>) TOYOTA REPAIR MANUAL Aug., 1999« FOREWORD This repair manual has been prepared to provide information covering general service repairs for’ ‘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 Pop. No- EwOo07F ILUX Electrical Wiring Diagram 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 musts @1999 TOYOTA MOTOR CORPORATION Allrights reserved. This book may not be repro- duced or copied, in whole or in part, without the ‘written permission of Toyota Motor Corporation. Elret Parting’ lin 171. 199901-900R1400-24 LSE Tw PREPARA DI ENGINE MECHANICAL [fay TURBOCHARGER [fixe EMISSION CONTROL IZ [ELECTRONIC CONTROL DIESEL [ay [ENGINE FUEL [i (COOLING Kee [LUBRICATION 1 STARTING CHARGING ALPHABETICAL INDEX [ty* INTRODUCTION rel *€ Pe (IDENTIFICATION INFORMATION 2... _IN-3] FOR ALL OF VEHICLES . ve IN PRECAUTION ... IN-8 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS . IND No GENERAL INFORMATION... ....--- HOW TO PROCEED ’ |_WITH TROUBLESHOOTING ........1.1..1. —IN=10] [HOW TO USE THE DIAGNOSTIC CHARTINTROUUETION ~ _ HOWTTOTOSETTHIs MANUAL’ HOW TO USE THIS MANUAL _ GENERAL INFORMATION odT + 1. INDEX . wwe wn . ‘An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page. 2. PRECAUTION At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN-9. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe- cial Service Materials) which should be prepared before beginning the operation and explains the purpose ofeachone. + 5. REPAIR PROCEDURES Mest repair operations begin with an overview illustration. parts fit together. ses so Example: - 3 . identifies the components and shows how the z Driven Rotor + 9ngq ort navin 618 uoy beriuper 9x8 veri! nadw aso. ated as, onatgte avorrag” 2 aveal of eved 1ev80 voY hebean & Ai bain. : tos, yprol noweee @ 0h 29 u oer. 26 eon @ Crankshaft Front Oil Seal ‘ 2 m™ bons 8 TURD 910083 amor balnszang cals 16 27" TOK ‘squt ytisd ae donne no OTE MONE oe. 918 OTH 18 quay qiert &—— rele Valve HEED gee eR getsmntaly THA 12 rat sheasees he aig ae Ieee ait alnevir vt ar s Spr wy pring ica ater. 5 bi e—— @ Gasket alee motpy OFE) m4 OE 292 & fina m (kgFom, f) | : Specified torque Bore, ‘# Non-reusable partIN-2 INTRODUCTION — HOWTO USE THIS MANUAL The procedures are presented in a step-by-step format: + The illustration shows what to do amd where to do it. + The task heading tells what to do. mes — + The detailed text tells how to perform the task and gives other information such as specifications andwamings. 5. oye “Task headiig what iodo 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (@) Place SST and a dial indicator onto the overdrive brake pis- * ton as shown in the illustration, SST 08350-20020, (09050-06120) a a3 Set part No. CBmponent partNo. : Detailed text: “how todo task " (0) Measure the stroke applying and releasing the compressed air (392 — 785 kPa, 4—8 kgl/cm? or 57 — 114 psi) as shown, in the ilustration. _ Piston stroke: 1.40 — 1.70 mm (0.0861 — 0.0669 in) This format provides the experienced technician wih a FAST TRACK tothe information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed informa tion. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Spectcations are presented In bold type throughout ihe text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick ref- erence. 8. CAUTIONS, NOTICES, HINTS: te wae f + CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other } people. 1 + NOTICES are also presented in bold type, and indicate the possibilty of damage to the components | _ being repaired. + HINTS are separated from the text but do not appear in bold. They frovide additional information td help you perform the repair efficiently. , i 9. SIUNIT ‘The UNITS given in this manual are primarily expressed according to the S! UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N-m (310 kat-cm, 22 ft-bf) | | a |IN-3 INTRODUCTION — IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration.Ina IWTROOUCTION —_ REPAIR INSTRUCTIONS @ (b) (0) (e) @ (9) REPAIR INSTRUCTIONS GENERAL INFORMATION Pt BASIC REPAIR HINT lan Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following operations: (1) Before performing electrical work, disconnect the negative (-) terminal cable trom the battery. (2) it is necessary to disconnect the battery for in- spection or repair, always disconnect the negative (G) terminal cable which is grounded to the vehicle body. (8) To prevent damage to the battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or oth- er abrasive objects. (5) Install the cable ends to the battery terminals with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. Check hose and wiring connectors to make sure that they are secure and correct. Non-reusable parts (1) Always replace cotter pins, gaskets, O-rings and oil seals etc. with new ones. (2) Non-reusable parts are indicated in the component illustrations by the °@" symbol. Precoated parts Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. (1) Ia precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. (3) Precoated parts are indicated in the component il- lustrations by the **” symbol. When necessary, use a sealer on gaskets to prevent leaks.INS <5 -WETRODUCTION —_REPAIS INSTRUCTIONS, . th) c @ = a an 2 er wiph anor Medium Current Fuse and High Current Fuse Equal Amperage Rating Carefully observe all specifications for bolt tightening torques. Always use a torque wrench, Use of special service tools (SST) and special service ma- terials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where speci- fied and follow the proper work procedure. A list of SST and SSM can be found in section PP (Preparation) in this manual. When replacing fuses, be sure the new fuse has the cor- rect amperage rating. DO NOT exceed the rating or use one with a lower rating a FUSE FUSE Fo MEDIUM CURRENT FUSE ee HIGH CURRENT FUSE es) cmunw ‘| aa, | rubiete Link SFL | peeve a . eae Gr # pst CIRCUIT BREAKER cay sess ose : “oteni yo evn—==y of donstw wer enmeto yet oi tees # ory OK, ‘s2orf sdf sro! revert .2QUBD MWL2BV & swob- Bee sow ad mw % isa ym fi @ | w oe ‘Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the prop- er locations. + Cancel the parking brake on the level place and 9 shift the transmission in Neutral (or N position). + When jacking up the front wheels of the vehicle at tz first place stoppers behind the rear wheels. + When jacking up the rear wheels of the vehicle at first place stoppers behind the rear wheels.