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1PZ
Toyota 1PZ User Manual
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LU-1
0
LUBRICATIO
N
SYSTE
M
-
Oi
l
Pum
p
(c
)
Remov
e
th
e
seve
n
bolts
,
timin
g
gea
r
cas
e
an
d
gasket
.
(d
)
Usin
g
a
plastic-face
d
hammer
,
lightl
y
ta
p
ou
t
th
e
timin
g
gea
r
case
.
(e
)
Remov
e
th
e
gasket
.
DISASSEMBL
Y
O
F
OI
L
PUM
P
1
.
REMOV
E
DRIVE
N
ROTO
R
2
.
REMOV
E
RELIE
F
VALV
E
Remov
e
th
e
plug
,
gasket
,
sprin
g
an
d
relie
f
valve
.
256
258
Table of Contents
Caution
3
Introduction Contents
5
How to Use this Manual
6
Repair Procedures
6
Identification Information
8
Engine Serial Number
8
General Repair Instructions
8
Abbreviations Used in this Manual
11
Table of Contents
12
Engine Mechanical Contents
12
Description
13
Troubleshooting
15
Diesel Engine Diagnosis
15
General
15
Preliminary Checks
15
Diesel Electrical System Diagnosis
25
Pre-Heating System
25
Fuel Cut Solenoid Valve
27
Engine Tune-Up
28
Inspection/Cleaning of Air Filter
28
Inspection of Alternator Drive Belt
29
Adjustment of Valve Clearance
30
Set no 1 Cylinder to Tdc/Compression
30
Adjusting Shim Selection Using Chart (Intake)
32
Adjusting Shim Selection Using Chart (Exhaust)
33
Adjustment of Injection Timing
34
Install SST and Dial Indicator
34
Release ACSD Advance
35
Adjust Injection Timing
35
Remove Metal Plate
36
Remove SST and Dial Indicator
37
Torque Union Nuts of Injection Pipes
37
Adjustment of Idle Speed and Maximum Speed
38
Initial Conditions
38
Adjust Idle Speed
38
Adjust Maximum Speed
38
Adjustment of Air Conditioner Idle-Up Setting Speed
40
Adjust Air Conditioner Idle-Up Setting Speed
40
Check Cylinder Compression Pressure
41
Compression Check
41
Components
43
Timing Belt
43
Removal of Timing Belt
44
Remove Timing Belt Cover
44
Set no 1 Cylinder to BDC
44
Remove Timing Belt Idler Pulley
45
Remove no 2 Camshaft Timing Pulley
45
Remove Intake Pipe
45
Remove Cylinder Head Cover
46
Remove no 1 Camshaft Timing Pulley
46
Inspection of Timing Belt Components
47
Inspect Idler Pulley
48
Inspect Tension Spring
48
Install Intake Pipe
49
Instal no 1 Camshaft Timing Pulley
49
Installation of Timing Belt
49
Install Cylinder Head Cover
49
Instal no 2 Camshaft Timing Pulley
50
Install Timing Belt Idler Pulley
50
Check Valve Timing
51
Install Timing Belt Cover
52
Timing Gears
53
Removal of Timing Gears
54
Remove Oil Pipe
54
Remove Vacuum Pump
54
Remove Crankshaft Pulley
54
Remove Timing Gear Cover
55
Check Thrust Clearance of Idler Gear
55
Remove Pump Drive Shaft Gear
55
Remove Crankshaft Timing Gear
56
Remove Idler Gear
56
Remove Injection Pump Drive Gear
56
Inspection of Timing Gears
57
Inspect Idler Gear
57
Inspect Injection Pump Drive Gear Bearing
57
Replace Injection Pump Drive Gear Bearing
57
Check Backlash of Timing Gears
58
Replacement of Crankshaft Front Oil Seal
59
Replacement of Injection Pump Drive Gear Oil Seal
60
Installation of Timing Gears
61
Install Crankshaft Timing Gear
61
Install Injection Pump Drive Gear
61
Install Idler Gear
61
Install Pump Drive Shaft Gear
62
Install Timing Gear Cover
62
Install no 1 Crankshaft Pulley
63
Install Vacuum Pump
64
Instal Oil Pipe
64
Cylinder Head
65
Removal of Cylinder Head
66
Remove Oil Dipstick and Oil Dipstick Guide
66
Remove Intake Manifold
66
Remove Nozzle Leakage Pipe
66
Remove Injection Nozzles
67
Remove Glow Plugs
68
Remove Exhaust Manifold
68
Separate Exhaust Manifold
69
Remove Camshaft
70
Remove Camshaft Oil Seal Retainer
70
Remove Cylinder Head
71
Disassembly of Cylinder Head
72
Remove Valves
72
Remove Combustion Chambers
73
Inspection, Cleaning and Repair of Cylinder Head Components
74
Clean Top of Pistons and Top of Block
74
Remove Gasket Material
74
Clean Combustion Chambers
74
Inspect Cylinder Head for Flatness
75
Inspect Cylinder Head for Cracks
75
Clean Valves
75
Inspect Valve Stems and Guide Bushings
75
Replace Valve Guide Bushings
76
Inspect and Grind Valves
77
Inspect and Clean Valve Seats
78
Inspect Valve Springs
79
Inspect Camshafts and Bearings
80
Inspect Valve Lifters and Lifter Bores
81
Inspect Intake and Exhaust Manifold
82
Inspect Cylinder Head Bolts
82
Replacement of Camshaft Oil Seal
83
Assembly of Cylinder Head
84
Install Half Circular Plug
84
Select Combustion Chamber Shim
84
Install Combustion Chambers
84
Install Valves
85
Install Valve Lifters and Shims
85
Installation of Cylinder Head
86
Check Piston Protrusion and Select Cylinder Head Gasket
86
Install Cylinder Head
88
Cylinder Block
88
Install Camshaft
89
Adjust Valve Clearance
90
Assembly Exhaust Manifolds
90
Install Camshaft Oil Seal Retainer
90
Install Pulleys and Timing Belt
90
Install Exhaust Manifold
91
Install Glow Plug
92
Install Injection Nozzles
93
Install Nozzle Leakage Pipe
93
Install Injection Pipes
94
Install Intake Manifold
94
Install Oil Dipstick Guide and Oil Dipstick
94
Install Water Outlet
94
Cylinder Block
95
Preparation for Disassembly
96
Check Connecting Rod Thrust Clearance
97
Disassembly of Cylinder Block
97
Remove Connecting Rod Caps and Check Oil Clearance
97
Remove Rear Oil Seal Retainer
97
Remove Piston and Connecting Rod Assemblies
99
Check Crankshaft Thrust Clearance
100
Remove Main Bearing Cap and Check Oil Clearance
100
Remove Check Valves and Oil Nozzles
103
Remove Crankshaft
103
Inspect Cylinder Bore Diameter
104
Inspect Cylinder for Vertical Scratches
104
Inspect Top of Cylinder Block for Flatness
104
Inspection of Cylinder Block
104
Inspect Main Bearing Cap Bolts
105
Remove Cylinder Ridge
105
Disassembly of Piston and Connecting Rod Assemblies
106
Disconnect Connecting Rod from Piston
106
Inspect Cylinder Block Orifice
106
Remove Piston Rings
106
Clean Piston
108
Inspect Piston Diameter and Oil Clearance
108
Inspection and Repair of Piston and Connecting Rod Assemblies
108
Inspect Clearance between Wall of Ring Groove and New Piston Ring
109
Inspect Piston Ring End Cap
109
Inspect Connecting Rod
110
Inspect Piston Pin Fit
110
Replace Connecting Rod Bushings
111
Bore and Hone Cylinders to Calculate Dimensions
114
Boring of Cylinders
114
Calculate Amount to Bore Cylinder
114
Keep Oversized Pistons
114
Grind and Hone Main Journals And/Or Crank Pins
115
Inspect Crankshaft for Runout
115
Inspect Main Journals and Crank Pins
115
Inspection and Repair of Crankshaft
115
Replacement of Crankshaft Oil Seal
116
Assembly of Piston and Connecting Rod Assemblies
117
Install Piston Rings
117
Install Bearings
118
Assembly of Cylinder Block
119
Install Main Bearings
119
Install Oil Nozzles and Check Valves
119
Install Main Bearing Cap
120
Install Thrust Washers
120
Install Connecting Rod Caps
122
Install Piston and Connecting Rod Assemblies
122
Install Rear Oil Seal Retainer
123
Post Assembly
124
Turbocharger Contents
125
Description
126
Operation of Turbocharger
127
Waste Gate Valve
127
Precautions
128
Troubleshooting
129
Turbocharger Electrical System Diagnosis (Hzj80
131
Check Turbocharging Pressure
132
Inspect Exhaust System
132
Inspect Intake Air System
132
On-Vehicle Inspection of Turbocharger
132
Removal of Turbocharger
134
Remove Exhaust Manifold Heater Insulator
134
Remove Turbo Heat Insulator
134
Remove Turbocharger Stay
134
Remove no 2 Turbo Heat Insulator
135
Remove Turbo Oil Pipe
135
Remove Turbocharger and Exhaust Manifold Assembly
135
Separate Turbocharger and Exhaust Manifold
135
Inspect Axial Play of Impeller Wheel
136
Inspect Impeller Wheel Rotation
136
Inspect Radial Play of Turbine Shaft
136
Inspection of Turbocharger
136
Inspect Actuator Operation
137
Install no 1 Turbo Water Pipe
137
Install Turbine Outlet Elbow
137
Installation of Turbocharger
137
Assemble Turbocharger and Exhaust Manifold
138
Install Turbo Oil Pipe
138
Install Turbocharger and Exhaust Manifold Assembly
138
Install Turbocharger Stay
138
Install Exhaust Manifold Heat Insulator
139
Install Turbocharger Heat Insulator
139
Fuel System Contents
140
Description
141
Injection Pump
142
Operation
142
Drain Fuel from Fuel Filter
143
Replacement of Fuel Filter
143
Fuel Heater System
145
System Circuit
145
Fuel Heater
146
Inspection of Components
146
Vacuum Switch
146
Fuel Heater Relay
147
INJECTION NOZZLES (1PZ and 1 HZ
148
Removal of Injection Nozzles
148
Remove Injection Pipes
148
Injection Pressure Test
149
Remove Nozzleleakage Pipe
149
Test of Injection Nozzles
149
Adjusting Shim Thickness
150
Leakage Test
150
Spray Pattern Test
150
Cleaning and Inspection of Injection Nozzles
151
Disassembly of Injection Nozzles
151
Inspect Nozzle Assembly
152
Assembly of Injection Nozzles
153
Injection Nozzles (1Hd-T
153
Installation of Injection Nozzles
153
Disconnect Injection Pipes
155
Adjust Pre-Lift
159
Assembly and Adjustment of Injection Nozzle
159
Check no 2 Opening Pressure
161
Adjust no 1 Opening Pressure
163
Removal of Injection Pump
166
Disassembly of Injection Pump
172
Remove Idle-Up Lever
172
Remove Thermo Wax
172
Remove Two Fuel Pipes
172
Remove Fuel Cut Solenoid
173
Remove PCS Actuator
173
Remove Adjusting Lever
174
Remove Governor Cover
174
Disassembly High Altitude Compensator
175
Remove Governor Adjusting Lever Shaft from Governor Cover
175
Disassemble Boost Compensator
177
Remove Distributive Head Plug
179
Remove Governor Shaft and Flyweight Holder
179
Remove Injection Pump Stay
179
Remove Delivery Valve Holders
180
Remove Distributive Head
180
Remove Face Camplate and Coupling
181
Remove Governor Link
181
Remove Pump Plunger
181
Remove Roller Ring and Drive Shaft
182
Remove Timer
183
Remove Fuel Feed Pump
184
Remove Fuel Inlet Hollow Screw
184
Remove Regulator Valve
184
Inspect Delivery Valves
185
Inspection of Injection Pump Components
185
Inspect Plunger Springs for Squareness
186
Inspect Pump Plunger, Spill Ring and Distributive Head
186
Inspect Spring Length
186
Inspect Fuel Cut Solenoid
187
Inspect Pickup Sensor
187
Inspect Roller Ring and Rollers
187
Replace Oil Seal
187
Assembly of Injection Pump
188
Install Fuel Feed Pump
188
Install Fuel Inlet Hollow Screw
188
Install Regulator Valve
188
Install Drive Shaft
189
Install Roller Ring
190
Install Timer Piston
190
Adjust Plunger Spring Shim
192
Plunger Spring Shim Selection Chart for 1 HD-T
192
Plunger Spring Shim Selection Chart for 1 PZ and 1 HZ
192
Plunger Adjusting Shim Selection Chart
194
Install Face Cam Plate
195
Install Governor Link
195
Install Pump Plunger
195
Install Distributive Head
196
Check Flyweight Holder Thrust Clearance
197
Install Delivery Valve Holders
197
Install Governor Shaft and Flyweight Holder
197
Adjust Protrusion of Governor Shaft
198
Assemble High Altitude Compensator
198
Assemble Boost Compensator
199
Install Adjusting Lever
200
Install Adjusting Lever Shaft to Governor Shaft
200
Install Governor Cover
200
Adjust Plunger Pre-Stroke
202
Install Distributive Head Plug
203
Install Fuel Cut Solenoid
206
Install no 1 Pcs Lever
206
Install Pcs Actuator
207
Install Thermo Wax
207
Install Idle-Up Lever
208
Perform Air Tight Test
208
Adjustment of Injection Pump
209
Pretest Check and Preparation
209
Preset Full Load Injection Volume
214
Adjust Pump Inner Pressure
215
Preset Maximum Speed
215
Adjust Timer
216
Check Overflow Volume
216
Release Cold Starting System for Next Inspections
216
Adjust Full Load Injection Volume
217
Check Air Tightness of Boost Compensator
217
Check Injection Volume
220
Adjust Boost Compensator Characteristic
223
Adjust Full Load Minimum Injection Volume
223
Check Hysteresis
224
Inspect Boost Compensator Characteristic Tendency
224
Adjust Load Sensing Timer
225
Adjust Cold Starting System
229
Adjust Fast Idle
230
Post Adjustment Check
230
Install Two Fuel Pipes
231
Seal Parts
231
Installation of Injection Pump
232
Inspect Power Control System
234
Inspection of Power Control System Components
234
On-Vehicle Inspection
234
Power Control System
234
Inspect Shift Position Switch
235
Cooling System Components
236
Description
237
Radiator
238
Radiator Cap
238
Reservoir Tank
238
Thermostat
238
Check and Replacement of Engine Coolant
239
Check Engine Coolant Level at Reservoir Tank
239
Check Engine Coolant Quality
239
Replace Engine Coolant
239
Troubleshooting
239
Water Pump
241
Removal of Water Pump
242
Inspect Fluid Coupling
243
Inspect of Water Pump
243
Installation of Water Pump
243
Install Water Pump Pulley, Fan and Drive Belt
244
Inspection of Thermostat
245
Removal of Thermostat
245
Install Water Inlet to Cylinder Block
246
Installation of Thermostat
246
Place Thermostat in Cylinder Block
246
Cleaning of Radiator
247
Inspect Cooling System for Leaks
247
Inspect Radiator Cap
247
Inspection of Radiator
247
Lubrication System Contents
248
Description
249
Oil Filter
250
Oil Pressure Regulator
250
Oil Pump
250
Troubleshooting
251
Check Engine Oil Level
252
Check Engine Oil Quality
252
Oil Pressure Check
252
Drain Engine Oil
253
Replace Oil Filter
253
Replacement of Engine Oil and Oil Filter
253
Fill with Engine Oil
254
Oilpump
255
Removal of Oil Pump
256
Remove Oil Pan
256
Disassembly of Oil Pump
257
Inspect Drive and Driven Rotors
258
Inspect Relief Valve
258
Inspection of Oil Pump
258
Assembly of Oil Pump
259
Install Relief Valve
259
Installation of Oil Pump
259
Pour Engine Oil into Oil Pump
260
Install Oil Pan
261
Install Oil Strainer
261
Oil Cooler, Relief Valve and Check Valve
262
Removal of Oil Cooler, Relief Valve and Check Valve
263
Inspection of Oil Cooler, Relief Valve and Check Valve
264
Assemble Oil Cooler and Oil Cooler Cover
265
Install Check Valve
265
Install Engine Drain Cock
265
Installation of Oil Cooler, Relief Valve and Check Valve
265
Install Oil Cooler and Oil Cooler Cover Assembly
266
Install Oil Dipstick Guide and Dipstick
266
Oil Nozzles and Check Valves
267
Removal of Oil Nozzles and Check Valves
267
Inspection of Oil Nozzles and Check Valves
268
Installation of Oil Nozzles and Check Valves
268
Starting System Contents
269
Pre-Heating System
270
Super Glow Type (Europe and Australia
270
Inspection of Pre-Heating System
271
Timer Characteristic Diagram
271
Inspect Preheating Timer Circuit
273
Inspect Relay Continuity
273
No. 1 Glow Plug Relay
273
Inspect Relay Operation
274
No.2 Glow Plug Relay
274
Glow Plug
275
Glow Plug Resistor
275
Water Temperature Sensor
276
Fixed Delay Type (HZJ80 and HDJ80) Ex. (Europe and Australia
277
Inspect Lighting Time of Glow Indicator Light
277
Inspection of Preheating System
277
Pre-Heating Timer
278
Fixed Delay Type (PZJ, HZJ75, HZB and HDB) Ex. (Europe and Australia
279
Glow Plug
280
Starting System Circuit
281
Troubleshooting
281
Disassembly of Starter
283
Remove Field Frame and Armature
283
Remove Starter Housing, Clutch Assembly and Gears
283
Starter
283
Remove Brush Holder
284
Remove Steel Ball
284
Armature Coil
285
Commutator
285
Inspect Commutator for Open Circuit
285
Inspection and Repair of Starter
285
Brush Springs
286
Brushes
286
Field Coil (Field Frame)
286
Inspect Undercut Depth
286
Brush Holder
287
Clutch and Gears
287
Inspect Clutch Pinion Gear
287
Inspect Gear Teeth
287
Bearings
289
Assembly of Starter
290
Magnetic Switch
290
Perform Pull/Hold-In Coil Open Circuit Test
290
Place Armature into Field Frame
290
Insert Steel Ball into Clutch Shaft Hole
291
Install Gear, Clutch Assembly and Starter Housing
291
Install Field Frame and Armature Assembly
292
Inspect Clutch Pinion Gear Return
293
Perform No-Load Performance Test
293
Perform Pull/Hold-In Test
293
Performance Test of Starter
293
Inspection of Starter Relay
294
Starter Relay (PZJ, HZJ and HDJ)
294
Starter Relay (HZB and HDB)
295
Inspection of Voltage Converter Timer
296
VOLTAGE CONVERTER TIMER (HZJ80 and HDJ80) (W/ 24 V Starter)
296
Inspection of Voltage Converter Relay
297
VOLTAGE CONVERTER RELAY (Hzj80And HDJ80) (W/24 V Starter)
297
HOLD WARNING RELAY (Hzj80And HDJ80) (W/ 24 V Starter)
298
Inspection of 24 V Hold Warning Relay
298
Charging System Contents
299
Precautions
300
Troubleshooting
300
Charging System Circuit
301
Check Battery Terminals, Fusible Links and Fuses
303
Inspect Battery Specific Gravity and Electrolyte Level
303
Inspect Drive Belts
303
On-Vehicle Inspection
303
Check Alternator Wiring and Listen for Abnormal Noises
304
Inspect Charging Circuit Without Load
304
Inspect Discharge Warning Light Circuit
304
Inspect Charging Circuit with Load
305
Alternator
306
Disassembly of Alternator
307
Remove Brush Holder and IC Regulator
307
Remove Rear End Cover
307
Remove Rectifier Holder
307
Remove Pulley
308
Remove Rectifier End Frime
308
Inspection and Repair of Alternator
310
Rotor
310
Stator (Drive End Frame)
310
Rectifiers (Rectifier Holder)
311
Assembly of Alternator
314
Install Rectifier End Frame
314
Install Rotor to Drive End Frame
314
Install Pulley
315
Install Rectifier Holder
315
Install IC Regulator and Brush Holder
316
Install Rear End Cover
317
Service Specifications Contents
318
Torque Specifications
324
Turbocharger System
325
Fuel System
326
Injection Pump Adjustment
330
1HD-T Plus
333
Adjusting
333
Injection
333
Lever Angle
333
Item
334
Adjusting
335
Lever Angle
335
(Europe) Plus
336
1Hd-T
336
Plus 21 - 3
336
Pump Rpm Measuring Strokes
336
Cooling System
338
Lubrication System
338
Starting System
339
Charging System
339
Standard Bolt Torque Specifications
340
How to Determine Bolt Strangth
341
SST and SSM
343
SST (Special Service Tools)
344
SSM (Special Service Materials)
348
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Toyota 1PZ Specifications
General
Brand
Toyota
Model
1PZ
Category
Engine
Language
English
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