Toyota 1PZ Betriebsanleitung

FOREWORD

Thisrepairmanualhasbeenpreparedtoprovideinformation

coveringgeneralservicerepairsforthe1 PZ,1 HZand1HD-T

enginesequippedontheTOYOTALANDCRUISERand

COASTER.

Applicablemodels:

PZJ70,73,75series

HZJ70,73,75,80series

HDJ80series

HZB30series

HDB30series

Pleasenotethatthepublicationsbelowhavealsobeenprepared

asrelevantservicemanualsforthecomponentsandsystemin

thisengine.

Allinformationinthismanualisbasedonthelatestproduct

informationatthetimeofpublication.However,specifications

andproceduresaresubjecttochangewithoutnotice.

TOYOTAMOTORCORPORATION

ManualName

LandCruiser(Wagon)NewCarFeatures

Pub.No.

NCF064E

CAUTION

Thismanualdoesnotincludeallthenecessaryitemsaboutrepairandservice,thismanualismade

forthepurposeoftheuseforthepersonswhohavespecialtechniquesandcertifications.Inthe

casesthatnon-specializedoruncertifiedtechniciansperformrepairorserviceonlyusingthismanu-

alorwithoutproperequipmentortool,thatmaycausesevereinjurytoyouorotherpeoplearound

andalsocausedamagetoyourcustomer'svehicle.

Inordertopreventdangerousoperation anddamagestoyourcustomer'svehicle,besuretofollow

theinstructionshownbelow.

Mustreadthismanualthoroughly.Itisespeciallyimportanttohavegoodunderstandingallthe

contentswritteninthePRECAUTIONof"IN"section.

Theservicemethodwritteninthismanualisveryeffectivetoperformrepairandservice.When

performingtheoperationsfollowingtheproceduresusingthismanual,besuretousetoolsspe-

cifiedandrecommended.Ifusingnon-specifiedorrecommendedtoolsandservicemethod,

besuretoconfirmsafetyofthetechniciansandanypossibilityofcausingpersonalinjuryor

damagetothecustomer'svehiclebeforestartingtheoperation.

Ifpartreplacementisnecessary,mustreplacethepartwiththesamepartnumberorequivalent

part.Donotreplaceitwithinferiorquality.

Itisimportanttonotethatthismanualcontainsvarious"Cautions"and"Notices"thatmustbe

carefullyobservedinordertoreducetheriskofpersonalinjuryduringserviceorrepair,orthe

possibilitythatimproperserviceorrepairmaydamagethevehicleorrenderitunsafe.Itisalso

importanttounderstandthatthese"Cautions"and"Notices"arenotexhaustive,becauseitis

importanttowarnofallthepossiblehazardousconsequencesthatmightresultfromfailureto

followtheseinstructions.

TOYOTA

1PZ,1HZ,1HD-TENGINE

REPAIRMANUAL

INTRODUCTION

ENGINEMECHANICAL

TURBOCHARGERSYSTEM

FUELSYSTEM

COOLINGSYSTEM

LUBRICATIONSYSTEM

STARTINGSYSTEM

CHARGINGSYSTEM

SERVICESPECIFICATIONS

STANDARDBOLTTORQUESPECIFICATIONS

SSTANDSSM

Allrightsreserved.Thisbookmaynotberepro-

ducedorcopied,inwholeorinpart,withoutthe

writtenpermissionofToyotaMotorCorporation.

FirstPrinting:Feb.8,199001-900208-00

34thPrinting:Aug.28,200134-010828-06-2

IN-1

INTRODUCTION

Page

HOWTOUSETHISMANUALIN-2

IDENTIFICATIONINFORMATIONIN-4

GENERALREPAIRINSTRUCTIONSIN-4

ABBREVIATIONSUSEDINTHISMANUALIN-7

IIM-2

INTRODUCTIONHowtoUseThisManual

HOWTOUSETHISMANUAL

Toassistyouinfindingyourwaythroughthismanual,the

SectionTitleandmajorheadingaregivenatthetopofevery

page.

AnINDEXisprovidedonthe1stpageofeachsectiontoguide

youtotheitemtoberepaired.

Atthebeginningofeachsection,PRECAUTIONSaregiventhat

pertaintoall repairoperationscontainedinthatsection.

Read these precautions before starting any repair task.

TROUBLESHOOTINGtablesareincludedforeachsystemto

helpyoudiagnosetheproblemandfindthecause.Therepairfor

eachpossiblecauseisreferencedintheremedycolumnto

quicklyleadyoutothesolution.

REPAIRPROCEDURES

Mostrepairoperationsbeginwithanoverviewillustration.It

identifiesthecomponentsandshowshowthepartsfittogether.

Example:

IN-3

INTRODUCTION- HowtoUseThisManual

Theproceduresarepresentedina step-by-stepformat:

•Theillustrationshowswhat todoandwhereto doit.

•Thetaskheadingtellswhat todo.

•Thedetailedtexttellshow toperformthetaskandgivesother

informationsuchasspecificationsandwarnings.

Example:

Thisformatprovidestheexperiencedtechnicianwitha

FASTTRACKtotheinformationneeded.Theuppercase

taskheadingcanbereadata glancewhennecessary,and

thetextbelowitprovidesdetailedinformation.Important

specificationsandwarningsalwaysstandoutinboldtype.

REFERENCES

Referenceshavebeenkepttoa minimum.However,whenthey

arerequired,youaregiventhepagetoreferto.

SPECIFICATIONS

Specificationsarepresentedinboldtypethroughoutthetext

whereneeded.Youneverhavetoleavetheproceduretolookup

yourspecifications.TheyarealsofoundinAppendixA forquick

reference.

CAUTIONS,NOTICES,HINTS:

•CAUTIONSarepresentedinboldtype,andindicatethereisa

possibilityofinjurytoyouorotherpeople.

•NOTICESarealsopresentedinboldtype,andindicatethe

possibilityofdamagetothecomponentsbeingrepaired.

•HINTSareseparatedfromthetextbutdonotappearinbold.

Theyprovideadditionalinformationtohelpyouefficiently

performtherepair.

IIM-4

INTRODUCTION- IdentificationInformation,GeneralRepairInstructions

IDENTIFICATIONINFORMATION

ENGINESERIALNUMBER

Theengineserialnumberisstampedontheleftsideofthe

cylinderblock.

GENERALREPAIRINSTRUCTIONS

1.Usefender,seatandfloorcoverstokeepthevehicleclean

andpreventdamage.

2.Duringdisassembly,keeppartsinordertofacilitatereas-

sembly.

3.Observethefollowing:

(a)Beforeperformingelectricalwork,disconnectthe

negative(—)cablefromthebatteryterminal.

(b)Ifitisnecessarytodisconnectthebatteryforinspec-

tionorrepair, alwaysdisconnectthecablefromthe

negative(—)terminalwhichisgroundedtothevehi-

clebody.

(c)Topreventdamagetothebatteryterminalpost,loosen

theterminalnutandraisethecablestraightupwith-

outtwistingorpryingit.

(d)Cleanthebatteryterminalpostsandcableterminals

witha shoprag.Donotscrapethemwitha fileor

otherabrasiveobject.

(e)Installthecableterminaltothebatterypostwiththe

nutloose,andtightenthenutafterinstallation.Donot

usea hammertotaptheterminalontothepost.

(f)Besurethecoverforthepositive(+) terminalis

properlyinplace.

4.Checkhoseandwiringconnectorstomakesurethatthey

aresecureandcorrect.

5.Non-reusableparts

(a)Alwaysreplacecotterpinsgaskets,O-rings,oilseals,

etc.withnewones.

(b)Non-reusablepartsareindicatedinthecomponent

illustrationsbythe"•"symbol.

6.PrecoatedParts

Precoatedpartsareboltsandnuts,etc.thatarecoatedwith

aseallockadhesiveatthefactory.

(a)Ifa precoatedpartisretightened,loosenedorcaused

tomoveinanyway,itmustberecoatedwiththe

specifiedadhesive.

IN-5

INTRODUCTION- GeneralRepairInstructions

(b)RecoatingofPrecoatedParts

(1)Cleanofftheoldadhesivefromthepart's

threads.

(2)Drywithcompressedair.

(3)Applythespecifiedseallockadhesive tothe

part'sthreads.

(c)Precoatedpartsareindicatedinthecomponentillus-

trationsbythe"*"symbol.

7.Whennecessary,usea sealerongasketstopreventleaks.

8.Carefullyobserveallspecificationsforbolttorques.Always

usea torquewrench.

9.Useofspecialservicetools(SST)andspecialservice

materials(SSM)mayberequired,dependingonthenature

oftherepair.BesuretouseSSTandSSMwherespecified

andfollowtheproperworkprocedure.A listofSSTand

SSMcanbefoundatthebackofthismanual.

10.Whenreplacingfuses,besurethenewfuseisthecorrect

amperage.DONOTexceedtheratingoruseoneofa lower

rating.

11.Caremustbetakenwhenjackingupandsupportingthe

vehicle.Besuretoliftandsupportthevehicleattheproper

locations.

(a)Ifthevehicleistobejackeduponlyatthefrontorrear

end,besuretoblockthewheelsinordertoensure

safety.

(b)Afterthevehicleisjackedup,besuretosupportiton

stands.Itisextremelydangeroustodoanyworkon

thevehicleraisedona jackalone,evenfora smalljob

thatcanbefinishedquickly.

12.Observethefollowingprecautionstoavoiddamagingthe

parts:

(a)Becarefulnottodropelectricalcomponents,suchas

sensorsorrelays.Iftheyaredroppedona hardfloor,

theyshouldbereplacedandnotreused.

(b)Topullapartelectricalconnectors,pullonthecon-

nectoritself,notthewires.

(c)Todisconnectvacuumhoses,pullontheend,notthe

middleofthehose.

IIM-6

INTRODUCTIONGeneralRepairInstructions

(d)Whensteamcleaninganengine,protecttheairfilter,

andinjectionpumpfromwater.

(e)Neveruseanimpactwrenchtoremoveorinstalltemp,

switchesortemp,sensors.

(f)Whencheckingcontinuityatthewireconnector,

insertthetesterprobecarefullytopreventterminals

frombending.

(g)Whenusinga vacuumgauge,neverforcethehose

ontoa connectorthatistoolarge.Usea step-down

adapterinstead.Oncethehosehasbeenstretched,it

mayleak.

13.Afterremovingandreinstallingtheinjectionpumpandfuel

hoses,cleanoffthefuelonenginecomponents.Inpartic-

ular,besuretochecktheradiatorhoseandby-passhose,

becausetheydeteriorateeasilyiftheycomeintocontact

withfuel.

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