Toyota 1hd Ft Engine Repair Manual

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@TOYOTA
1HD-FT
ENGINE
REPAIR MANUAL
Jan., 1995

..

Pub. No. RM437E

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 FOREWORD

This repair manual has been prepared to provide information

covering general service repairs for the 1HD-FT engine
equipped in 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.

0 1HD·FT Engine Emission Control Repair ERM111E
Manual

All information in this manual is based on the latest product in-

formation at the time of publication. However, specifications
and procedures are subject to change without notice.

TOYOTA MOTOR CORPORATION

© 1995 TOYOTA MOTOR CORPORATION

All rights reserved. This book may not be
reproduced or copied, in whole or in part,
without the written permission of Toyota
Motor Corporation.

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 INTRODUCTION
ENGINE
STARTING SYSTEM ~=
CHARGING SYSTEM

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 IN-1

INTRODUCTION

HOW TO USE THIS MANUAL IN- 2

IDENTIFICATION INFORMATION IN- 4
GENERAL REPAIR INSTRUCTIONS IN- 5
ABBREVIATIONS USED IN THIS
MANUAL IN- 8
STANDARD BOLT TORQUE
SPECIFICATIONS .•..........................•....... IN- 9

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 IN-2
INTROOUCTION - HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL __ n

INDEX
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.
IN
GENERAL DESCRIPTION
At the beginning of each section. a General Description is given that pertains to all repaIr
operations contained in that section.
Read these precautions before starting any repair task.

TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to 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 of each one.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and
shows how the parts fit together.
Example:

Plug 0' R
1 • Gasket riven otor

~J r"'""
~--

Timing Gear Case

• Non-reusable part

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 IN-3
INTROOUCTION - HOW TO USE THIS MANUAL

The procedures are presented in a step-by-step format:

• The illustration shows what to do and where to do it.
• The task heading tells what to do.
• The detailed text tells how to perform the task and gives other information such as
specifications and warnings.
Example:
N

Task heading: what to do

6_
/
INSTALL CRANKSHAFT PULLEY
(a) Using SST, install the bolt.
SST 0921 ~54015 (90119-~' 26)
Set part No. Component part No.
Illustration:
what to do and where Detailed text: how to do task
(b) Install the b".
Torque: 30 N·m (310 kgf.cm. 22 ft.lbf)

"
Specification

This format provides the experienced technician with a FAST TRACK to the information needed.
The upper case task heading can be read at a glance when necessary, and the text below it
provides detailed information. Important specifications and warnings always stand out in bold
type.

REFERENCES
References have been kept to a minimum. However. when they are required you are given the
page to refer to.

SPECIFICATlONS
Specifications are presented in bold type throughout the text where needed. You never have to
leave the procedure to look up your specifications. They are also found at the end of each section.
for quick reference.

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 IN-4
INTRODUCTION - IDENTIFICATION INFORMATION

CAUTIONS, NOTICES, HINTS:

• CAUTIONS are presented in bold type. and indicate there is a possibility of injury to you or
other people.
• NOTICES are also presented in bold type, and indicate the possibility of damage to the
components being repaired.
IN • HINTS are separated from the text but do not appear in bold. They provide additional
information to help you perform the repair efficiently.

SI UNIT
The UNITS given in this manual are primarily expressed according to the 51 UNIT(lnternational
System of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N·m (310 kgf.cm. 22 ft·lbf)

IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
_.-
The engine serial number is stamped on the engine
block as shown.

..
"'

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 IN-5
INTROOUCTION - GENERAL REPAIR INSTRUCTIONS

GENERAL REPAIR INSTRUCTIONS

1. --,
Use fender. seat and floor covers to keep the vehicle
clean and prevent damage.
2. During disassembly, keep parts in the appropriate
order to facilitate reassembly.
3. Observe the following:
(a) Before performing electrical work. disconnect
the negative cable from the battery terminal.
(b) If it is necessary to disconnect the battery for
inspection or repair. always disconnect the cable
from the negative (-) terminal which is grounded
to the vehicle body.
(c) To prevent damage to the battery terminal post.
loosen the terminal nut and raise the cable strai-
ght up without twisting or prying it.
(d) Clean the battery terminal posts and cable termi-
nals with a clean shop rag. Do not scrape them
with a file or other abrasive objects.
(e) Install the cable terminal to the battery post with
the nut loose. and tighten the nut after installa·
tion. Do not use a hammer to tap the terminal
onto the post.
(f) Be sure the cover for the positive (+) terminal is
properly in place.
4. Check hose and wiring connectors to make sure that
they are secure and correct.
5. Non-reusable parts
(a) Always replace cotter pins. gaskets. 0 -rings and
oil seals etc. with new ones.
(b) Non-reusable parts are indicated in the compo-
nent illustrations by the .... symbol.
6. Pre coated parts
Pre coated parts are bolts and nuts. etc. that are
coated with a seal lock adhesive at the factory.
(a) If a pre coated part is retightened. loosened or
caused to move in any way. it must be recoated
Seal lock Adhesive with the specified adhesive.
INOO:Ml (b) 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.
(c) Precoated parts are indicated in the component

7.
illustrations by the"'*. symbol.
When necessary. use a sealer on gaskets to prevent
leaks.
8. Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.

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 IN-6
INTRODUCTION - GENERAL REPAIR INSTRUCTIONS

9. Use of special service tools (SSn and special service

materials (SSM) may be required. depending on the
nature of the repair. Be sure to use SST and SSM
where specified and follow the proper work proce-
dure. A list of SST and SSM can be found in the
preparation part at the front of each section in this
IN manual.

Fu", 10. When replacing fuses. be sure the new fuse has the
correct amperage rating. 00 NOT exceed the rating or
EQual Amperage Rali~
use one with a lower rating.
10 ) 10 )

illustration Symbol Abbreviation

IE559-t
~
.., . FUSE FUSE

~ MEDIUM CURRENT FUSE M.fUSE

~ HIGH CURRENT FUSE H·FUSE

~ FUSIBLE LINK FL
8£5517

tnSM
-R-..,.. CIRCUIT BREAKER CB

11. Care must be taken when jacking up and supporting

the vehicle. Be sure to lift and support the vehicle at
the proper locations.
(a) If the vehicle is to be jacked up only at the front
or rear end. be sure to block the wheels at the
opposite end in order to ensure safety.

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 IN.'
INTROOUCTION - GENERAL REPAIR INSTRUCTIONS

(b) After the vehicle is jacked up. be sure to support

it on stands. It is extremely dangerous to do any
work on a vehicle raised on a jack alone. even for
a small job that can be finished quickly.
12. Observe the following precautions to avoid damage to
the parts:
(a) Do not open the cover or case of the EeU unless
absolutely necessary. (If the Ie terminals are tou-
ched. the Ie may be destroyed by static electric-
ity.)
(bl To disconnect vacuum hoses. pull on the end. not
WRONG CORRECT
the middle of the hose.
Ie) To pull apart electrical connectors. pull on the
connector itself. not the wires.
(d) Be careful not to drop electrical components.
such as sensors or relays. If they are dropped on
a hard floor. they should be replaced and not
reused.
(e) When steam cleaning an engine. protect the dis·
""'" tributor. air filter. and VCV from water.
(f) Never use an impact wrench to remove or install
WRONG CORRECT temperature switches or temperature sensors.
(g) When checking continuity at the wire connector.
insert the tester probe carefully to prevent termi·
nals from bending.
(h) When using a vacuum gauge. never force the
hose onto a connector that is too large. Use a
step-down adapter instead. Once the hose has
IH025' been stretched. it may leak.

Example 13. Tag hoses before disconnecting them:

(a) When disconnecting vacuum hoses. use tags to
identify how they should be reconnected.
(b) After completing a job. double check that the
vacuum hoses are properly connected. A label
under the hood shows the proper layout.
14. Unless otherwise stated. all resistance is measured at
an ambient temperature of 20°C (68°F). Because the
resistance may be outside specifications if measured
at high temperatures immediately after the vehicle
has been running. measurements should be made
when the engine has cooled down.

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 IN-8
INTROOUCTION - A88REVIATIONS USED IN THIS MANUAL

ABBREVIATIONS USED IN THIS MANUAL _ _M

A/C Air Conditioner

ACV Air Control V,lve
ACSO Automatic Cold Stnt Device
, IN
Approx. Approximately

AfT Automatic T'.n111niaaion

BACS Boo.t and "'tiudl Coml*'Ntion Stopper
BOC Bottom Deed C.nter
ECU Engine Control Unit
EGR Exhlu.t Gil Rlcireul.tion
FIPG Formed in Pl.e. Gllket
LHO Left Hand Driv.
LST Laid Sensing Tim.r
MP Multipurpou

MfT Menu.l Tran'minion

OHC Ova, He.d Camahaft
O/S Oversized
PCS POWI' Control SY5tlm
PCV po,itiva Cr.nke••• Ventil.tion
PS POWI, St•• ring
RHO Right-Hand Drive
SICS Starting Injection Control Syttem
SSM Special Service Mllerials
SST Special Sel"t/iCi Tool.
STO Stand.rd
SW Switch
TOC Top o.,d Clntlr
TEMP. Tlmperalur.
U/S Under,ill
VSV Vacuum SwitChing V.IIII
w/ With
wi. Without

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 IN-9
INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS

STANDARD BOLT TORQUE SPECIFICATIONS

HOW TO DETERMINE BOLT STRENGTH

--.
Mark Class Mark Class

---------------
Hexagon 4- 4T ---------
Stud bolt
head bolt 5- 5T
Bolt 6- 6T
rOr'head No. 7- 7T ~ No mark
B- BT
B- 9T 4T
'0- lOT
11- ,n

0 No mark 4T

Hexagon
flange bolt
wI washer
hexagon bolt
o Nom,,' 4T
v
~ Grooved

6T
Hexagon

OJ
head bolt 2
protruding 5T
lines

Hexagon

0
flange bolt 2
protruding 6T Welded bolt
wI washer
lines
hexagon bolt

Hexagon

0
head bolt 3

~
protruding 7T
lines 4T

Hexagon

0
head bolt 4
protruding BT
lines

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 IN-IO INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS

SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Diamete' Pitch
Class mm mm
Hexagon h.ad bot! Hexagon flange bolt
N'm kif-em ft·lbf N'm kgl'em ft·lbf

6 1 5 55 48 in.·lbf 6 60 52 in.·lbf
IN 8 , .25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83 - - -
6 1 6.5 65 56 in.-lbf 7.5 75 65 in.·lbf
8 1.25 15.5 160 12 17.5 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
'4 1.5 91 930 67 100 1.050 76
16 1.5 140 1,400 101 - - -
6 1 8 80 69 in.·lbf 9 90 78 in..lbf
8 1.25 19 195 14 21 210 '5
10 , .25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1.250 90
16 1.5 170 1,750 127 - - -
6 1 10.5 110 8 12 120 9
8 , .25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 105 1.050 76
14 1.5 145 1,500 108 '65 1,700 123
16 1.5 230 2,300 166 - - -

8 1.25 29 300 22 33 330 24

8T 10 1.25 61 620 45 68 690 50
12 1.25 110 1.100 80 120 1,250 90

8 1.25 34 340 25 37 380 27

9T 10 1.25 70 710 51 78 790 57
12 , .25 125 1.300 94 '40 1.450 105

8 1.25 38 390 28 42 430 31

,OT 10 1.25 78 600 58 88 890 64
12 1.25 140 1,450 105 155 1.600 116

8 1.25 42 430 31 47 480 35

11T 10 1.25 67 890 64 97 990 72
12 1.25 155 1,600 116 175 1,800 130

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 EG·'

ENGINE

ENGINE MECHANICAL EG- 1 LUBRICATION SYSTEM EG-191

PREPARATION EG- 2 PREPARATION EG-l92
TROUBLESHOOTING EG- 6 OIL PRESSURE CHECK EG-193
AIR FILTER INSPECTION AND OIL AND FILTER REPLACEMENT EG-l93
CLEANING EG - 11 OIL PUMP EG-195
COMPRESSION CHECK EG-12 OIL COOLER EG- 203
VALVE CLEARANCE INSPECTION AND OIL NOZZLE EG- 208
ADJUSTMENT······································· EG-14 SERVICE SPECiFICATIONS·············· .. ······ .. EG- 209
INJECTION TIMING INSPECTION AND
ADJUSTMENT······································· EG- 15
tOLE SPEED AND MAXIMUM SPEED
INSPECTION AND ADJUSTMENT EG- 17
PS IDLE-UP SPEED INSPECTION AND
ADJUSTMENT (M/T)······························ EG- 19
Ale IDLE - UP SPEED INSPECTION AND
ADJUSTMENT·············· .. ·· .. ·.. ··· ··· .. ···· EG- 20
TIMING BELT EG- 21
TIMING GEAR EG- 28
CYLINDER HEAD EG- 38
CYLINDER BLOCK EG- 64
SERVICE SPECiFiCATIONS .. ··················· .. · EG- 89
TURBOCHARGER SYSTEM EG- 93
PREPARATION EG- 93
PRECAUTION EG- 94
TROUBLESHOOTING EG- 95
TURBOCHARGER EG- 97
SERVICE SPECiFiCATIONS .. ······················ EG-103
FUEL SySTEM·········································· EG-I04
PREPARATION EG-l04
FUEL FILTER EG-l07
FUEL HEATER SYSTEM EG-l08
INJECTION NOZZLE EG-ll0
INJECTION PUMP EG-122
STARTING INJECTION CONTROL
SYSTEM (SICS) EG-172
SERVICE SPECiFiCATIONS·· · · .. ·.. · EG-174
COOLING SYSTEM EG-117
PREPARATION EG-l77
COOLANT CHECK EG-178
COOLANT REPLACEMENT · · EG-178
WATER PUMP EG-laO
THERMOSTAT EG-l84
RADIATOR EG-l86
SERVICE SPECIFICATIONS EG-l9l

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 EG-2
ENGINE - ENGINE MECHANICAL

ENGINE MECHANICAL
PREPARATION

SST (SPECIAL SERVICE TOOLS)

_....
09201 '0000 V,Iv, Guidi Bu.hinQ R.mover "

~
:EG Repllcer Set

, ..... . .............. .-.......... ........... - ...........

(09201-01070) v,tv, Guid, Buahing RIlTICIYer I:

~
Rlpllcer 7

09201-41020 V,tv, Stem Oil Seal Repl.e.,.

~
09202-70020 V,Iv, Sprine Compressor

~~ . . -----.-- ................ --- .............................. ,._- ...

(09202-00010) Attlchmll'll

~
{i) -', - 09213-58012 Crlnkah,ft PuM.., Holding Tool

-
~

@
.....
(90201-08131) Wlth'r
... ..-....... ......... ... _... .--..............

." ....... ........ ......... ............. ............................. _................

(91111-50845) Bolt

0 =1 09214-60010

09214 76011
C'lnhh,ft Puu,., &. G..,
R.plle...

erlnkshaft Pull., Repllcer

Cranktt\.ft pulley

In)ection pump driv. S1..r baaring

~
Illjeetion pump drive gur oil
g.'
09222-11010 Connecting Rod Bu.hing Remoyer

e:§3EJ §El & Repl,eef

..... -- -----.- ........ - -......... ......_----_._.- . .- .....

(09222-05020) RemO~f & Repl.e.,

B ... ..... .................._.. ........... ......... ...

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 EG-3
ENGINE - ENGINE MECHANICAL
.. ........ .......... .. .................... .................. ......... .. ....... ..........
(09222-05030) Guide

§
...... ................. -----------------------. ,-.,- .. .......................
(O9222-05040) Bm

fJ
09223 00010 Cover &: Seel Repl,ee. C'anklh,ft timing gear

0 09223-46011 Cranklhaft Front Oil Seal

Oil pump drive shaft ge8'

Cernlhafl oil ..,I

~
Replacer

09223-56010 Cr.nk.hlft Re,r Oil Se.l

~
Replacer

09223-78010 Crankshaft Oil Seal Replacer C"nk$hef1 front oil sui

~ (2a
09275-54011 Plunger Stroke Menu.ing Tool

~ 09308-10010 O~ Seal Puller C,anklh,ft front oil $811

~
09330 00021 Comp.nion FI.nge Holding Tool Crenk,heft pulley

~
09950-40010 Puller B Set
~-&~f~
~: ~~~
.... ....
... , ........ ........... .............
'

(09951-04010) Hang.r 150 No.1 camshaft timing pulley

~
Oil pump drive sheft gear
Crankshaft timing gear
Injection pump drive g98r bearing
..... .............. , , ......... ................. .............. ............. ................................. ,
(09952 -0401 0) Slide Aim No.1 camshaft liming pulley

~~<liil
O~ pump driv. shalt gear
Crankshaft timing gear
de Injection pump drive gear bearing
...
(09953-04010) Center Bolt 100 Oil pump drive shaft gear

~
Crankshaft timing g98r

....... ................... .............................. ....... ............. ................. ..... ........................... ........ ................. ...................... ...
(09953-04020) Center Bolt 150 No.1 camshaft timing pulla.,.

~
Oil pump drive shalt g98r
Crankshaft timing gaar
Injection pump drive gear bear,ng
... .....
, ........ . ..... ...... .............. ...... .....
"

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 EG-4
ENGINE - ENGINE MECHANICAL

(09954-04010) Arm 25 No.1 cllmahalt timing pulley

Oil pump drive Ih.ft gear
<£Po!O' Crankshalt timing gear
Injection pump drivll gear bearing

(09955-04060) Claw No.6 No.' umshaft timing pulley

~
Oil pump drive Illaflg'a,
Cranksh.ft timing ge,r
Injection pump drive gur be,ring

'EG @-r-
~
. ...~
~ IJrn
'"".0
.--...ir;fii'
""""""..,, -::::--
09950-50010

(09951-05010)
Puller C Se1

Hanger 150 C•• nklhaft pulley

~
Injection pump drive gell'

(09952-05010) Slide Atm Cr,nksh,ft pulley

0000
Injection pump drive geer

(09953-05010) Center Boll 100 Crtnkshaft pulley

~
Injection pump drive gear

(09953-05020) Cenler 8011150 Crankstlllft pulley

~
(09954-05020) Claw No.2 Crankstlaft pulley

~.."P' Injection pump drive gear

09950-70010 Handle Set

a~
(09951-07100) Handle 100 Velve guide bustling

~
09960-10010 V'riebl, Pin Wrench Set

~
(09962-01000) Variable Pin Wrench Arm Assy lrljection pump drive ge.,

~
(09963-00700) Pin 7 Injectiorl pump drive gear

09992 00024 Cylinder Compression Check Ga ...ge

So<

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 EG-5
ENGINE - ENGINE MECHANICAL
, ............. .. ...... .. ........ ........... .....
(09992-0021l) G.UiI' Any

~
09992-00400 Atuc:hment No.7 Cylinder c:ompression c:tlec:lt

RECOMMENDED TOOLS
--..
09040-00010 Heugon Wrenc:h Set.

~~
~
09200 00010 Engine Adj... tt Kit.

=~
~"A
..
09904-00010 E..pender Set.

~~
. --
EOUIPMENT
Caliper gauge

Connecting rod aligner

Cylinder gauge

Dial indicator

Dve penelrant

Engine tune up tester

Heater

Micrometer

Piston ring compressor

Piston ring expander

Plastigage

Precision straight edge

Soft brush

Spring tester Vel", .pring

Steel square V,I", .pring

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 EG-6
ENGINE - ENGINE MECHANICAL

Thermometer

Torque wrench

Valve seat cutter

V-block

Vernier calipers

SSM (SERVICE SPECIAL MATERIALS)

08826-00080 Seal Paeking Black or equivalent Timing belt cover
(FIPG) Timing gear cove.
Camshaft oil sell reUlinar
Cylinder he.d lemi-circyla. plug
08826 00080 Seal Packing Black or equivel'nt Cylinder hflld cover
(FIPGj Main bearing cover
R... oil leal retainer

08826-00100 Seal Packing 12828. Water temperature sender gauge

THREE BONO 12828 or equivalerlt
(FIPGI

TROUBLESHOOTING
_-0'
Diesel Engine Diagnosis

GENERAL
1. Diesel engine problems are usually caused by the engine or fuel system. The injection pump is
very rarely the cause of fuel system problems.
2. Before beginning fuel system tests, first check that the engine compression. valve timing and
other major systems are within specifications.
PRELIMINARY CHECKS
1. Before performing fuel system checks, ensure that the engine is in good running condition. If
necessary, first check the compression. timing and major components or systems.
2. Check the air filter, and clean or replace it if necessary.
3. Check that there is sufficient fuel in the tank.
4. Check if the fuel is contaminated with gasoline or other foreign elements. Only good-quality
diesel fuel should be used.
5. Bleed air from the system by pumping the priming.
6. Check for water in the fuel filter and fuel tank. and drain as necessary.
7. If the engine will not crank or if it cranks slowly, first troubleshoot the electrical system.

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 Toyota 1hd Ft Engine Repair Manual
Full download: http://manualplace.com/download/toyota-1hd-ft-engine-repair-manual/ EG-7
ENGINE - ENGINE MECHANICAL

PRECAUTION,
1. The basic troubleshooting procedures for the diesel engine (velve clearance. compression.
bearings, vatves. pistons. etc.) are the same checks you would make for gasoline engine.
2. Repair of the injection pump requires considerable skill and use of 8 special test bench.

N ~ '"

\\'-__s_e_e_p_._9_. +'~"_.+~,'+,~'-t,~'-t-'~"'+~".+;"'-t,~'-t-,~,'+~".+-'+"~'-t-'-+-' +-'+-'+-,~,'+,~e'+-'+"~'-t-'-+

Suspect area

.~

~
o

Symptom \ a;; ,
;;

~
~ ;;
,
~
o
z ~
,

oc
'"
Engine does not crank 2 1 3 6 4 5
~rf__---------t___+-+-f__+-+_--t-+-t___+-+___t-+-t___+-+-t__+-t___+-+_j

,,"
00
Engine cranks normally 5 2 1 6 4

~r Engine cranks slowly 2 3

Bo
:E ;;;I--------+-il-+--+-I-+-I-t-+_j-+-+-I-+--+-t-+-I-t-+-I--I
".
'·0
Engine cranks normally 2

r
~
High engine idle speed 3
Rough idle with warm
engine
6 7 2 5

lack of power 9 6 12 5 8 1 2

Engine suddenly SlOPS 2 4 1 3

Engine does not shut
2
off with key
Excessive exhaust 4 3 2
smoke

"•
~

6
Excessi....e fuel
consumption
8 10 5 7

Engine overheat 7

Low oil pressure

High oil pressure

Engine noise when
2
warm

HINT: When inspecting a wire harness or circuit the Electrical Wiring Diagram repair manual should be
referred to and the circuits of related systems also should be checked.

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