Toyota 1HD-FT Operating instructions

@TOYOTA

1HD-FT

ENGINE

REPAIR

MANUAL

Jan.,

1995

Pub. No. RM437E

1995

TOYOTA

MOTOR

CORPORATION

reproduced

copied,

whole

in part,

without the written permission of Toyota

Motor Corporation.

FOREWORD

This

repair manual has been prepared

provide

information

covering

general service repairs

for

the

1HD-FT engine

equipped

the

TQYOTA

LAND

CRUISER.

Applicable models:

HDJ80

series

Please

note

that

the

publications

below

have also

been

pre-

pared as relevant service manuals

for

the

components

and

system

in this engine.

Manual

Name Pub. No.

01HD·FT Engine Emission

Control

Repair ERM111E

Manual

All

information

this

manual is based

the

latest

product

in-

formation

the

time

publication.

However,

specifications

and procedures are

subject

change

without

notice.

TOYOTA MOTOR CORPORATION

INTRODUCTION

ENGINE

STARTING SYSTEM

CHARGING SYSTEM

IN-1

INTRODUCTION

HOW

USE

THIS

MANUAL

IN-

IDENTIFICATION INFORMATION

IN-

GENERAL REPAIR INSTRUCTIONS

IN-

ABBREVIATIONS USED

THIS

MANUAL

IN-

STANDARD BOLT TORQUE

SPECIFICATIONS

.•..........................•.......

IN-

IN-2

INTROOUCTION -

HOW

USE

THIS

MANUAL

HOW

TO USE

THIS

MANUAL

INDEX

An INDEX is provided

the

first

page

each

section

guide

you

the

item

repaired.

assist

you

finding

your

way

through

the

manual.

the

Section

Title

and

major

heading

are

given

the

top

every

page.

GENERAL DESCRIPTION

the

beginning

each

section.

aGeneral Description is given

that

pertains

all

repaIr

operations

contained

that

section.

Read

these

precautions

before

starting

any

repair task.

TROUBLESHOOTING

TROUBLESHOOTING tables are included

for

each

system

help

you

diagnose

the

problem and

find

the

cause.

PREPARATION

Preparation

lists

the

SST (Special Service Tools).

recommended

tools.

equipment.

lubricant

and

SSM (Special

Service

Materials)

which

should be

prepared

before

beginning

the

operation

and

explains

the

purpose

each

one.

REPAIR PROCEDURES

Most

repair

operations

begin with

overview illustration.

identifies

the

components

and

shows

how

the

parts

fit

together.

Example:

Plug

1 • Gasket riven

otor

r"'""

~--

Timing Gear Case

•Non-reusable part

INTROOUCTION -

HOW

USE

THIS

MANUAL

IN-3

The

procedures

are

presented

step-by-step

format:

•

The

illustration

shows

what

and

where

it.

•

The

task

heading

tells

what

do.

•The detailed

text

tells

how

perform the task and gives

other

information

such

specifications

and

warnings.

Example: N

Illustration:

what to

and

where

Task

heading:

what

INSTALL

CRANKSHAFT

PULLEY

(a) Using SST, install the bolt.

SST 0921

~54015

(90119-~'

26)

Set part No. Component part No.

Detailed text:

how

to do task

(b) Install the

b".

Torque:

N·m (310

kgf.cm.

ft.lbf)

Specification

This

format

provides

the

experienced

technician with aFAST TRACK

the

information

needed.

The

upper

case

task

heading

can

read

glance

when

necessary,

and

the

text

below it

provides detailed

information.

Important

specifications

and

warnings

always

stand

out

bold

type.

REFERENCES

References have been

kept

minimum.

However.

when

they

are required you are

given

the

page

refer

to.

SPECIFICA

TlONS

Specifications

are presented in bold

type

throughout

the

text

where

needed.

You

never

have

leave

the

procedure

look

your

specifications.

They are also

found

the

end

each section.

for

quick

reference.

IN-4

INTRODUCTION -IDENTIFICATION INFORMATION

CAUTIONS, NOTICES, HINTS:

•CAUTIONS

are

presented

bold

type.

and

indicate

there

is apossibility

injury

you

other

people.

•NOTICES are

also

presented

bold

type,

and

indicate

the

possibility

damage

the

components

being repaired.

•HINTS

are

separated

from

the

text

but

not

appear

bold.

They

provide

additional

information

help

you

perform

the

repair efficiently.

UNIT

The UNITS given in

this

manual are primarily expressed according

the

UNIT(lnternational

System

Unit), and alternately expressed

the

metric

system and in

the

English System.

Example:

Torque:

N·m

(310

kgf.cm.

ft·lbf)

The engine serial number is stamped on

the

engine

block

shown.

IDENTIFICATION INFORMATION

ENGINE SERIAL NUMBER

_.-

INTROOUCTION -GENERAL REPAIR INSTRUCTIONS

GENERAL REPAIR INSTRUCTIONS

IN-5

Seal

lock

Adhesive

INOO:Ml

--,

Use fender.

seat

and

floor

covers

keep

the

vehicle

clean

and

prevent

damage.

During disassembly, keep

parts

in the appropriate

order

facilitate

reassembly.

Observe the following:

(a)

Before performing electrical

work.

disconnect

the

negative

cable from

the

battery

terminal.

(b)

it is

necessary

disconnect

the

battery

for

inspection

repair. always

disconnect

the cable

from

the

negative

(-)

terminal

which

grounded

the

vehicle body.

(c)

prevent

damage

the

battery

terminal

post.

loosen

the

terminal

nut

and

raise

the

cable

strai-

ght

without

twisting

prying it.

(d)

Clean

the

battery

terminal

posts

and

cable

termi-

nals with aclean

shop

rag.

not

scrape

them

with a

file

other

abrasive objects.

(e)

Install

the

cable terminal

the

battery

post

with

the

nut loose.

and

tighten

the

nut after installa·

tion.

not use a

hammer

tap

the terminal

onto

the

post.

(f)

sure

the

cover

for

the

positive

(+)

terminal is

properly

place.

Check

hose

and

wiring

connectors

make sure

that

they

are

secure

and correct.

Non-reusable

parts

(a)

Always replace

cotter

pins.

gaskets.

-rings

and

oil

seals

etc. with

new

ones.

(b)

Non-reusable

parts

are indicated

the

compo-

nent

illustrations by

the

....

symbol.

Pre

coated

parts

Pre

coated

parts

are bolts

and

nuts. etc.

that

are

coated

with aseal lock adhesive

the

factory.

(a)

apre

coated

part

is retightened. loosened or

caused

move

any way. it

must

recoated

with

the

specified adhesive.

(b)

When reusing

precoated

parts. clean off

the

old

adhesive and dry with

compressed

air. Then

apply

the

specified seal lock adhesive

the

bolt.

nut

threads.

(c)

Precoated

parts

are indicated

the

component

illustrations by

the

"'*

symbol.

When necessary.

use

sealer

gaskets

to prevent

leaks.

Carefully observe

all

specifications for bolt tightening

torques. Always

use

torque

wrench.

IN-6

INTRODUCTION -GENERAL REPAIR INSTRUCTIONS

9. Use

special

service

tools

(SSn

and

special

service

materials (SSM) may

required. depending on

the

nature

the

repair.

sure

use

SST

and

SSM

where

specified and

the

proper

work

proce-

dure. Alist

SST and SSM can

found

in the

preparation

part

the

front

each

section

this

manual.

Fu",

EQual

Amperage

Rali~

)

10.

When

replacing fuses. be sure

the

new

fuse

has

the

correct

amperage

rating.

NOT

exceed

the

rating

use

one

with alower rating.

illustration

Symbol Abbreviation

IE559-t

8£5517

tnSM

FUSE

..,

MEDIUM CURRENT FUSE

HIGH CURRENT FUSE

FUSIBLE LINK

-R-

CIRCUIT BREAKER

..,..

FUSE

M.fUSE

H·FUSE

11. Care

must

taken

when

jacking

and

supporting

the

vehicle.

sure

lift and

support

the

vehicle

the

proper locations.

(a)

the

vehicle

jacked

up only

the

front

rear

end.

sure

block

the

wheels

the

opposite

end

order

ensure

safety.

INTROOUCTION -GENERAL REPAIR INSTRUCTIONS

IN.'

WRONG

CORRECT

""'"

CORRECT

IH025'

(b)

After

the

vehicle

jacked

up.

sure

support

stands.

It is

extremely

dangerous

any

work

vehicle

raised

jack

alone.

even

for

asmall

job

that

can

finished quickly.

12.

Observe

the

following

precautions

avoid

damage

the

parts:

(a)

not

open the

cover

case

the

EeU unless

absolutely necessary. (If

the

Ie terminals are

tou-

ched.

the

may

destroyed

static

electric-

ity.)

(bl

disconnect

vacuum

hoses.

pull

the

end.

not

the

middle

the

hose.

Ie)

pull

apart

electrical

connectors.

pull

the

connector

itself. not the wires.

(d)

careful

not

drop

electrical

components.

such

sensors

relays. If

they

are

dropped

hard

floor.

they

should

replaced

and

not

reused.

(e)

When

steam

cleaning

engine.

protect

the

dis·

tributor. air filter.

and

VCV

from

water.

(f)

Never

use

impact

wrench

remove

install

temperature

switches

temperature

sensors.

(g)

When

checking

continuity

the

wire

connector.

insert

the

tester

probe

carefully

prevent

termi·

nals from

bending.

(h)

When

using

vacuum

gauge.

never

force

the

hose

onto

connector

that

too

large. Use a

step-down

adapter

instead.

Once

the

hose

has

been

stretched.

may

leak.

Example

13.

Tag

hoses

before

disconnecting

them:

(a)

When

disconnecting

vacuum

hoses.

use

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