 1kz Hilux

a Remove the glove compartment See page ED-25 . b Disconnect the E4 connector from the engine ECU. c Turn the ignition switch ON. CHECK S n K Measure the voltage between terminal SPV of the engine ECU connector and body ground. Check for open or short in harness and connector between spill control valve and engine ECU, and spill control valve and spill control valve relay See page IN-20 . a Remove the glove compartment See page ED-25 . b Turn the ignition switch ON. CHECK Measure the voltage...

Adjust Valve Clearance

Valve Lash Cam Toyota Corolla 1997

1 Turn the crankshaft to position the cam lob of the camshaft on the adjusting valve upward. 2 Using SST, press down the valve lifter. SST 09248-64011 Before pressing down the valve lifter, position the notch on the exhaust manifold side. 3 Remove the adjusting shim with small screwdriver and magnetic finger. b Determine the replacement adjusting shim size by using following the formula or charts 1 Using a micrometer, measure the thickness of the shim which was removed. 2 Calculate the...

Inspect Ecd Main Relay

1 Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2 Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 1 Apply battery voltage across terminals 1 and 2. 2 Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL ENGINE ROOM R B COVER __ELECTffONfC CON I VOL CHESEL - SPttrCOrrmOTVACVE HELAT...

Install Oil Level Sensor

Toyota 1kz Oil Level Sensor

Install the oil level sensor with the 4 bolts. Connect the oil level sensor connector. INSTALL WATER PUMP See page CO-8 INSTALL ALTERNATOR AND ALTERNATOR BRACKET See page CO-8 INSTALL ALTERNATOR ADJUSTING BAR the adjusting bar with the bolt and lock bolt. Torque 21 N m 210 kgf-cm, 15 ft lbf INSTALL TIMING GEARS See page EM-34 INSTALL TIMING BELT See page EM-18 INSTALL WATER PUMP PULLEY, FAN AND DRIVE BELT See page CO-8 FILL WITH ENGINE OIL FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR OIL...

Toyota 1kz Engine Fuel Temp Sensor Location

Sensor Circuit Malfunction The fuel temperature sensor senses the fuel temperature. A thermistor built into the sensor changes the resistance value according to the fuel temperature. The lower the fuel temperature, the greater the thermistor resistance value, and the higher the fuel temperature, the lower the thermistor resistance value See Fig. 1 . The fuel temperature sensor is connected to the engine ECU See below . The 5 V power source voltage in the engine ECU is applied to the...

1kz-te Piston Specs

Hilux Engine Vacuum Sensor

c Check the lever link position of the illustration. Standard Link is levered lowest position. Same position as that before staring 4. INSPECT HOT ENGINE CONDITION g j a Check that the vacuum gauge in the chambers A and B will not move during idling. As no vacuum is loaded in the chamber, sub-throttle valve is fully open. b When opening the throttle valve from idling condition, check that the vacuum gauges of chambers A and B will c Check the link position of the lower diaphragm. Standard v a...

Replace Glow Plugs

How Change Glow Plugs

The cylinder head and glow plug hole can seize up with carbon deposits. And if the glow plug is forcefully twisted when you remove it, the torsion can crack the ceramic. So keep removal of the glow plugs to a minimum. The heater element is ceramic. So if you drop or knock a glow plug even once, replace the glow plug. Replace it regardless of it being new or used, having a normal resistance value and no sign of external damage. a Remove the intake pipe. See pSge EM-44 1 Remove the 4 screw...