Extra Hybrid System

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Print-Toyota Service Information 11/3/17, 6(42 pm
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1GD-FTV LUBRICATION ENGINE OIL COOLER COMPONENTS
ILLUSTRATION
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*1 OIL COOLER ASSEMBLY *2 WATER OUTLET PIPE GASKET

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*3 O-RING - -
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N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part
Engine oil - -
© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.
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1GD-FTV LUBRICATION ENGINE OIL COOLER INSPECTION
PROCEDURE
1.INSPECT OIL COOLER ASSEMBLY 15710
a. Visually check the oil cooler assembly for cracks or damage.

If cracks or damage is found, replace the oil cooler assembly.
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1GD-FTV LUBRICATION ENGINE OIL COOLER INSTALLATION
PROCEDURE
1.INSTALL OIL COOLER ASSEMBLY 15710
a. Apply a light coat of engine oil to the 2 new O-rings.
b. Install the 2 O-rings to the cylinder block sub-assembly.
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c. Install a new water outlet pipe gasket to the cylinder block sub-assembly.
d. Install the oil cooler assembly to the cylinder block sub-assembly with the bolt and 5 nuts.
Torque:
15 N*m (153 kgf*cm, 11 ft.*lbf)
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2.INSTALL TURBOCHARGER SUB-ASSEMBLY 17201
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Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/
TURBOCHARGER>INSTALLATION

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1GD-FTV LUBRICATION ENGINE OIL COOLER REMOVAL
PROCEDURE
1.REMOVE TURBOCHARGER SUB-ASSEMBLY 17201

TURBOCHARGER>REMOVAL
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2.REMOVE OIL COOLER ASSEMBLY 15710
a.
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Bolt
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Remove the 5 nuts and bolt from the oil cooler assembly.
b. Remove the oil cooler assembly and water outlet pipe gasket from the cylinder block sub-assembly.
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c.
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Remove the 2 O-rings from the cylinder block sub-assembly.

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1GD-FTV LUBRICATION LUBRICATION SYSTEM ON-VEHICLE INSPECTION
CAUTION / NOTICE / HINT
CAUTION:
·
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To prevent injury due to contact with an operating fan and generator V-belt or cooling fan, keep your
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hands and clothing away from the fan and generator V-belt and cooling fans when working in the engine
compartment with the engine running.
·
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To prevent burns, do not touch the engine, exhaust manifold or other high temperature components
while the engine is hot.
·
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To prevent burns, do not remove the engine oil pressure switch assembly while the engine is hot.
PROCEDURE
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1.INSPECT OIL QUALITY
a. Check the engine oil for deterioration, water contamination, discoloration or thinning.
If the quality is visibly poor, replace the engine oil and oil filter sub-assembly.
Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL AND OIL FILTER>REPLACEMENT
2.INSPECT ENGINE OIL LEVEL
a. Warm up the engine, and then stop the engine and wait 5 minutes.
b. Check that the engine oil level is between the engine oil level dipstick low level mark and full level mark.
If the engine oil level is low, check for leaks and add engine oil to the full level mark.
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NOTICE:
Do not fill engine oil above the full level mark.
HINT:
A certain amount of engine oil will be consumed while driving. In the following situations, oil consumption
may increase, and engine oil may need to be refilled in between oil maintenance intervals.
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· When the engine is new, for example directly after purchasing the vehicle or after replacing the
engine.
· If low quality oil or oil of an inappropriate viscosity is used.
· When driving at a high engine speed or with a heavy load, when towing, or when driving while
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accelerating or decelerating frequently.
· When idling for a long time, or when driving frequently through heavy traffic.
When judging the amount of oil consumption, keep in mind that the oil may have become diluted, making
it difficult to judge the true level accurately.
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3.INSPECT ENGINE OIL PRESSURE
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CAUTION:
· To prevent injury due to contact with an operating fan and generator V-belt or cooling fan, keep your
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· To prevent burns, do not touch the engine, exhaust manifold or other high temperature components
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· To prevent burns, do not remove the engine oil pressure switch assembly while the engine is hot.
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a. Remove the engine oil pressure switch assembly.

Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL PRESSURE SWITCH>REMOVAL
b.
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*a Oil Pressure Gauge

*b Adapter

Install an oil pressure gauge with the adapter.

NOTICE:
Before and after measurement, clean equipment and hoses.
c. Warm up the engine.
d. Measure the engine oil pressure, and check that it is within the standard range.
Standard Engine Oil Pressure:
Condition Specified Condition
29 kPa (0.3 kgf/cm2, 4.2 psi)
Idle
or higher
245 kPa (2.5 kgf/cm2, 36 psi)
3000 rpm
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or higher
If the result is not as specified, check the quality of the engine oil and check the oil paths for clogging.
Repair or replace if necessary. If the engine oil pressure is still not as specified, replace the timing chain
case assembly.
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HINT:
Replace the timing chain case assembly as the engine oil pump is built into the timing chain case
assembly.
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e. Remove the oil pressure gauge and adapter.
f. Install the engine oil pressure switch assembly.

Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL PRESSURE SWITCH>INSTALLATION
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1GD-FTV LUBRICATION OIL AND OIL FILTER COMPONENTS
ILLUSTRATION
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*A for 4WD and Pre-Runner - -

*1 NO. 1 ENGINE UNDER COVER ASSEMBLY *2 NO. 2 ENGINE UNDER COVER ASSEMBLY
*3 OIL FILTER SUB-ASSEMBLY *4 OIL PAN DRAIN PLUG
*5 GASKET *6 OIL FILLER CAP ASSEMBLY
Tightening torque for "Major areas involving

basic vehicle performance such as N*m (kgf*cm, ft.*lbf): Specified torque
moving/turning/stopping" : N*m (kgf*cm,
ft.*lbf)
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● Non-reusable part Engine oil
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1GD-FTV LUBRICATION OIL AND OIL FILTER COMPONENTS
ILLUSTRATION
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*1 NO. 1 ENGINE UNDER COVER ASSEMBLY *2 NO. 2 ENGINE UNDER COVER ASSEMBLY
*3 OIL FILTER SUB-ASSEMBLY *4 OIL PAN DRAIN PLUG
*5 GASKET *6 OIL FILLER CAP ASSEMBLY

ft.*lbf)
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1GD-FTV LUBRICATION OIL AND OIL FILTER REPLACEMENT
CAUTION:
· Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin,
leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
· Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact
with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The
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skin should be washed with soap and water, or use waterless hand cleaner, to remove any used engine
oil thoroughly. Do not use gasoline, thinners or solvents.
· In order to protect the environment, used oil and used oil filters must be disposed of at designated
disposal sites.
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To prevent burns, do not remove the oil pan drain plug and oil filter sub-assembly while the engine is
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hot.
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PROCEDURE
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1.REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY (for 4WD and Pre-Runner) 51410
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3.DRAIN ENGINE OIL
CAUTION:
To prevent burns, do not remove the oil pan drain plug while the engine is hot.
a. Remove the oil filler cap assembly.
b. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.
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c. Clean and install a new gasket and the oil pan drain plug.
Torque:
40 N*m (408 kgf*cm, 30 ft.*lbf)
4.REMOVE OIL FILTER SUB-ASSEMBLY 15601
CAUTION:
To prevent burns, do not remove the oil filter sub-assembly while the engine is hot.
a.
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Using SST, remove the oil filter sub-assembly.
SST
09228-07501
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HINT:
· Before removing the oil filter sub-assembly, place cloth where the oil may splash.
· Use a container to catch the draining engine oil.
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5.INSTALL OIL FILTER SUB-ASSEMBLY 15601

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a. Check and clean the oil filter sub-assembly installation surface.
b. Apply clean engine oil to the gasket of a new oil filter sub-assembly.
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c. Lightly screw the oil filter sub-assembly into place by hand. Tighten it until the gasket contacts the seat.
d.
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3/4 Turn

Using SST, tighten the oil filter sub-assembly.

SST
09228-07501
i. Depending on the space available, choose from the following.

If enough space is available, use a torque wrench to tighten the oil filter sub-assembly.
Torque:
12 N*m (122 kgf*cm, 9 ft.*lbf)
ii. If enough space is not available to use a torque wrench, tighten the oil filter sub-assembly 3/4 of a turn
by hand or with a common wrench.
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6.ADD ENGINE OIL
a. Add new engine oil and install the oil filler cap assembly.
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Standard Oil Grade:
Item Oil Grade Oil Viscosity (SAE)
ACEA C2
(Using engine oil other than - 0W-30
w/ DPF
ACEA C2 may damage the - 5W-30
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catalytic converter)
- 5W-30
w/o DPF API-CF-4, CF or ACEA B1 - 10W-30
- 15W-40
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Standard Capacity:
Item Specified Condition
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Drain and refill without oil filter sub-assembly
7.0 liters (7.4 US qts, 6.2 Imp. qts)
change
Drain and refill with oil filter sub-assembly
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change
Dry fill 8.0 liters (8.5 US qts, 7.0 Imp. qts)
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7.INSPECT FOR OIL LEAK
a. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.
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Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>LUBRICATION SYSTEM>ON-VEHICLE INSPECTION

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9.INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY (for 4WD and Pre-Runner) 51442
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE ASSEMBLY>INSTALLATION

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1GD-FTV LUBRICATION OIL AND OIL FILTER REPLACEMENT
CAUTION:
· Prolonged and repeated contact with engine oil will result in the removal of natural oils from the skin,
leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
· Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact
with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The
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skin should be washed with soap and water, or use waterless hand cleaner, to remove any used engine
oil thoroughly. Do not use gasoline, thinners or solvents.
· In order to protect the environment, used oil and used oil filters must be disposed of at designated
disposal sites.
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To prevent burns, do not remove the oil pan drain plug and oil filter sub-assembly while the engine is
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hot.
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PROCEDURE
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3.DRAIN ENGINE OIL
CAUTION:
To prevent burns, do not remove the oil pan drain plug while the engine is hot.
a. Remove the oil filler cap assembly.
b. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

c. Clean and install a new gasket and the oil pan drain plug.
Torque:
40 N*m (408 kgf*cm, 30 ft.*lbf)
CAUTION:
To prevent burns, do not remove the oil filter sub-assembly while the engine is hot.
a.
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Using SST, remove the oil filter sub-assembly.
SST
09228-07501
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HINT:
· Before removing the oil filter sub-assembly, place cloth where the oil may splash.
· Use a container to catch the draining engine oil.
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a. Check and clean the oil filter sub-assembly installation surface.
b. Apply clean engine oil to the gasket of a new oil filter sub-assembly.
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c. Lightly screw the oil filter sub-assembly into place by hand. Tighten it until the gasket contacts the seat.
d.
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3/4 Turn

Using SST, tighten the oil filter sub-assembly.

SST
09228-07501
i. Depending on the space available, choose from the following.

If enough space is available, use a torque wrench to tighten the oil filter sub-assembly.
Torque:
ii. If enough space is not available to use a torque wrench, tighten the oil filter sub-assembly 3/4 of a turn
by hand or with a common wrench.
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6.ADD ENGINE OIL
a. Add new engine oil and install the oil filler cap assembly.
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Standard Oil Grade:
Item Oil Grade Oil Viscosity (SAE)
ACEA C2
(Using engine oil other than - 0W-30
w/ DPF
ACEA C2 may damage the - 5W-30
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catalytic converter)
- 5W-30
w/o DPF API-CF-4, CF or ACEA B1 - 10W-30
- 15W-40
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Standard Capacity:
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Drain and refill without oil filter sub-assembly
change
Drain and refill with oil filter sub-assembly
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change
Dry fill 8.0 liters (8.5 US qts, 7.0 Imp. qts)
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a. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.
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1GD-FTV LUBRICATION OIL LEVEL SENSOR COMPONENTS
ILLUSTRATION
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*1 ENGINE OIL LEVEL SENSOR *2 NO. 1 ENGINE UNDER COVER ASSEMBLY
*3 NO. 2 ENGINE UNDER COVER ASSEMBLY - -
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N*m (kgf*cm, ft.*lbf): Specified torque - -

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1GD-FTV LUBRICATION OIL LEVEL SENSOR COMPONENTS
ILLUSTRATION
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*1 ENGINE OIL LEVEL SENSOR *2 NO. 1 ENGINE UNDER COVER ASSEMBLY
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1GD-FTV LUBRICATION OIL LEVEL SENSOR INSPECTION
PROCEDURE
1.INSPECT ENGINE OIL LEVEL SENSOR 89491
a.
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Component without harness connected
*a
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(Engine Oil Level Sensor)
*b On
*c Off
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Measure the resistance according to the value(s) in the table below.

Standard Resistance:
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Tester Switch Specified

Connection Condition Condition
On at below
Below 1 Ω
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40°C
Off at below
Below 1 Ω
40°C
1-2
On at 60°C or
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Below 1 Ω
higher
Off at 60°C or 10 kΩ or
higher higher
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CAUTION:
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· Do not put your hands in the water warmed up during the inspection.
· Touching the hot water may result in burns.
NOTICE:
When checking the engine oil level sensor in water, do not allow water to contact the terminals. After
completing the check, dry the engine oil level sensor.
HINT:
· In addition to a level switch, the oil level sensor also has a temperature switch. Therefore, make
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sure to check the oil level sensor at both high and low temperatures.
· If the result is not as specified, replace the engine oil level sensor.
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1GD-FTV LUBRICATION OIL LEVEL SENSOR INSPECTION
PROCEDURE
1.INSPECT ENGINE OIL LEVEL SENSOR 89491
a.
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*a
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(Engine Oil Level Sensor)
*b On
*c Off
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On at below
Below 1 Ω
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40°C
Off at below
Below 1 Ω
40°C
1-2
On at 60°C or
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Below 1 Ω
higher
Off at 60°C or 10 kΩ or
higher higher
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CAUTION:
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· Do not put your hands in the water warmed up during the inspection.
· Touching the hot water may result in burns.
NOTICE:
When checking the engine oil level sensor in water, do not allow water to contact the terminals. After
completing the check, dry the engine oil level sensor.
HINT:
· In addition to a level switch, the oil level sensor also has a temperature switch. Therefore, make

sure to check the oil level sensor at both high and low temperatures.
· If the result is not as specified, replace the engine oil level sensor.
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1GD-FTV LUBRICATION OIL LEVEL SENSOR INSTALLATION
PROCEDURE
1.INSTALL ENGINE OIL LEVEL SENSOR 89491
a. Install the engine oil level sensor to the oil pan sub-assembly with the 4 bolts.
Torque:
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b. Connect the engine oil level sensor connector.
2.ADD ENGINE OIL
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51410
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6.INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for 4WD and Pre-Runner)

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1GD-FTV LUBRICATION OIL LEVEL SENSOR INSTALLATION
PROCEDURE
a. Install the engine oil level sensor to the oil pan sub-assembly with the 4 bolts.
Torque:
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b. Connect the engine oil level sensor connector.
2.ADD ENGINE OIL
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6.INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for 4WD and Pre-Runner)

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1GD-FTV LUBRICATION OIL LEVEL SENSOR REMOVAL
CAUTION:
To prevent burns, do not remove the engine oil level sensor while the engine is hot.
PROCEDURE
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3.DRAIN ENGINE OIL
CAUTION:
4.REMOVE ENGINE OIL LEVEL SENSOR
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To prevent burns, do not remove the engine oil level sensor while the engine is hot.
a. Disconnect the engine oil level sensor connector.

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Remove the 4 bolts and engine oil level sensor from oil pan sub-assembly.
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1GD-FTV LUBRICATION OIL PRESSURE SWITCH COMPONENTS
ILLUSTRATION
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*1 ENGINE OIL PRESSURE SWITCH ASSEMBLY *2 NO. 1 ENGINE UNDER COVER ASSEMBLY
TOYOTA Genuine Adhesive 1344, Three Bond

N*m (kgf*cm, ft.*lbf): Specified torque
1344 or equivalent.
Precoated part - -
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1GD-FTV LUBRICATION OIL PRESSURE SWITCH INSPECTION
PROCEDURE
1.INSPECT ENGINE OIL PRESSURE SWITCH ASSEMBLY 83530
a. Disconnect the engine oil pressure switch connector.
b. Start the engine.
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c. Measure the resistance according to the value(s) in the table below.
Tester Specified
Condition
Connection Condition
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Engine stopped Below 1 Ω
1 - Body
ground 10 kΩ or
Engine idling
higher
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If the result is not as specified, replace the engine oil pressure switch assembly.
d. Connect the engine oil pressure switch connector.

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1GD-FTV LUBRICATION OIL PRESSURE SWITCH INSTALLATION
PROCEDURE
1.INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 83530
a.
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*a Adhesive
Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly.

Adhesive:
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Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
NOTICE:
Do not apply adhesive to the oil inlet port of the engine oil pressure switch assembly.
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b. Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly to the oil filter bracket.
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Torque:
15 N*m (153 kgf*cm, 11 ft.*lbf)
NOTICE:
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Do not start the engine for at least 1 hour after the installation.
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c. Connect the engine oil pressure switch connector.

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2.ADD ENGINE OIL

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1GD-FTV LUBRICATION OIL PRESSURE SWITCH REMOVAL
CAUTION:
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PROCEDURE
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3.DRAIN ENGINE OIL

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4.REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 83530
CAUTION:
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a. Disconnect the engine oil pressure switch connector.

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b.
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Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly from the oil filter
bracket.
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1GD-FTV LUBRICATION OIL PUMP COMPONENTS
ILLUSTRATION
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*A w/ DPF - -
*1 DIFFERENTIAL PRESSURE SENSOR *2 NO. 1 EXHAUST GAS TEMPERATURE SENSOR
*3 NO. 2 EXHAUST GAS TEMPERATURE SENSOR *4 NO. 3 EXHAUST GAS TEMPERATURE SENSOR
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*5 NO. 1 VACUUM PIPE *6 NO. 2 VACUUM PIPE

*7 PIPE CLAMP *8 CLAMP
N*m (kgf*cm, ft.*lbf): Specified torque * For use with union nut wrench
ILLUSTRATION
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*A for Cold Area Specification Vehicles - -

*1 DIESEL THROTTLE BODY ASSEMBLY *2 DIESEL TURBO PRESSURE SENSOR
*3 ENGINE COVER BRACKET *4 GAS FILTER
*5 HOSE BRACKET *6 INTERCOOLER AIR TUBE
*7 NO. 2 ENGINE COVER BRACKET *8 NO. 2 HOSE TO HOSE TUBE
*9 NO. 2 WATER BY-PASS PIPE *10 NO. 11 WATER BY-PASS HOSE
*11 NO. 14 WATER BY-PASS HOSE *12 GASKET

ILLUSTRATION
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*1 CONNECTING WIRE *2 EGR VALVE BRACKET
NO. 1 EGR COOLER AND NO. 2 EGR VALVE
*3 ENGINE OIL LEVEL DIPSTICK GUIDE *4 ASSEMBLY WITH ELECTRIC EGR CONTROL
VALVE ASSEMBLY

*5 NO. 1 EGR PIPE SUB-ASSEMBLY *6 NO. 2 EGR PIPE

*7 NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY *8 NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY
*9 VACUUM CONTROL VALVE SET *10 ENGINE OIL LEVEL DIPSTICK
*11 GASKET *12 O-RING
*13 STUD BOLT - -
Engine oil - -
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ILLUSTRATION
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*A w/ DPF - -
*1 FUEL INJECTION PUMP COVER SUB-ASSEMBLY *2 FUEL PUMP MOTOR WIRE
*3 MANIFOLD STAY *4 NO. 1 FUEL HOSE
*5 NO. 2 FUEL HOSE *6 NO. 2 FUEL PIPE
*7 NO. 3 FUEL PIPE *8 NO. 4 FUEL PIPE SUB-ASSEMBLY
*9 WIRING HARNESS CLAMP BRACKET *10 FUEL PIPE CLAMP
*11 SUPPLY PUMP HOLLOW SCREW *12 UNION BOLT
*13 GASKET - -

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*A w/ DPF - -

*1 FUEL INLET PIPE SUB-ASSEMBLY *2 INTAKE MANIFOLD

*3 NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY *4 WIRING HARNESS CLAMP BRACKET
*5 INJECTION PIPE CLAMP *6 NO. 2 INJECTION PIPE CLAMP
*7 GASKET - -

basic vehicle performance such as
ft.*lbf)
* For use with SST or union nut wrench ● Non-reusable part
ILLUSTRATION
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*A w/ DPF *B w/ Air Conditioning System

*C w/o Air Conditioning System - -
*1 NO. 1 COMPRESSOR MOUNTING BRACKET *2 NO. 1 FUEL PIPE
*3 IDLER PULLEY SUB-ASSEMBLY *4 NO. 1 INJECTION PIPE SUB-ASSEMBLY
*5 NO. 2 INJECTION PIPE SUB-ASSEMBLY *6 NOZZLE LEAKAGE PIPE ASSEMBLY
*7 WIRING HARNESS CLAMP BRACKET *8 UNION BOLT
*9 GASKET - -


ft.*lbf)
* For use with SST ● Non-reusable part
ILLUSTRATION
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*A w/ DPF - -
EXHAUST MANIFOLD CONVERTER SUB-
*1 AIR FUEL RATIO SENSOR *2
ASSEMBLY
https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000M7SX.html?PUB_TYPE=RM&MODE=1 Page 10 of 24

*3 EXHAUST PIPE SUPPORT STAY *4 NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

*5 NO. 1 INJECTOR HOLDER *6 NO. 1 TURBO INSULATOR
*7 NO. 1 WATER HOSE CLAMP BRACKET *8 NO. 2 EXHAUST PIPE SUPPORT STAY
*9 NO. 4 WATER BY-PASS HOSE *10 NO. 5 WATER BY-PASS HOSE
*11 EXHAUST PIPE CLAMP *12 GASKET
N*m (kgf*cm, ft.*lbf): Specified torque * For use with SST
● Non-reusable part - -
ILLUSTRATION
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*A w/o DPF - -
*1 *2 EXHAUST PIPE SUPPORT STAY
ASSEMBLY
*3 NO. 1 EXHAUST MANIFOLD HEAT INSULATOR *4 NO. 1 TURBO INSULATOR
*5 NO. 2 EXHAUST PIPE SUPPORT STAY *6 EXHAUST PIPE CLAMP
*7 GASKET - -

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*A except Cold Area Specification Vehicles *B for Cold Area Specification Vehicles
*C w/ Viscous Heater - -
*1 NO. 1 VISCOUS HEATER BRACKET SUB- *2 NO. 3 WATER BY-PASS PIPE

ASSEMBLY
*3 PCV HOSE *4 PCV PIPE

ILLUSTRATION
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*1 NO. 1 TURBO WATER HOSE *2 NO. 2 TURBO WATER HOSE

*3 TURBO OIL INLET PIPE SUB-ASSEMBLY *4 TURBO OIL OUTLET PIPE

*5 TURBOCHARGER STAY *6 TURBOCHARGER SUB-ASSEMBLY
*7 UNION BOLT *8 GASKET

ft.*lbf)
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*A w/ DPF *B for Cold Area Specification Vehicles

*1 NO. 1 WATER BY-PASS PIPE *2 NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY
*3 THERMOSTAT *4 WATER INLET

*5 WATER OUTLET SUB-ASSEMBLY *6 GASKET
ILLUSTRATION
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*A w/o Viscous Heater *B w/ Viscous Heater

*1 CRANKSHAFT PULLEY *2 CRANKSHAFT PULLY COVER
*3 NO. 1 IDLER PULLEY SUB-ASSEMBLY *4 VISCOUS HEATER CRANKSHAFT PULLEY
*5 V-RIBBED BELT TENSIONER ASSEMBLY *6 CRANKSHAFT PULLEY SET BOLT

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*A w/ DPF *B w/o DPF

*1 GENERATOR BRACKET SUB-ASSEMBLY *2 INJECTION PUMP INSULATOR

*3 NO. 1 ENGINE HANGER *4 SUPPLY PUMP ASSEMBLY
*5 TIMING CHAIN COVER PLATE *6 SUPPLY PUMP SHAFT NUT
*7 NO. 1 FUEL PUMP BRACKET *8 GASKET
*9 O-RING - -

ft.*lbf)
ILLUSTRATION
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*1 CAMSHAFT POSITION SENSOR *2 CYLINDER HEAD COVER SUB-ASSEMBLY

*3 INJECTOR ASSEMBLY *4 NOZZLE HOLDER GASKET

*5 CYLINDER HEAD COVER GASKET *6 NO. 2 CYLINDER HEAD COVER GASKET
*7 CAMSHAFT BEARING CAP OIL HOLE GASKET *8 NOZZLE HOLDER CLAMP
*9 INJECTION NOZZLE SEAT *10 NOZZLE HOLDER CLAMP SEAT
*11 WASHER *12 O-RING

ft.*lbf)
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ILLUSTRATION
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*1 ENGINE OIL LEVEL SENSOR *2 OIL PAN COVER SILENCER

*3 OIL PAN SUB-ASSEMBLY *4 OIL PAN DRAIN PLUG
*5 GASKET - -

ILLUSTRATION
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*1 CAMSHAFT TIMING SPROCKET (for Exhaust *2 CAMSHAFT TIMING SPROCKET (for Intake
Side) Side)
*3 FRONT CRANKSHAFT OIL SEAL *4 NO. 2 CHAIN SUB-ASSEMBLY
*5 NO. 2 CHAIN TENSIONER ASSEMBLY *6 NO. 2 CHAIN TENSIONER SLIPPER
*7 NO. 2 CHAIN VIBRATION DAMPER *8 TIMING CHAIN COVER SUB-ASSEMBLY
*9 TIMING CHAIN GUIDE *10 TIMING CHAIN CASE GASKET
*11 CAMSHAFT TIMING SPROCKET BOLT - -

MP grease Engine oil
ILLUSTRATION
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*1 CRANKSHAFT TIMING SPROCKET *2 INJECTION PUMP DRIVE GEAR

*3 NO. 1 CHAIN SUB-ASSEMBLY *4 ENGINE WATER PUMP ASSEMBLY
*7 NO. 1 CHAIN VIBRATION DAMPER *8 OIL PUMP DRIVE GEAR
*9 TIMING CHAIN CASE ASSEMBLY *10 NO. 1 CHAIN TENSIONER ASSEMBLY BODY
*11 SPRING *12 PLUNGER

Engine oil - -
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Print Exit
1GD-FTV LUBRICATION OIL PUMP INSTALLATION
NOTICE:
· When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2
injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.
Replaced Parts (A) Pipes Requiring New Replacement
· Injector assembly (including shuffling the
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injector assemblies between the
· No. 1 injection pipe sub-assembly
cylinders)
· Common rail assembly
· Cylinder head sub-assembly
· Supply pump assembly
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· Cylinder block sub-assembly
· Cylinder head sub-assembly Fuel inlet pipe sub-assembly
· Cylinder head gasket
· Timing chain case assembly
·
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After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet
pipe sub-assembly, clean them with a brush and compressed air.
The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or
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dropped.
· Make sure foreign matter does not enter the fuel path.
· The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck
or dropped.
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· Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control
valve or fuel pipe, etc.
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PROCEDURE
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1.INSTALL TIMING CHAIN CASE ASSEMBLY AND ENGINE WATER PUMP ASSEMBLY 11310
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a. Apply a light coat of engine oil to the 4 new O-rings.
b. Install the 4 O-rings to the cylinder block sub-assembly and cylinder head sub-assembly.
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c. Clean and degrease the contact surfaces of the timing chain case assembly, cylinder head sub-assembly
and cylinder block sub-assembly.
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d. Apply a coating of seal packing to the timing chain case assembly at the points shown in the illustration.
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https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000M7TG.html?PUB_TYPE=RM&MODE=1 Page 1 of 17

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*a 46 mm (1.81 in.) *b 50 mm (1.97 in.)

*c 2.0 to 3.0 mm (0.0787 to 0.118 in.) *d 2.5 to 3.5 mm (0.0984 to 0.138 in.)
*e 3.0 to 4.0 mm (0.118 to 0.158 in.) *f 1.5 to 2.5 mm (0.0591 to 0.0984 in.)
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*g 13 to 15 mm (0.512 to 0.591 in.) *h 9.0 to 11 mm (0.354 to 0.433 in.)

*i 31 to 33 mm (1.22 to 1.30 in.) - -
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Seal packing:
for line area D:
Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent.
for line area A-A, B-B, C-C and E:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.
Seal Packing Application Specification:

Seal Packing Seal Packing
Line Type and Area Application Area
Diameter Application Length

Dashed Line 1.5 to 2.5 mm (0.0591 2.0 to 3.0 mm (0.0787 -

to 0.0984 in.) to 0.118 in.)
2.5 to 3.5 mm (0.0984 2.0 to 3.0 mm (0.0787
A-A 46 mm (1.81 in.)
to 0.138 in.) to 0.118 in.)
2.5 to 3.5 mm (0.0984 2.0 to 3.0 mm (0.0787
B-B 50 mm (1.97 in.)
to 0.138 in.) to 0.118 in.)
1.5 to 2.5 mm (0.0591 3.0 to 4.0 mm (0.118 to
D -
to 0.0984 in.) 0.158 in.)
NOTICE:
· Using non-residue solvent, clean and remove any oil from the installation surface.
· Install the part within 3 minutes and tighten the bolts within 10 minutes after applying seal
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packing.
· Do not add engine oil for at least 2 hours after installation.
· Do not start the engine within 2 hours after installation.
e. Temporarily install the timing chain case assembly with the 15 bolts.
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*a Type of bolt *b Tightening

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Bolt Length:
Thread
Item Length
Diameter
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30 mm (1.18 8.0 mm (0.315

Bolt A
in.) in.)
45 mm (1.77 8.0 mm (0.315
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Bolt B
in.) in.)
65 mm (2.56 8.0 mm (0.315
Bolt C
in.) in.)
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30 mm (1.18 10 mm (0.394
Bolt D
in.) in.)
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f. Temporarily install a new gasket and the engine water pump assembly with the 8 bolts.
g. Tighten the 23 bolts in the order shown in the illustration.

Torque:
for bolt A, B and C : 25 N*m (255 kgf*cm, 18 ft.*lbf)
for bolt D : 43 N*m (438 kgf*cm, 32 ft.*lbf)
NOTICE:

Check the torque of bolt 1 after tightening bolt 23.
2.INSTALL INJECTION PUMP INSULATOR 22815A
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE UNIT>REASSEMBLY
3.INSTALL SUPPLY PUMP ASSEMBLY 22100
4.INSTALL NO. 1 CHAIN TENSIONER SLIPPER 13559
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5.TEMPORARILY INSTALL NO. 1 CHAIN VIBRATION DAMPER 13561
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6.INSTALL CRANKSHAFT TIMING SPROCKET, INJECTION PUMP DRIVE GEAR WITH 13506
NO. 1 CHAIN SUB-ASSEMBLY
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7.TIGHTEN NO. 1 CHAIN VIBRATION DAMPER 13561

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8.INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 13540
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9.INSTALL SUPPLY PUMP SHAFT NUT

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10.INSTALL CAMSHAFT TIMING SPROCKET 13523

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11.INSTALL NO. 2 CHAIN VIBRATION DAMPER 13562

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12.INSTALL NO. 2 CHAIN SUB-ASSEMBLY 13507

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15.INSTALL TIMING CHAIN GUIDE 13566B
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>CAMSHAFT>INSTALLATION

16.CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
17.INSTALL OIL PUMP DRIVE GEAR 13519
a. Install the oil pump drive gear to the crankshaft.
18.INSTALL TIMING CHAIN COVER PLATE 11324
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL SUPPLY PUMP>INSTALLATION
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19.INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 11302
a. Apply a light coat of engine oil to a new timing chain case gasket.
b. Install the timing chain case gasket to the timing chain case assembly.
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c. Clean and degrease the contact surfaces of the timing chain cover sub-assembly and timing chain case
assembly.
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d. Apply a coating of seal packing to the timing chain cover sub-assembly at the points shown in the
illustration. ar
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*a 2.0 to 3.0 mm (0.0787 to 0.118 in.) *b 2.5 to 3.5 mm (0.0984 to 0.138 in.)
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Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.
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Standard seal packing diameter:

2.5 to 3.5 mm (0.0984 to 0.138 in.)
NOTICE:
· Using non-residue solvent, clean and remove any oil from the installation surface.
· Install the part within 3 minutes and tighten the bolts within 10 minutes after applying seal
packing.

e. Temporarily install the timing chain cover sub-assembly with the 20 bolts.
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*a Type of bolt *b Tightening
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Bolt Length:
Thread
Item Length
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Diameter
40 mm (1.57 8.0 mm (0.315
Bolt A
in.) in.)
25 mm (0.984 8.0 mm (0.315
Bolt B
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in.) in.)
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f. Tighten the 20 bolts in the order shown in the illustration.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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NOTICE:
Check the torque of bolt 1 after tightening bolt 20.
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20.INSTALL FRONT CRANKSHAFT OIL SEAL 11303A

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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>FRONT CRANKSHAFT OIL

SEAL>INSTALLATION
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21.INSTALL OIL PAN SUB-ASSEMBLY 12101

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a. Clean and degrease the contact surfaces of the oil pan sub-assembly and cylinder block sub-assembly.
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b.
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Seal Packing
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Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
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Standard seal diameter:
3.5 to 4.5 mm (0.138 to 0.177 in.)
NOTICE:
· Remove any oil from the contact surface.
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· Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes
after applying seal packing.
· Do not add engine oil within 2 hours after installation.
· Do not start the engine for at least 2 hours after installation.
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Bolt
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Nut
Install the oil pan sub-assembly to the cylinder block sub-assembly with the 23 bolts and 2 nuts.
Torque:

NOTICE:
Check the torque of all nuts and bolts labeled A again.
Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL LEVEL SENSOR>INSTALLATION
23.INSTALL OIL PAN COVER SILENCER 12144
a. Install the oil pan cover silencer to the oil pan sub-assembly with the 5 bolts.
Torque:
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24.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 11201
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a. Apply a light coat of engine oil to the O-ring of the camshaft position sensor.
b. Install a new cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil
hole gaskets to the cylinder head cover sub-assembly.
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c. Clean and degrease the contact surfaces of the cylinder head cover sub-assembly and cylinder head sub-
assembly.
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d. Apply seal packing as shown in the illustration.
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*1 Timing Chain Cover Sub-assembly *2 Timing Chain Case Assembly

*3 Cylinder Head Sub-assembly *4 No. 3 Camshaft Bearing Cap
Seal Diameter: 3.0 to 6.0 mm (0.118 to 0.236
*a *b Application Width: 7.0 mm (0.276 in.)
in.)
*c Application Width: 9.0 mm (0.354 in.) *d Application Width: 11.0 mm (0.433 in.)
Seal packing:

3.0 to 6.0 mm (0.118 to 0.236 in.)
NOTICE:
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· Remove any oil from the contact surface.
· Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 10
minutes after applying seal packing.
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Bolt
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Nut
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Nozzle Holder Clamp Seat

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Tighten the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and camshaft position sensor in the order shown
in the illustration.
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Torque:
NOTICE:
· When reusing the camshaft position sensor, check the O-rings.
· Make sure that the O-ring is not cracked or jammed when installing it on the cylinder head cover
sub-assembly.
· Replace with a new part if it is dropped or if it receives a strong impact.
· Check the torque of bolts 1 to 4 again.
https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000M7TG.html?PUB_TYPE=RM&MODE=1 Page 10 of 17

25.INSTALL NOZZLE HOLDER GASKET 23682
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>INSTALLATION
26.TEMPORARILY INSTALL INJECTOR ASSEMBLY 23670
27.INSTALL GENERATOR BRACKET SUB-ASSEMBLY 12501
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28.INSTALL NO. 1 ENGINE HANGER 12281A
29.INSTALL NO. 1 WATER HOSE CLAMP BRACKET (w/ DPF) 16575C
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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE UNIT>INSTALLATION
30.INSTALL CRANKSHAFT PULLEY 13471
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SEAL>INSTALLATION
31.INSTALL CRANKSHAFT PULLEY COVER 13496

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SEAL>INSTALLATION
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32.INSTALL VISCOUS HEATER CRANKSHAFT PULLEY (w/ Viscous Heater) 88451B

SEAL>INSTALLATION
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33.INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 16620

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a. Install the V-ribbed belt tensioner assembly to the timing chain cover sub-assembly with 3 bolts.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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34.INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY 16603
a. Install the No. 1 idler pulley sub-assembly to the generator bracket sub-assembly with the bolt.
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Torque:
43 N*m (438 kgf*cm, 32 ft.*lbf)
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35.INSTALL THERMOSTAT 16331A
Click hereEngine / Hybrid System>1GD-FTV COOLING>THERMOSTAT>INSTALLATION
36.INSTALL WATER INLET 16321

37.INSTALL WATER OUTLET SUB-ASSEMBLY 16304
38.INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 16207
39.TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY 15407

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40.TEMPORARILY INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB- 17141
ASSEMBLY

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41.INSTALL TURBO OIL OUTLET PIPE 15474

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42.TEMPORARILY INSTALL TURBOCHARGER STAY 17293

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43.TIGHTEN EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY 17141
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44.TIGHTEN TURBOCHARGER STAY 17293

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45.INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous 87101

Heater)
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46.CONNECT NO. 1 AND NO. 2 TURBO WATER HOSE 16284

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47.INSTALL NO. 1 WATER BY-PASS PIPE 16268

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49.INSTALL PCV HOSE (except Cold Area Specification Vehicles) 12261

50.INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 25051
· w/ DPF:
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHIC CONVERTER(w/
DPF)>INSTALLATION
· w/o DPF:
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHIC CONVERTER(w/o
DPF)>INSTALLATION
51.INSTALL NO. 2 EXHAUST PIPE SUPPORT STAY
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· w/ DPF:
DPF)>INSTALLATION
· w/o DPF:
DPF)>INSTALLATION
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52.INSTALL NO. 1 TURBO INSULATOR 17271
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· w/ DPF:
DPF)>INSTALLATION
· w/o DPF:
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DPF)>INSTALLATION
53.INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 17167

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· w/ DPF:
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DPF)>INSTALLATION
· w/o DPF:
DPF)>INSTALLATION
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54.INSTALL AIR FUEL RATIO SENSOR (w/ DPF) 89467B

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Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>AIR FUEL RATIO SENSOR>INSTALLATION

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55.INSTALL NO. 1 INJECTOR HOLDER (w/ DPF) 23295D
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EXHAUST FUEL ADDITION

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INJECTOR>INSTALLATION
56.CONNECT NO. 4 WATER BY-PASS HOSE (w/ DPF) 16281

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57.INSTALL NO. 5 WATER BY-PASS HOSE (w/ DPF) 16282

58.INSTALL PCV PIPE (for Cold Area Specification Vehicles) 12229


59.INSTALL IDLER PULLEY ASSEMBLY (w/o Air Conditioning System) 16630D
60.INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning 88431

System)
61.INSTALL HOSE BRACKET 44781
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62.TEMPORARILY INSTALL NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY 23701
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63.TIGHTEN INJECTOR ASSEMBLY 23670
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64.TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY 23701

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65.INSTALL WIRING HARNESS CLAMP BRACKET

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66.INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY 23760

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67.INSTALL NO. 1 FUEL PIPE (w/ DPF) 23811H

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69.INSTALL INTAKE MANIFOLD 17111

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Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>INTAKE MANIFOLD>INSTALLATION
70.INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY 23770

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71.INSTALL FUEL INLET PIPE SUB-ASSEMBLY 23804C
72.INSTALL NO. 3 FUEL PIPE (w/ DPF) 23815D

73.INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ DPF) 23804D
74.INSTALL NO. 1 FUEL HOSE 23271H
76.INSTALL FUEL PUMP MOTOR WIRE 23243B
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77.INSTALL FUEL INJECTION PUMP COVER SUB-ASSEMBLY 22803
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78.INSTALL MANIFOLD STAY 17118
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80.INSTALL NO. 2 FUEL PIPE 23812D
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81.INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 11409

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82.INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC 25800
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EGR CONTROL VALVE ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EGR COOLER>INSTALLATION

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84.INSTALL VACUUM CONTROL VALVE SET 25804

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Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EGR VALVE>INSTALLATION

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85.INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 25601
86.INSTALL CONNECTING WIRE 27148A
87.INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY 16206B

88.INSTALL NO. 2 EGR PIPE 25612
89.INSTALL EGR VALVE BRACKET 25625
90.INSTALL DIESEL TURBO PRESSURE SENSOR 89421C
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>MANIFOLD ABSOLUTE PRESSURE

SENSOR>INSTALLATION
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91.INSTALL GAS FILTER 23265C
92.INSTALL ENGINE COVER BRACKET 12631A
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93.INSTALL PIPE CLAMP (w/ DPF) 17578B
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DPF)>INSTALLATION
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94.TEMPORARILY INSTALL NO. 2 VACUUM PIPE (w/ DPF) 25734

DPF)>INSTALLATION
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95.TEMPORARILY INSTALL NO. 1 VACUUM PIPE (w/ DPF) 25733A

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DPF)>INSTALLATION
96.TIGHTEN NO. 2 VACUUM PIPE (w/ DPF) 25734

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DPF)>INSTALLATION
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97.TIGHTEN NO. 1 VACUUM PIPE (w/ DPF) 25733A

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DPF)>INSTALLATION
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98.INSTALL EXHAUST GAS TEMPERATURE SENSOR (w/ DPF) 89425
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EXHAUST GAS TEMPERATURE

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SENSOR>INSTALLATION
99.INSTALL DIFFERENTIAL PRESSURE SENSOR (w/ DPF) 89481B
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>DIFFERENTIAL PRESSURE

SENSOR>INSTALLATION

101.INSTALL DIESEL THROTTLE BODY ASSEMBLY 26100G
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>DIESEL THROTTLE BODY>INSTALLATION
102.INSTALL INTERCOOLER AIR TUBE 17363K
103.INSTALL ENGINE WIRE 82121
104.INSTALL NO. 2 ENGINE COVER BRACKET 12632
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105.INSTALL NO. 2 HOSE TO HOSE TUBE 44763C
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106.INSTALL ENGINE ASSEMBLY
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1GD-FTV LUBRICATION OIL PUMP REMOVAL
The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after
parts are removed, installed, or replaced during the timing chain case assembly removal/installation are shown
below.
Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Effects/Inoperative
Necessary Procedures Link
Procedure when not Performed
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· Injector
compensation · ( )
code registration Engine starting · w/ DPF:
· Pilot quantity ( )
learning
Replacement of engine
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assembly
· ( )
Clear Crank Time · w/ DPF:
Engine starting
Compensation Data
( )
Replacement of injector
· Injector
compensation
code registration
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Engine starting
·
·
( )
w/ DPF:
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assembly · Pilot quantity ( )
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· Replacement of
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diesel throttle
body assembly
· Replacement of
electric EGR
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control valve
assembly · ( )
· Replacement of
· w/ DPF:
turbocharger sub- Perform initialization -
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assembly ( )
· Replacement of
turbocharger sub-
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assembly or
turbocharger
variable nozzle
motor
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NOTICE:
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cylinders)

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1GD-FTV COOLING COOLING SYSTEM ON-VEHICLE INSPECTION
CAUTION:
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Do not remove the radiator reservoir cap sub-assembly while the engine and radiator assembly are still hot.
Pressurized, hot engine coolant and steam may be released and cause serious burns.
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PROCEDURE
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1.INSPECT FOR COOLANT LEAK

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CAUTION:
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NOTICE:
Before each inspection, turn the A/C switch off.
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a. Remove the radiator reservoir cap sub-assembly.
b. Fill the radiator assembly with engine coolant and attach a radiator cap tester.
d. Using the radiator cap tester, increase the pressure inside the radiator assembly to 118 kPa (1.2 kgf/cm2,
17 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks.
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If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block
assembly and cylinder head sub-assembly.
e. Remove the radiator cap tester and install the radiator reservoir cap sub-assembly.
2.INSPECT ENGINE COOLANT LEVEL ON RESERVOIR
a. Check that the engine coolant level is between the L and F lines when the engine is cold.
If the engine coolant level is low, check for leaks and add TOYOTA Super Long Life Coolant or similar high
quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant with long-life
hybrid organic acid technology up to the F line.
NOTICE:
Do not substitute plain water for engine coolant.
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3.INSPECT ENGINE COOLANT QUALITY
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CAUTION:
a. Remove the radiator reservoir cap sub-assembly.
b.
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Check for any excessive deposits of rust or scale around the radiator reservoir cap sub-assembly and check
that the engine coolant is free of oil.
If the engine coolant is excessively dirty, replace the engine coolant.
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c. Install the radiator reservoir cap sub-assembly.
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1GD-FTV COOLING COOLING SYSTEM PRECAUTION
IGNITION SWITCH EXPRESSIONS
a. The type of ignition switch used on this model differs depending on the specifications of the vehicle. The
expressions listed in the table below are used in this section.
Ignition Switch Engine Switch
Expression
(Position) (Condition)
Ignition Switch off LOCK Off (Lock)
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Ignition Switch ACC ACC On (ACC)
Ignition Switch ON ON On (IG)
Engine Start START On (Start)
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1GD-FTV COOLING COOLANT REPLACEMENT
CAUTION:
·
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Do not remove the radiator reservoir cap sub-assembly, vent plug, radiator drain cock plug while the
engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released
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and cause serious burns.

·
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To prevent injury due to contact with an operating fan and generator V-belt or cooling fan, keep your
PROCEDURE
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1.REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 12601B
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>DIESEL THROTTLE BODY>REMOVAL
2.DRAIN ENGINE COOLANT
CAUTION:
Do not remove the radiator reservoir cap sub-assembly, vent plug, radiator drain cock plug while the engine and
radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious
burns.
a.
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*a HOSE
Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock as shown in the
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illustration.
b. Loosen the radiator drain cock plug.

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*1 Radiator Reservoir *2 Radiator Reservoir Cap Sub-Assembly

*3 Vent Plug *4 Cylinder Block Drain Cock Plug

*5 Radiator Drain Cock Plug - -
HINT:
Collect the engine coolant in a container and dispose of it according to the regulations in your area.
c.
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Using a wrench, remove the vent plug and radiator reservoir cap sub-assembly, and then drain the engine
coolant.
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d. Loosen the cylinder block drain cock plug.
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Slide the hose clamp and remove the vent plug, and then drain the engine coolant from the water by-pass
pipe assembly.
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f. Tighten the cylinder block drain cock plug.

Torque:
12.7 N*m (130 kgf*cm, 9 ft.*lbf)
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g. Tighten the radiator drain cock plug by hand and remove the hose from the radiator drain cock.
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3.ADD ENGINE COOLANT

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CAUTION:
· Do not remove the radiator reservoir cap sub-assembly, vent plug, radiator drain cock plug while the
engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released
and cause serious burns.
· To prevent injury due to contact with an operating fan and generator V belt or cooling fan, keep your
hands and clothing away from the fan and generator V belt and the fan when working in the engine
compartment with the engine running or the ignition switch to ON.

a.
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Add engine coolant to the radiator reservoir filler opening until it is filled to the B line at the base of the
radiator reservoir filler neck.
Standard Capacity:
8.6 liters (9.1 US qts, 7.6
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w/o DPF
for Manual Imp. qts)
Transmission 8.7 liters (9.2 US qts, 7.7
w/ DPF
Imp. qts)
w/o Viscous Heater
9.1 liters (9.6 US qts, 8.0
w/o DPF
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for Automatic Imp. qts)
Transmission 9.2 liters (9.7 US qts, 8.1
w/ DPF
Imp. qts)
for Automatic 9.6 liters (10.1 US qts,
w/ Viscous Heater w/ DPF
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Transmission 8.4 Imp. qts)
NOTICE:
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Do not substitute plain water for engine coolant.
HINT:
· TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the
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engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality
ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life
hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a
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combination of low phosphates and organic acids).

· The B line is the lower edge of the inner wall of the filler neck.
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b. Press the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of
the engine coolant.
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If the coolant level drops below the B line, add engine coolant to the B line.
c. Install the radiator reservoir cap sub-assembly.

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d.
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*1 Vent Plug
*2 Hose Clamp
*a 1.0 to 3.0 mm (0.0394 to 0.118 in.)
Install the vent plug to the water by-pass pipe assembly and slide the hose clamp to secure the plug.
NOTICE:
Make sure the hose clamp is securely installed at the location shown in the illustration. Otherwise, coolant
may leak.
e. Using a wrench, install the vent plug.

Torque:
2.0 N*m (20 kgf*cm, 17 in.*lbf)
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f. Bleed air from the cooling system.
i. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the engine
coolant for several minutes.
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ii. Maintain the engine speed at 2500 to 3000 rpm.
iii. Press the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.
CAUTION:
· Wear protective gloves.
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· Be careful as the radiator hoses are hot.
· Keep your hands away from the radiator fan.
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iv. Stop the engine and wait until the engine coolant cools down to ambient temperature.
g. After the engine coolant cools down, check that the coolant level is at the F line.
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If the coolant level is below the F line, add engine coolant to the F line.
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Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION

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5.INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 12601B

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1GD-FTV COOLING RADIATOR COMPONENTS
ILLUSTRATION
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*1 NO. 1 ENGINE COVER SUB-ASSEMBLY *2 NO. 1 ENGINE UNDER COVER ASSEMBLY

*3 NO. 1 OIL RESERVOIR BRACKET *4 NO. 1 RADIATOR AIR GUIDE
*5 NO. 2 AIR TUBE *6 NO. 4 AIR HOSE
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*7 RADIATOR RESERVOIR *8 VANE PUMP OIL RESERVOIR ASSEMBLY

*9 RADIATOR RESERVOIR CAP SUB-ASSEMBLY *10 OIL RETURN HOSE
ILLUSTRATION
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*A w/ Viscous Heater *B for Automatic Transmission

*C w/o Air Conditioning System - -
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*1 FAN SHROUD *2 NO. 1 OIL COOLER INLET HOSE

*3 NO. 1 OIL COOLER OUTLET HOSE *4 NO. 1 RADIATOR HOSE
*5 NO. 2 RADIATOR HOSE *6 RADIATOR ASSEMBLY
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*7 RADIATOR DRAIN COCK PLUG *8 RADIATOR PROTECTOR

*9 VISCOUS HEATER V BELT *10 FAN AND GENERATOR V BELT
*11 FAN WITH FLUID COUPLING ASSEMBLY *12 FAN PULLEY
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*13 O-RING - -
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1GD-FTV COOLING RADIATOR INSTALLATION
PROCEDURE
1.INSTALL RADIATOR DRAIN COCK PLUG 16400B
a. Install a new O-ring to the radiator drain cock plug.
b. Install the radiator drain cock plug to the radiator assembly.
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2.INSTALL RADIATOR PROTECTOR (w/o Air Conditioning System) 16546
a. Attach the 2 guides and 2 claws to install the radiator protector to the radiator assembly.
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3.INSTALL RADIATOR ASSEMBLY 16400
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a. Temporarily install the radiator assembly to the vehicle.
b. w/ Air Conditioning System:

Attach the 2 guides and 2 claws to connect the cooler condenser assembly to the radiator assembly.
NOTICE:
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· Do not apply any excessive force to the cooler condenser assembly and cooler pipe.
· Do not allow the radiator assembly to interfere with other parts.
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*a Claw
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Hook the claw of the radiator assembly as shown in the illustration.

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d.
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Install the radiator assembly with the 4 bolts in the order shown in the illustration.
Torque:
22 N*m (224 kgf*cm, 16 ft.*lbf)
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4.CONNECT NO. 2 RADIATOR HOSE 16572D
a. Connect the No. 2 radiator hose to the radiator assembly and slide the hose clamp to secure the hose.
5.INSTALL FAN SHROUD
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a. Install the fan pulley to the engine water pump assembly.
b. Place the fan shroud together with the fan with fluid coupling assembly between the engine and radiator
assembly.
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NOTICE:
Do not allow the radiator assembly to interfere with other parts.
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c. Temporarily install the fan with fluid coupling assembly to the engine water pump assembly with the 4 nuts.
NOTICE:
· Make sure to match the paint mark colors on the fan with fluid coupling assembly with the stud
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bolts of the same color on the engine water pump assembly.

· When installing the fan and generator V belt, make sure to securely tighten the nuts of the fan
with fluid coupling assembly so that the fan pulley is properly aligned.
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d. Attach the 2 guides and 2 claws to install the fan shroud to the radiator assembly.
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e. Install the fan and generator V belt.

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>DRIVE BELT>INSTALLATION
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f. Tighten the 4 nuts holding the fan with fluid coupling assembly.
Torque:
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23 N*m (235 kgf*cm, 17 ft.*lbf)
g. Attach the 2 wire harness clamps.
6.CONNECT NO. 1 OIL COOLER INLET HOSE (for Automatic Transmission) 32941
a. Connect the No. 1 oil cooler inlet hose to the radiator assembly and slide the hose clamp to secure the
hose.
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b. Attach the clamp to connect the No. 1 oil cooler inlet hose to the fan shroud.
7.CONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission) 32942
a. Connect the No. 1 oil cooler outlet tube to the radiator assembly and slide the hose clamp to secure the
hose.
8.INSTALL VISCOUS HEATER V BELT (w/ Viscous Heater) 88359
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9.INSTALL RADIATOR RESERVOIR 16470
a. Install the radiator reservoir with the 2 bolts.

Torque:
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5.0 N*m (51 kgf*cm, 44 in.*lbf)
b. Connect the water by-pass hose to the radiator assembly and slide the hose clamp to secure the hose.
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c. Connect the No. 2 water by-pass hose to the radiator assembly and slide the hose clamp to secure the
hose.
d. Attach the clamp to connect the No. 2 water by-pass hose to the fan shroud.
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10.INSTALL NO. 1 OIL RESERVOIR BRACKET 44369A
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a. Temporarily install the No. 1 oil reservoir bracket with the 3 bolts and tighten the 3 bolts.
Torque:
4.5 N*m (46 kgf*cm, 40 in.*lbf)
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11.CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY 44360

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a. Attach the claw to connect the vane pump oil reservoir assembly to the vane pump oil reservoir bracket.
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b. Attach the clamp to connect the pressure feed tube assembly to the fan shroud.
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12.INSTALL NO. 1 RADIATOR HOSE 16571C

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a. Install the No. 1 radiator hose and slide the 2 hose clamps to secure the hose.
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13.INSTALL NO. 2 AIR TUBE 17362B
a. Install the No. 2 air tube with the 2 bolts and tighten the hose clamp to secure the tube.
Torque:
for bolt : 8.0 N*m (82 kgf*cm, 71 in.*lbf)
for hose clamp : 6.5 N*m (66 kgf*cm, 58 in.*lbf)
b. Attach the 4 clamps to connect the oil return hose to the No. 2 air tube.

14.INSTALL NO. 4 AIR HOSE 17344E
a. Install the No. 4 air hose and tighten the 2 hose clamps to secure the hose.
Torque:
6.5 N*m (66 kgf*cm, 58 in.*lbf)
b. Attach the 2 clamps to connect the oil return hose to the No. 4 air hose.
Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLANT>REPLACEMENT
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17.INSTALL NO. 1 RADIATOR AIR GUIDE 16593
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a. Install the No. 1 radiator air guide with 4 new clips.
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19.INSTALL RADIATOR SIDE DEFLECTOR 53293C
· for Steel Type Bumper:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER(for Steel Type
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Bumper)>INSTALLATION
· for Resin Type Bumper:
Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER(for Resin Type
Bumper)>INSTALLATION
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1GD-FTV COOLING RADIATOR ON-VEHICLE INSPECTION
CAUTION:
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PROCEDURE
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1.CHECK RADIATOR RESERVOIR CAP SUB-ASSEMBLY 16471

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CAUTION:
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a.
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*a O-Ring
*b Rubber Packing
Measure the valve opening pressure.

i. If there are water stains or foreign matter on the O-ring, clean it with water and finger scouring.
ii. Check that the O-ring is not deformed, cracked or swollen.
iii. Apply engine coolant to the O-ring and rubber packing before using a radiator cap tester.
iv.
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*1 Radiator Reservoir Cap Sub-Assembly
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*a Radiator Cap Tester
*b 30° or more
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When using the radiator cap tester, tilt it 30° or more.
v. Pump the radiator cap tester several times, and check the maximum pressure*.
Pump speed:
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1 pump per second
*: Even if the radiator reservoir cap sub-assembly cannot maintain the maximum pressure, it is not a
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defect.
Judgment Criterion:
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93 to 123 kPa (1.0 to

Standard value
1.3 kgf/cm2, 13.5 to
(for brand-new cap)
18 psi)
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Minimum standard
79 kPa (0.8 kgf/cm2,
value
11.4 psi)
(after using cap)
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If the maximum pressure is less than the minimum standard value, replace the radiator reservoir cap
sub-assembly.
2.INSPECT FINS FOR BLOCKAGE 16400

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a. If the fins are clogged, wash them with water or a steam cleaner and dry them with compressed air.
NOTICE:
· To avoid damaging the fins, the injection direction should be at right angles to the core surface.
· If the steam cleaner is too close to the core, there is a possibility of damaging the fins, so
maintain the following injection distances.
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Standard Injection Distance:
Specified
Injection Pressure
Condition
2942 to 4903 kPa
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(30.0 to 50.0
300 mm (11.8 in.)
kgf/cm2, 427 to 711
psi)
4903 to 7845 kPa
(50.0 to 80.0
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500 mm (19.7 in.)
kgf/cm2, 711 to 1138
psi)
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· If the fins are bent, straighten them with a screwdriver or pliers.
· Do not expose electronic components to water.
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b. Dry the fins with compressed air.

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1GD-FTV COOLING RADIATOR REMOVAL
PROCEDURE
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3.REMOVE RADIATOR SIDE DEFLECTOR 53294C
· for Steel Type Bumper:
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Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER(for Steel Type Bumper)>REMOVAL
· for Resin Type Bumper:
Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER(for Resin Type Bumper)>REMOVAL
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5.REMOVE NO. 1 RADIATOR AIR GUIDE 16593

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Remove the 4 clips and No. 1 radiator air guide.

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NOTICE:
Do not reuse the clip.
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6.REMOVE NO. 4 AIR HOSE 17344E

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a.
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Detach the 2 clamps to disconnect the oil return hose from the No. 4 air hose.
b. Loosen the 2 hose clamps and remove the No. 4 air hose.
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7.REMOVE NO. 2 AIR TUBE 17362B
a.
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Detach the 4 clamps to disconnect the oil return hose from the No. 2 air tube.
b. Loosen the hose clamp and remove the 2 bolts and No. 2 air tube.
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8.REMOVE NO. 1 RADIATOR HOSE 16571C

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Slide the 2 hose clamps and remove the No. 1 radiator hose.
9.DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY 44360

a.
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Detach the clamp to disconnect the pressure feed tube assembly from the fan shroud.
b. Detach the claw and disconnect the vane pump oil reservoir assembly from the No. 1 oil reservoir bracket
as shown in the illustration.
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10.REMOVE NO. 1 OIL RESERVOIR BRACKET 44369A
a.
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Remove the 3 bolts and No. 1 oil reservoir bracket.

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11.REMOVE RADIATOR RESERVOIR 16470

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a.
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Detach the clamp to disconnect the No. 2 water by-pass hose from the fan shroud.
b. Slide the hose clamp and disconnect the No. 2 water by-pass hose from the radiator assembly.

c.
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Slide the hose clamp and disconnect the water by-pass hose from the radiator assembly.
d. Remove the 2 bolts and radiator reservoir.
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12.REMOVE VISCOUS HEATER V BELT (w/ Viscous Heater) 88359
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>DRIVE BELT>REMOVAL
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13.DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission) 32942
a.
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Slide the hose clamp and disconnect the No. 1 oil cooler outlet hose from the radiator assembly.
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14.DISCONNECT NO. 1 OIL COOLER INLET HOSE (for Automatic Transmission) 32941
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a.
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Detach the clamp to disconnect the No. 1 oil cooler inlet hose from the fan shroud.
b. Slide the hose clamp and disconnect the No. 1 oil cooler inlet hose from the radiator assembly.

15.REMOVE FAN SHROUD 16711
a.
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Detach the 6 wire harness clamps.
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b.
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Loosen the 4 nuts holding the fan with fluid coupling assembly.
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c. Remove the fan and generator V belt.

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d.
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Detach the 2 claws and 2 guides to disconnect the fan shroud from the radiator assembly.
e. Remove the 4 nuts of the fan with fluid coupling assembly and remove the fan shroud together with the
fluid coupling assembly.
NOTICE:
Do not allow the radiator assembly to interfere with other parts.
f. Remove the fan pulley from the engine water pump assembly.

16.DISCONNECT NO. 2 RADIATOR HOSE 16572D
a.
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Slide the hose clamp and disconnect the No. 2 radiator hose from the radiator assembly.
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17.REMOVE RADIATOR ASSEMBLY 16400
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Remove the 4 bolts.

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b.
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w/ Air Conditioning System:

Detach the 2 claws and 2 guides to disconnect the cooler condenser assembly from radiator assembly.
NOTICE:
· Do not allow the radiator assembly to interfere with other parts.
· Do not apply any excessive force to the cooler condenser assembly and cooler pipe.

c. Remove the radiator assembly from the vehicle.
18.REMOVE RADIATOR PROTECTOR (w/o Air Conditioning System) 16546
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Detach the 2 claws and 2 guides to remove the radiator protector.
19.REMOVE RADIATOR DRAIN COCK PLUG 16400B
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a. Remove the radiator drain cock plug from the radiator assembly.
b. Remove the O-ring from the radiator drain cock plug.

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1GD-FTV COOLING THERMOSTAT COMPONENTS
ILLUSTRATION
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*A w/ Viscous Heater - -
*1 NO. 2 RADIATOR HOSE *2 NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY
*3 THERMOSTAT *4 WATER HOSE SUB-ASSEMBLY
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*5 WATER INLET *6 GASKET

*7 SUCTION HOSE SUB-ASSEMBLY - -
*a w/ Air Conditioning System without Viscous - -

Heater
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1GD-FTV COOLING THERMOSTAT INSPECTION
PROCEDURE
1.INSPECT THERMOSTAT 16331A
HINT:
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The valve opening temperature is inscribed on the thermostat.
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Immerse the thermostat in water and then gradually heat the water.
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CAUTION:
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· Do not your hands into the water that has been heated for the inspection.
· Touching the heated water could result in burns.
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b. Check the valve opening temperature.

Standard valve opening temperature:
80 to 84°C (176 to 183°F)
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If the valve opening temperature is not within the specified range, replace the thermostat.
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c.
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Check the valve lift.
Standard valve lift:
10 mm (0.394 in.) or more at 95°C (203°F)
If the valve lift is not as specified, replace the thermostat.
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d. Check that the valve is fully closed when the thermostat is below 77°C (171°F).
If the valve is not fully closed, replace the thermostat.
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1GD-FTV COOLING THERMOSTAT INSTALLATION
PROCEDURE
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*1 Gasket
*a CORRECT
*b INCORRECT
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Install a new gasket to the thermostat.
NOTICE:
When installing the gasket to the thermostat, be careful not to deform the gasket. Make sure that the
groove of the gasket is properly installed to the thermostat as shown in the illustration.
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*a Upward
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*b 30°
*c Jiggle Valve
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Insert the thermostat into the engine water pump assembly with the jiggle valve facing straight upward.
HINT:
The jiggle valve may be set to within 30° on either side of the prescribed position.
a. Install the water inlet with the 3 bolts.

Torque:
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13 N*m (133 kgf*cm, 10 ft.*lbf)
a. Connect the No. 2 radiator hose to the water inlet and slide the hose clamp to secure the hose.
b. w/ Air Conditioning System without Viscous Heater:

Connect the suction hose sub-assembly to the water inlet with the bolt.
Torque:
5.4 N*m (55 kgf*cm, 48 in.*lbf)
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4.CONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 16207
a. Connect the No. 2 water by-pass pipe sub-assembly to the engine water pump assembly and water inlet
with the 2 bolts.
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Torque:
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5.INSTALL WATER HOSE SUB-ASSEMBLY (w/ Viscous Heater)

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6.INSTALL FAN SHROUD 16711
Click hereEngine / Hybrid System>1GD-FTV COOLING>RADIATOR>INSTALLATION

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1GD-FTV COOLING THERMOSTAT REMOVAL
PROCEDURE
Click hereEngine / Hybrid System>1GD-FTV COOLING>RADIATOR>REMOVAL
2.REMOVE WATER HOSE SUB-ASSEMBLY (w/ Viscous Heater)
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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE ASSEMBLY>REMOVAL
3.DISCONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 16207
a.
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Remove the 2 bolts and disconnect the No. 2 water by-pass pipe sub-assembly from the engine water
pump assembly and water inlet.
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w/ Air Conditioning System without Viscous Heater:

Remove the bolt and disconnect the suction hose sub-assembly from the water inlet.
b. Slide the hose clamp and disconnect the No. 2 radiator hose from the water inlet.
5.REMOVE WATER INLET 16321
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Remove the 3 bolts and water inlet.
6.REMOVE THERMOSTAT 16331A
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a. Remove the thermostat from the engine water pump assembly.
b. Remove the gasket from the thermostat.
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1GD-FTV COOLING WATER PUMP COMPONENTS
ILLUSTRATION
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*A w/ Viscous Heater *B w/o Viscous Heater

*1 ENGINE WATER PUMP ASSEMBLY *2 NO. 1 TURBO WATER HOSE
*3 NO. 1 WATER BY-PASS PIPE *4 FAN
*5 FLUID COUPLING *6 GASKET
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1GD-FTV COOLING WATER PUMP INSTALLATION
PROCEDURE
1.INSTALL ENGINE WATER PUMP ASSEMBLY 16100
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Bolt A
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Bolt B
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Temporarily install a new gasket and the engine water pump assembly with the 8 bolts.
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Bolt Length:
Item Length
Bolt A 45 mm (1.77 in.)
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Bolt B 65 mm (2.56 in.)

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b. Tighten the 8 bolts in the order shown in the illustration.

Torque:
25 N*m (255 kgf*cm, 18 ft.*lbf)
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2.CONNECT NO. 1 TURBO WATER HOSE 16284

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a. Connect the No. 1 turbo water hose to the engine water pump assembly and slide the hose clamp to secure
the hose.
3.CONNECT NO. 1 WATER BY-PASS PIPE 16268
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*a Claw
Install a new gasket to the No. 1 water by-pass pipe as shown in the illustration.
HINT:
Make sure that the claws of the gasket are facing the No. 1 water by-pass pipe.
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b. Connect the No. 1 water by-pass pipe to the engine water pump assembly with the 3 bolts.
Torque:
c.
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Attach the wire harness clamp and connect the 2 connectors to the turbocharger sub-assembly.
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1GD-FTV COOLING WATER PUMP ON-VEHICLE INSPECTION
PROCEDURE
HINT:
· The sliding surface inside the engine water pump assembly is lubricated by engine coolant. As some
engine coolant is discharged during normal operation, coolant residue (solids) may be found on the drain
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plug or the bottom of the engine water pump assembly. Also, engine coolant may leak if foreign matter
enters the engine water pump assembly, however the sealing performance will recover when the foreign
matter is pushed out or breaks into fine pieces. In this case, check the area around the engine water
pump assembly.
· Before performing this inspection, check that there is no coolant leaking from any parts other than the
engine water pump assembly. If there are leaks, inspect those areas.
· Perform this inspection when the engine is cold.
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a. Visually check the engine water pump assembly.
i. Check that engine coolant is not dripping from the engine water pump assembly.
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HINT:
· If engine coolant is dripping, replace the engine water pump assembly.
· If engine coolant is not dripping, perform the following check.
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b. Inspect the area around the engine water pump assembly.
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HINT:
Check for deposits around the drain plug of the engine water pump assembly.
i. Remove the fan pulley.

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*a Drain Plug
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*b Air Hole
Press a piece of paper towel against the drain plug or deposits on the lip of the drain plug and check
that the paper towel is not wet.
HINT:
· If the thin paper towel is wet, replace the engine water pump assembly.
· If the thin paper towel is dry, clean the area around the engine water pump assembly.
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2.INSPECT ENGINE WATER PUMP ASSEMBLY 16100
a.
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Turn the water pump pulley and check that the water pump bearing moves smoothly and quietly.
If necessary, replace the engine water pump assembly.
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b. Install the fan pulley.
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3.INSPECT FLUID COUPLING ASSEMBLY 16210
a. Remove the fan with fluid coupling assembly.

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Remove the 4 nuts and fan from the fluid coupling assembly.
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c.
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Check that the fluid coupling assembly is not damaged and that no silicon oil leaks.
If necessary, replace the fluid coupling assembly.

d. Install the fan to the fluid coupling assembly with the 4 nuts.
Torque:
6.0 N*m (61 kgf*cm, 53 in.*lbf)
e. Install the fan with fluid coupling assembly.

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1GD-FTV COOLING WATER PUMP REMOVAL
PROCEDURE
Click hereEngine / Hybrid System>1GD-FTV COOLING>THERMOSTAT>REMOVAL
2.DISCONNECT NO. 1 WATER BY-PASS PIPE 16268
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a.
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Detach the wire harness clamp and disconnect the 2 connectors from the turbocharger sub-assembly.
b.
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Remove the 3 bolts and disconnect the No. 1 water by-pass pipe from the engine water pump assembly.
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c. Remove the gasket from the No. 1 water by-pass pipe.

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3.DISCONNECT NO. 1 TURBO WATER HOSE 16284

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1GD-FTV EMISSION CONTROL DIFFERENTIAL PRESSURE SENSOR COMPONENTS
ILLUSTRATION
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*1 DIFFERENTIAL PRESSURE SENSOR *2 NO. 1 ENGINE COVER SUB-ASSEMBLY

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*3 AIR HOSE - -
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1GD-FTV EMISSION CONTROL DIFFERENTIAL PRESSURE SENSOR INSTALLATION
PROCEDURE
1.INSTALL DIFFERENTIAL PRESSURE SENSOR 89481B
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*a Paint Mark
Install the 2 air hoses to the differential pressure sensor, and slide the 2 clamps to secure the 2 hoses.
HINT:
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Make sure the paint mark of the air hose side the differential pressure sensor.
b. Connect the 2 air hoses to the No. 1 vacuum pipe and No. 2 vacuum pipe, and slide the 2 clamps to secure
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the 2 hoses.
c. Install the differential pressure sensor to the pipe clamp with the bolt.
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Torque:
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d. Connect the connector to the differential pressure sensor.

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1GD-FTV EMISSION CONTROL DIFFERENTIAL PRESSURE SENSOR ON-VEHICLE INSPECTION
PROCEDURE
1.INSPECT DIFFERENTIAL PRESSURE SENSOR 89481B
a. Connect the GTS to the DLC3.
b. Remove the No. 1 engine cover sub-assembly.
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c. Slide the clamp and disconnect the air hose from the differential pressure sensor.
d.
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Install SST to the differential pressure sensor.

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SST
09992-00242
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e. Turn the ignition switch to ON.

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f. Turn the GTS on.
g. Enter the following menus: Powertrain / Engine / Data List / DPF Differential Pressure.
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*a Pressure
Apply pressure to the differential pressure sensor assembly.
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Check the pressure value of the differential pressure sensor.
Standard pressure:
Approximately the same pressure as the applied pressure is indicated on the GTS.
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NOTICE:
Perform the inspection within the range of 0 to 98 kPa (0 to 1.0 kgf/cm2, 0 to 14.2 psi).
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If the result is not as specified, check the differential pressure sensor circuit.
j. Remove SST from the differential pressure sensor.

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k. Connect the air hose to the differential pressure sensor, and slide the clamp to secure the hose.
l. Install the No. 1 engine cover sub-assembly.

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1GD-FTV EMISSION CONTROL DIFFERENTIAL PRESSURE SENSOR REMOVAL
CAUTION:
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To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the
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engine is hot.
PROCEDURE
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2.REMOVE DIFFERENTIAL PRESSURE SENSOR 89481B

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CAUTION:
engine is hot.
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a.
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Disconnect the connector from the differential pressure sensor.
b. Remove the bolt and differential pressure sensor from the pipe clamp.
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c.
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Slide the 2 clamps and disconnect the 2 air hoses from the No. 1 vacuum pipe and No. 2 vacuum pipe.
d.
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Slide the 2 clamps and remove the 2 No. 1 air hoses from the differential pressure sensor.
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1GD-FTV EMISSION CONTROL EGR BYPASS VALVE SWITCHING VALVE COMPONENTS
ILLUSTRATION
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*1 NO. 1 ENGINE COVER SUB-ASSEMBLY *2 VACUUM CONTROL VALVE SET

*3 ENGINE WIRE BRACKET - -
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ILLUSTRATION
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*1 NO. 1 VACUUM SWITCHING VALVE ASSEMBLY *2 BRACKET

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1GD-FTV EMISSION CONTROL EGR BYPASS VALVE SWITCHING VALVE INSPECTION
PROCEDURE
1.INSPECT NO. 1 VACUUM SWITCHING VALVE ASSEMBLY 25860
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*a
(No. 1 vacuum switching valve assembly)

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Tester Specified
Condition
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1-2 20°C (68°F) 33 to 39 Ω

1 - Body
ground
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20°C (68°F) 1 MΩ or higher

2 - Body
ground
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If the result is not as specified, replace the No. 1 vacuum switching valve assembly.
b. Check operation of the No. 1 vacuum switching valve assembly.
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*a Vacuum
*b Air
*c Port E
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*d Port F
*e Filter
When a vacuum of 60 kPa (450 mmHg, 18 in.Hg) is applied to port F, check that air flows from port E to
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the filter.
ii.
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*a Air
*b Port F
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*c Port E
Apply battery voltage 12V across terminals 1 and 2.

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iii. Check that air flows from port E to port F.

If the result is not as specified, replace the No. 1 vacuum switching valve assembly.
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1GD-FTV EMISSION CONTROL EGR BYPASS VALVE SWITCHING VALVE INSTALLATION
PROCEDURE
1.INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY 25860
a. Install the No. 1 vacuum switching valve assembly to the bracket with the screw.
Torque:
1.4 N*m (14 kgf*cm, 12 in.*lbf)
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b. Connect the vacuum hose to the No. 1 vacuum switching valve assembly.
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a. Install the vacuum control valve set to the intake manifold with the 2 bolts.
Torque:
b.
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Connect the 2 vacuum hoses to the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR valve
assembly.
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c. Connect the engine wire bracket with the bolt.
Torque:
18.5 N*m (189 kgf*cm, 14 ft.*lbf)
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1GD-FTV EMISSION CONTROL EGR BYPASS VALVE SWITCHING VALVE REMOVAL
CAUTION:
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engine is hot.
PROCEDURE
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2.REMOVE VACUUM CONTROL VALVE SET 25804

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Remove the bolt and disconnect the engine wire bracket.

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Disconnect the 2 vacuum hoses from the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR
valve assembly.
c.
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Remove the 2 bolts and vacuum control valve set from the intake manifold.
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3.REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY 25860

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Disconnect the vacuum hose from the No. 1 vacuum switching valve assembly.
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Remove the screw and No. 1 vacuum switching valve assembly from the bracket.
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1GD-FTV EMISSION CONTROL EGR COOLER COMPONENTS
ILLUSTRATION
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*1 ENGINE WIRE *2 FUEL FILTER ASSEMBLY

*3 GAS FILTER *4 NO. 2 ENGINE COVER BRACKET
*5 NO. 2 HOSE TO HOSE TUBE *6 NO. 2 WATER BY-PASS PIPE
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*7 TURBO PRESSURE SENSOR - -

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ILLUSTRATION
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*1 EGR VALVE BRACKET *2 ASSEMBLY WITH ELECTRIC EGR CONTROL
VALVE ASSEMBLY
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*7 VACUUM CONTROL VALVE SET *8 NO. 4 FUEL HOSE
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*11 NO. 8 WATER BY-PASS HOSE *12 WATER HOSE
*13 NO. 7 WATER BY-PASS HOSE *14 ENGINE WIRE BRACKET
*15 STUD BOLT - -

ILLUSTRATION
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*1
*3
NO. 1 EGR COOLER
GASKET
*2
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-
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1GD-FTV EMISSION CONTROL EGR COOLER INSTALLATION
PROCEDURE
1.INSTALL NO. 1 EGR COOLER 25681
a. Install a new gasket and the No. 1 EGR cooler to the No. 2 EGR valve assembly with electric EGR control
valve assembly with the 4 bolts.
Torque:
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25 N*m (255 kgf*cm, 18 ft.*lbf)
2.INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL
VALVE ASSEMBLY
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a. Temporarily install the No. 1 EGR cooler and No. 2 EGR valve assembly with electric EGR control valve
assembly to the intake manifold with the 4 bolts.
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NOTICE:
Make sure to tighten the bolts in the order.
Torque:
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21 N*m (214 kgf*cm, 15 ft.*lbf)

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a. Install the No. 3 water by-pass pipe sub-assembly to the No. 1 EGR cooler with the 2 bolts.
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Torque:
b. Connect the No. 9 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to
secure the hose.
c. Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe sub-assembly, and slide the clamp
to secure the hose.
d. Connect the No. 4 fuel hose to the No. 3 water by-pass pipe sub-assembly.
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9.CONNECT ENGINE WIRE 82121
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10.CONNECT FUEL FILTER ASSEMBLY 23300

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13.INSTALL TURBO PRESSURE SENSOR 89421C

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1GD-FTV EMISSION CONTROL EGR COOLER REMOVAL
parts are removed, installed, or replaced during the EGR cooler removal/installation are shown below.
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Replacement of diesel
Perform initialization - ( )
throttle body assembly
Replacement of electric
EGR control valve Perform initialization - ( )
assembly
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CAUTION:
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engine is hot.
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PROCEDURE
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2.REMOVE DIESEL THROTTLE BODY ASSEMBLY 26100G

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3.REMOVE NO. 2 WATER BY-PASS PIPE 16278

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Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EGR VALVE>REMOVAL
4.REMOVE GAS FILTER 23265C
5.REMOVE TURBO PRESSURE SENSOR 89421C
6.REMOVE NO. 2 HOSE TO HOSE TUBE 44763C
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7.REMOVE NO. 2 ENGINE COVER BRACKET 12632
8.DISCONNECT FUEL FILTER ASSEMBLY 23300
9.DISCONNECT ENGINE WIRE 82121
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10.REMOVE EGR VALVE BRACKET 25625
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11.REMOVE NO. 2 EGR PIPE 25612
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12.DISCONNECT NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY 16206B
CAUTION:
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engine is hot.
a.
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Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.
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b.
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Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-
assembly.

c. Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.
d. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the No. 1 EGR cooler.
14.REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY 25601
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16.REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR
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CONTROL VALVE ASSEMBLY
CAUTION:
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a.
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Remove the 4 bolts and No. 1 EGR cooler and No. 2 EGR valve assembly with electric EGR control valve
assembly from the intake manifold.
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17.REMOVE NO. 1 EGR COOLER 25681

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a.
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Remove the 4 bolts and No. 1 EGR cooler from the No. 2 EGR valve assembly with electric EGR control
valve assembly.

b. Remove the gasket.
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1GD-FTV EMISSION CONTROL EGR VALVE COMPONENTS
ILLUSTRATION
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*1 EGR VALVE BRACKET *2 ELECTRIC EGR CONTROL VALVE ASSEMBLY

*3 ENGINE WIRE *4 FUEL FILTER ASSEMBLY
*5 GAS FILTER *6 NO. 2 EGR PIPE
*9 NO. 2 WATER BY-PASS PIPE *10 TURBO PRESSURE SENSOR
*11 CONNECTING WIRE *12 GASKET
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ILLUSTRATION
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*1 *2 NO. 1 EGR PIPE SUB-ASSEMBLY
ASSEMBLY
*9 GASKET *10 ENGINE WIRE BRACKET
*11 WATER HOSE *12 NO. 7 WATER BY-PASS HOSE

*13 STUD BOLT - -
ILLUSTRATION
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*1 EGR VALVE ADAPTER *2 NO. 2 EGR VALVE ASSEMBLY

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*3 NO. 1 EGR COOLER *4 GASKET

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1GD-FTV EMISSION CONTROL EGR VALVE INSPECTION
PROCEDURE
1.VISUALLY CHECK ELECTRIC EGR CONTROL VALVE ASSEMBLY 25800
a. Visually check the electric EGR control valve assembly for deposits.
NOTICE:
· When cleaning the electric EGR control valve assembly, make sure the valve is completely closed.
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· Do not forcibly open the valve as it may be damaged or deformed.
· When cleaning the electric EGR control valve assembly, use a piece of cloth soaked with cleaning
solvent. Spraying the solvent directly onto this part or soaking the part in solvent may damage
the part.
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*a Seal Ring End

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*b Gap
*c CORRECT
*d INCORRECT
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Hold the electric EGR control valve assembly up to a light, and then from the side indicated by the arrow in
the illustration, visually check that there is no gap between the valve and body.
OK:
No light passes through (there is no gap between the valve and body).
HINT:
Light passes through part even if the valve is completely closed as there is an opening in the seal ring of
the valve, this is not a problem.
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If light passes through (there is a gap between the valve and body), replace the electric EGR control valve
assembly.
2.INSPECT NO. 2 EGR VALVE ASSEMBLY 25630
NOTICE:
· Do not forcibly open the valve as it may be damaged or deformed.
· When cleaning the No. 2 EGR valve assembly, use a piece of cloth soaked with cleaning solvent. Spraying
the solvent directly onto this part or soaking the part in solvent may damage the part.
a.
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When a vacuum of 69.7 kPa (523 mmHg, 20.6 in.Hg) is applied to the diaphragm chamber, check that the
valve turns and air flows out.
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b. Maintaining the above conditions, check that there are no leaks and the valve does not return.
c. Check that the valve does not have heavy carbon deposits and is not stuck.
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If necessary, replace the No. 2 EGR valve assembly.

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1GD-FTV EMISSION CONTROL EGR VALVE INSTALLATION
PROCEDURE
1.INSTALL NO. 2 EGR VALVE ASSEMBLY 25630
a. Using an E8 "TORX" socket wrench, install the 4 stud bolts to the No. 2 EGR valve assembly.
Torque:
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b. Install a new gasket and the No. 2 EGR valve assembly to the No. 1 EGR cooler with the 4 bolts.
Torque:
25 N*m (255 kgf*cm, 18 ft.*lbf)
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2.INSTALL EGR VALVE ADAPTER 25624
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a. Install a new gasket and the EGR valve adapter to the No. 2 EGR valve assembly with the 2 bolts.
Torque:
25 N*m (255 kgf*cm, 18 ft.*lbf)
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3.INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY
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a. Temporarily install the No. 1 EGR cooler and No. 2 EGR valve assembly to the intake manifold with the 4
bolts.
b.
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Tighten the 4 bolts in the order shown in the illustration.

NOTICE:
Make sure to tighten the bolts in the order.
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Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
a. Install the vacuum control valve set to the intake manifold with the 2 bolts.
Torque:
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b. Connect the 2 vacuum hoses to the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR valve
assembly.
c. Install the engine wire bracket with the bolt.

Torque:
18.5 N*m (189 kgf*cm, 14 ft.*lbf)
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a. Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.
Torque:
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b. Install 2 new gaskets and the No. 1 EGR pipe sub-assembly to the exhaust manifold and EGR valve adapter
with 4 new nuts.
Torque:
29 N*m (296 kgf*cm, 21 ft.*lbf)
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c. Connect the No. 1 EGR pipe sub-assembly to the vacuum transmitting pipe sub-assembly with the bolt.
Torque:
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a. Connect the No. 4 water by-pass pipe sub-assembly to the intake manifold with the 2 bolts.
Torque:
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b. Connect the water hose to the No. 2 EGR valve assembly, and slide the clamp to secure the hose.
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c. Connect the No. 7 water by-pass hose to the No. 1 EGR cooler, and slide the clamp to secure the hose.
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a. Install the No. 3 water by-pass pipe sub-assembly to the No. 1 EGR cooler with the 2 bolts.
Torque:
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b. Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe sub-assembly, and slide the clamp
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to secure the hose.
c. Connect the No. 4 fuel hose to the No. 3 water by-pass pipe sub-assembly.
8.INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY 25800
a. Install a new gasket and the electric EGR control valve assembly to the No. 2 EGR valve assembly with the
2 bolts.
Torque:

25 N*m (255 kgf*cm, 18 ft.*lbf)
b. Connect the No. 9 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to
secure the hose.
c. Attach the clamp and connect the connector to the common rail assembly.
a. Install 2 new gaskets and No. 2 EGR pipe to the electric EGR control valve assembly and the intake
manifold with the 4 nuts.
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Torque:
29 N*m (296 kgf*cm, 21 ft.*lbf)
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a. Install the EGR valve bracket to the electric EGR control valve assembly and intake manifold with the bolt
and nut.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
11.CONNECT ENGINE WIRE

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a. Connect the connector to the vacuum control valve set.
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b. Attach the clamp and install the bolt.
Torque:
18.5 N*m (189 kgf*cm, 14 ft.*lbf)
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c. Attach the clamp and connect the connector to the power steering oil pressure switch.
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d. w/o DPF:
i. Attach the clamp and install the bolt.
Torque:
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12.5 N*m (127 kgf*cm, 9 ft.*lbf)
ii. Connect the connector to the sensor wire of the common rail assembly.
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iii. Connect the connector to the glow plug connector.
iv. Connect the connector to the electric EGR control valve assembly.
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v. Connect the 4 connectors to the 4 injector assemblies.

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vi. Connect the connector to the camshaft position sensor.
e. w/ DPF:
i. Attach the 2 clamps and install the bolt.
Torque:
12.5 N*m (127 kgf*cm, 9 ft.*lbf)
ii. Connect the connector to the sensor wire of the common rail assembly.

iii. Connect the connector to the glow plug connector.
iv. Connect the connector to the electric EGR control valve assembly.
v. Connect the 4 connectors to the 4 injector assemblies.
vi. Connect the connector to the camshaft position sensor.
vii. Connect the connector to the exhaust fuel addition injector assembly.
viii. Connect the 3 connectors to the 3 exhaust gas temperature sensors.
ix. Connect the connector to the differential pressure sensor.
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f. Attach the 2 clamps and connect the 2 connectors to the turbocharger sub-assembly.
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a. Connect the fuel filter assembly to the fuel filter support.
b.
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Attach the clamp and slide the lead wire as shown in the illustration to install it.
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a. Install the No. 2 engine cover bracket to the No. 3 water by-pass pipe sub-assembly and No. 2 EGR valve
assembly with the 2 bolts.
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Torque:
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a. Install the No. 2 hose to hose tube to the cylinder head cover sub-assembly and hose bracket with the 2
bolts.
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Torque:
b. Connect the union to check valve hose to the vacuum pump assembly, and slide the clamp to secure the
hose.
c. Connect the union to connector tube hose to the No. 1 hose to hose tube, and slide the clamp to secure the
hose.

a. Install the turbo pressure sensor to the No. 3 water by-pass pipe sub-assembly with the bolt.
Torque:
b. Connect the connector to the turbo pressure sensor.
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a. Install the gas filter to the gas filter bracket.
b. Connect the 2 vacuum hoses to the turbo pressure sensor and intake manifold.
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a. Install the No. 2 water by-pass pipe to the cylinder head cover sub-assembly, No. 3 water by-pass pipe
sub-assembly and No. 2 engine cover bracket with the 4 bolts.
Torque:
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b. Connect the No. 16 water by-pass hose to the No. 1 EGR cooler, and slide the clamp to secure the hose.
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c. Connect the 2 heater hoses to the No. 2 water by-pass pipe, and slide the 2 clamps to secure the 2 hoses.
d. Connect the No. 15 water by-pass hose to the water by-pass pipe, and slide the clamp to secure the hose.
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e. w/o Viscous Heater:

Connect the No. 2 water by-pass pipe to the No. 13 water by-pass hose, and slide the clamp to secure the
hose.
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f. w/ Viscous Heater:
Connect the No. 2 water by-pass pipe to the water hose sub-assembly, and slide the clamp to secure the
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1GD-FTV EMISSION CONTROL EGR VALVE ON-VEHICLE INSPECTION
CAUTION:
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To prevent injury due to contact with an operating fan and generator V belt or cooling fan, keep your hands and
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clothing away from the fan and generator V belt and cooling fans when working in the engine compartment with
the engine running.
PROCEDURE
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*a EGR Cooler By-pass Valve Regulating Link

*b Bypass Position
*c Cooler Position
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With the engine stopped, check that the EGR cooler by-pass valve regulating link is in the bypass position
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b. Start the engine.
d. When the engine coolant temperature is 80°C (176°F) or more, racing the engine at 1500 rpm or more,
check that the EGR cooler by-pass valve regulating link is in the cooler position. The EGR cooler by-pass
valve regulating link returns to the bypass position when idling.
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1GD-FTV EMISSION CONTROL EGR VALVE REMOVAL
parts are removed, installed, or replaced during the EGR valve removal/installation are shown below.
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Replacement of diesel
Perform initialization - ( )
Replacement of electric
EGR control valve Perform initialization - ( )
assembly
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CAUTION:
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PROCEDURE
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CAUTION:
engine is hot.

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*1 Water Hose Sub-assembly
*2 No. 13 Water By-pass Hose
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*4 Heater Hose
w/ Viscous Heater:
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Slide the clamp and disconnect the No. 2 water by-pass pipe from the water hose sub-assembly.
b. w/o Viscous Heater:

Slide the clamp and disconnect the No. 2 water by-pass pipe from the No. 13 water by-pass hose.
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c. Slide the clamp and disconnect the No. 15 water by-pass hose from the water by-pass pipe.
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d. Slide the 2 clamps and disconnect the 2 heater hoses from the No. 2 water by-pass pipe.
e. Slide the clamp and disconnect the No. 16 water by-pass hose from the No. 1 EGR cooler.
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f. Remove the 4 bolts and No. 2 water by-pass pipe from the cylinder head cover sub-assembly, No. 3 water
by-pass pipe sub-assembly and No. 2 engine cover bracket.
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a.
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Disconnect the 2 vacuum hoses from the turbo pressure sensor and intake manifold.

b. Remove the gas filter from the gas filter bracket.
a.
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Disconnect the connector from the turbo pressure sensor.
b. Remove the bolt and turbo pressure sensor from the No. 3 water by-pass pipe sub-assembly.
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Slide the clamp to disconnect the union to connector tube hose from the No. 1 hose to hose tube.
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b. Slide the clamp to disconnect the union to check valve hose from the vacuum pump assembly.
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c. Remove the 2 bolts and No. 2 hose to hose tube from the cylinder head cover sub-assembly and hose
bracket.
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a.
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Remove the 2 bolts and No. 2 engine cover bracket from the No. 3 water by-pass pipe sub-assembly and
No. 2 EGR valve assembly.
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Disconnect the clamp and slide the lead wire as shown in the illustration to remove it.
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b.
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Disconnect the fuel filter assembly from the fuel filter support.
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Detach the 2 clamps and disconnect the 2 connectors from the turbocharger sub-assembly.
b.
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w/ DPF:
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i. Disconnect the connector from the differential pressure sensor.
ii. Disconnect the 3 connectors from the 3 exhaust gas temperature sensors
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iii. Disconnect the connector from the exhaust fuel addition injector assembly.
iv. Disconnect the connector from the camshaft position sensor.

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v. Disconnect the 4 connectors from the 4 injector assemblies.
vi. Disconnect the connector from the electric EGR control valve assembly.
vii. Disconnect the connector from the glow plug connector.
viii. Disconnect the connector from the sensor wire of common rail assembly.
ix. Detach the 2 clamps and remove the bolt.

c.
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w/o DPF:
i. Disconnect the connector from the camshaft position sensor.
ii. Disconnect the 4 connectors from the 4 injector assemblies.

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iii. Disconnect the connector from the electric EGR control valve assembly.
iv. Disconnect the connector from the glow plug connector.

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v. Disconnect the connector from the sensor wire of common rail assembly.
vi. Detach the clamp and remove the bolt.

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d.
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Detach the clamp and disconnect the connector from the power steering oil pressure switch.
e. Detach the clamp and remove the bolt.
f. Disconnect the connector from the vacuum control valve set.

CAUTION:
engine is hot.
a.
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Remove the bolt, nut and EGR valve bracket from the electric EGR control valve assembly and intake
manifold.
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CAUTION:
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engine is hot.
a.
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Remove the bolt, 4 nuts and No. 2 EGR pipe from the electric EGR control valve assembly and intake
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manifold.
b. Remove the 2 gaskets.

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12.REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY 25800

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CAUTION:
engine is hot.

a.
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Detach the clamp and disconnect the connector from the common rail assembly.
b.
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Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.
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c. Remove the 2 bolts and electric EGR control valve assembly.
d. Remove the gasket.

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13.REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY 16206B

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CAUTION:
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engine is hot.
a.
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Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

b.
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assembly.
c. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the No. 1 EGR cooler.
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CAUTION:
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a.
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*A for Cold Area Specification Vehicle

*B except Cold Area Specification Vehicle
Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 1 EGR cooler.
b. Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.

c. Remove the 2 bolts and disconnect the No. 4 water by-pass pipe sub-assembly from the intake manifold.
CAUTION:
engine is hot.
a.
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Remove the bolt and disconnect the No. 1 EGR pipe sub-assembly from the vacuum transmitting pipe sub-
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assembly.
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Remove the 4 nuts and the No. 1 EGR pipe from the exhaust manifold and EGR valve adapter.
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c. Remove the 2 gaskets.
d.
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Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.
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Remove the bolt and engine wire bracket.
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Disconnect the 2 vacuum hoses from the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR
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valve assembly.
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Remove the 2 bolts and vacuum control valve set from the intake manifold.
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17.REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY
CAUTION:
engine is hot.

a.
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Remove the 4 bolts and No. 1 EGR cooler and No. 2 EGR valve assembly from the intake manifold.
18.REMOVE EGR VALVE ADAPTER 25624
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Remove the 2 bolts and EGR valve adapter from the No. 2 EGR valve assembly.
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19.REMOVE NO. 2 EGR VALVE ASSEMBLY 25630
a.
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Remove the 4 bolts and No. 2 EGR valve assembly from the No. 1 EGR cooler.

c.
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Using an E8 "TORX" socket wrench, remove the 4 stud bolts from the No. 2 EGR valve assembly.
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1GD-FTV EMISSION CONTROL EMISSION CONTROL SYSTEM ON-VEHICLE INSPECTION
CAUTION:
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the engine running.
HINT:
When there is a malfunction which causes the EGR system to remain on, black or white smoke may be emitted
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from the exhaust pipe.
PROCEDURE
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1.CHECK SEATING OF EGR VALVE

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a. Check that the engine starts and idles.

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b. Stop the engine.
2.CHECK ELECTRIC EGR CONTROL VALVE ASSEMBLY OPERATION 25800

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b. Turn the ignition switch to ON and turn the GTS on.

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c. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the EGR Step Position.
d. Check the Data List.

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Enter the following menus: Powertrain / Engine and ECT / Data List / Target EGR Valve Pos and Actual EGR
Valve Pos
Powertrain > Engine and ECT > Active Test
Active Test Display
Control the EGR Step Position
Data List Display
Target EGR Valve Pos
Actual EGR Valve Pos

Execute
OK:
Control Range Condition Specified Condition
Active Test performed (Set EGR position to 0% → Actual EGR valve opening percentage changes
30% → 60% → 90% → 60% → 30% → 0%) according to Active Test operation
If the result is not as specified, refer to DTC P042E.

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>P042E
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Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EGR VALVE>ON-VEHICLE INSPECTION
4.VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS
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a. Visually check that the hoses, connections and gaskets have no cracks, leaks or damage.
NOTICE:
· Detachment or other problems with the engine oil level dipstick, oil filler cap sub-assembly, PCV
hose or other components may cause the engine to run improperly.
· Air suction caused by disconnections, looseness or cracks in the parts of the air induction system
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between the diesel throttle body assembly and cylinder head sub-assembly will cause engine
failure or engine malfunctions.
If the result is not as specified, replace parts as necessary.

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5.CHECK VACUUM PUMP ASSEMBLY 29300
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Click hereBrake>BRAKE SYSTEM (OTHER)>VACUUM PUMP(for 1GD-FTV, 2GD-FTV)>ON-VEHICLE INSPECTION
6.PERFORM DPF FORCIBLE REGENERATION PROCEDURE

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a. Disconnect the cable from the negative (-) battery terminal or remove the EFI fuse for 1 minute or more.
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HINT:
· If the MIL is illuminated, first clear the DTCs using the intelligent tester, and then initialize the
value for the amount of particulate matter recorded by the ECM by disconnecting the cable from
the negative (-) battery terminal or removing the EFI fuse. Otherwise, forced DPF regeneration
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cannot be performed using the Active Test.

· If the MIL is not illuminated, proceed to the next step, as initialization is not necessary.
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b. Connect the intelligent tester to the DLC3.

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c. Start the engine and warm up it.

HINT:
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· Make sure the engine coolant temperature sensor reaches 70°C (158°F) or higher.
· Make sure the No. 3 exhaust gas temperature sensor reaches 115°C (239°F) or higher.
d. for Manual Transmission:

Move the shift lever to N and set the parking brake.
e. for Automatic Transmission:

Move the shift lever to P and set the parking brake.

f. Turn the tester on.
g. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the DPF Rejuvenate (PM).
Powertrain > Engine > Active Test
Tester Display
Activate the DPF Rejuvenate (PM)
Execute
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CAUTION:
Before performing the Active Test, make sure that there are no combustible materials around the DPF and
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tailpipe.
NOTICE:
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*a Air
If the ambient temperature is 30°C (86°F) or higher, the DPF and surrounding area become very hot. Use

a fan, etc. to cool the exhaust gas temperature sensors, air-fuel ratio sensor and surrounding areas.
HINT:
· During the Active Test, the engine speed increases to 2000 rpm, and then decreases to a speed
between 1200 and 1400 rpm which is determined by the intake air temperature. The Active Test
then continues with the engine running at that speed.
· The engine speed increases during the Active Test and the engine speed returns to idle when the
Active Test is completed.
· The time it takes to complete the Active Test varies depending on the PM volume stored. However,
it usually takes approximately 30 minutes or more to complete the Active Test.
· Do not cancel the Active Test unless absolutely necessary.
· If the Active Test needs to be canceled, depress the accelerator pedal and race the engine or
depress the clutch pedal to cancel the process. Even if the Active Test is stopped before it finishes,
"Compl(complete) for DPNR/DPF Status Reju(PM)" is displayed on the intelligent tester. If the
Active Test is canceled, it must be performed again.
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· If the differential pressure value increases too much during the Active Test, the fail-safe function
activates and the Active Test is stopped.
· It may not be possible to perform the Active Test when the ambient temperature is extremely low
or the elevation is extremely high. In this case, perform the Active Test indoors (with the tailpipe
pointed towards the outside) or drive the vehicle at a speed of approximately 60 km/h (37 mph)
or more for approximately 30 minutes or more to perform regeneration.
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· Depending on various conditions, the Active Test may not be completed within 30 minutes. If 60
minutes elapse, the system stops the Active Test and illuminates the MIL. If this happens,
disconnect the cable from the negative (-) battery terminal or remove the EFI fuse for 1 minute or
more so that the MIL turns off, and then perform the Active Test again.
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1GD-FTV EMISSION CONTROL EMISSION CONTROL SYSTEM PARTS LOCATION
ILLUSTRATION
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*A for LHD *B for RHD

INSTRUMENT PANEL JUNCTION BLOCK
*1 ECM *2
- EFI NO. 1 FUSE
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ILLUSTRATION
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*1 EGR BYPASS VALVE SWITCHING VALVE *2 NO. 2 EGR VALVE ASSEMBLY

*3 ELECTRIC EGR CONTROL VALVE ASSEMBLY *4 NO. 1 EGR COOLER
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ILLUSTRATION
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*A w/ DPF: - -
*1 DIFFERENTIAL PRESSURE SENSOR *2 EXHAUST FUEL ADDITION INJECTOR
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*3 EXHAUST GAS TEMPERATURE SENSOR *4 NO. 2 EXHAUST GAS TEMPERATURE SENSOR

*5 NO. 3 EXHAUST GAS TEMPERATURE SENSOR *6 EXHAUST MONOLITHIC CONVERTER
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ILLUSTRATION
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*A w/o DPF - -
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*1 EXHAUST MONOLITHIC CONVERTER - -

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1GD-FTV EMISSION CONTROL EMISSION CONTROL SYSTEM PRECAUTION
Expression
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1GD-FTV EMISSION CONTROL EMISSION CONTROL SYSTEM SYSTEM DIAGRAM
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1GD-FTV EMISSION CONTROL EXHAUST FUEL ADDITION INJECTOR COMPONENTS
ILLUSTRATION
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*1 NO. 1 ENGINE COVER SUB-ASSEMBLY *2 NO. 1 FUEL PIPE

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*3 NO. 1 INJECTOR HOLDER *4 NO. 4 WATER BY-PASS HOSE

*5 NO. 5 WATER BY-PASS HOSE *6 UNION BOLT
*7 GASKET *8 NO. 4 FUEL PIPE
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ILLUSTRATION
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EXHAUST FUEL ADDITION INJECTOR

*1 *2 INJECTOR HOLDER
ASSEMBLY
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*3 NO. 1 INJECTOR HOLDER *4 NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

*5 NO. 2 NOZZLE HOLDER CLAMP *6 E-RING
*7 NO. 3 FUEL INJECTOR BACK-UP RING *8 O-RING
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*9 NO. 2 FUEL INJECTOR BACK-UP RING *10 NO. 1 FUEL INJECTOR BACK-UP RING
*11 GASKET - -
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1GD-FTV EMISSION CONTROL EXHAUST FUEL ADDITION INJECTOR INSPECTION
PROCEDURE
1.INSPECT EXHAUST FUEL ADDITION INJECTOR ASSEMBLY 23710B
a. Measure the resistance according to the value(s) in the table below.

Tester Specified
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Condition
1-2 20°C (68°F) 7.1 to 7.9 Ω
HINT:
The temperature indicated in "Condition" is the temperature of the exhaust fuel addition injector
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assembly.
If the result is not as specified, replace the exhaust fuel addition injector assembly.
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1GD-FTV EMISSION CONTROL EXHAUST FUEL ADDITION INJECTOR INSTALLATION
PROCEDURE
1.INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY 23710B
a. Install a new No. 1 fuel injector back-up ring, No. 2 fuel injector back-up ring, O-ring and No. 3 fuel injector
back-up ring to the exhaust fuel addition injector assembly.
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b. Install a new E-ring to the exhaust fuel addition injector assembly.
c. Install a new gasket and the exhaust fuel addition injector assembly to the No. 1 injector holder.
2.INSTALL NO. 2 NOZZLE HOLDER CLAMP 23695B
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a. Using a T40 "TORX" socket wrench, install the No. 2 nozzle holder clamp with the bolt.
Torque:
11.5 N*m (117 kgf*cm, 8 ft.*lbf)
3.INSTALL INJECTOR HOLDER

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a. Install the injector holder to the No. 1 injector holder with the 2 bolts.
Torque:
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4.INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
a. Install a new gasket and the No. 2 exhaust manifold heat insulator to the No. 1 injector holder with the 3
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nuts.
Torque:
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5.INSTALL NO. 1 INJECTOR HOLDER 23295D

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a. Install the No. 1 injector holder to the exhaust manifold with 3 new nuts.
Torque:
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43 N*m (438 kgf*cm, 32 ft.*lbf)

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b. Connect the connector to the exhaust fuel addition injector assembly.
6.CONNECT NO. 5 WATER BY-PASS HOSE 16282
a. Connect the No. 5 water by-pass hose to the No. 1 injector holder, and slide the clamp to secure the hose.
7.CONNECT NO. 4 WATER BY-PASS HOSE 16281
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8.INSTALL NO. 1 FUEL PIPE 23811H
a. Connect the No. 1 fuel pipe to the No. 4 fuel pipe.
b. Install a new gasket and the No. 1 fuel pipe to the cylinder head cover sub-assembly and exhaust fuel
addition injector assembly with the union bolt and bolt.
Torque:
for bolt : 10 N*m (102 kgf*cm, 7 ft.*lbf)
for union bolt : 26 N*m (265 kgf*cm, 19 ft.*lbf)
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9.BLEED AIR FROM FUEL SYSTEM
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION
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1GD-FTV EMISSION CONTROL EXHAUST FUEL ADDITION INJECTOR REMOVAL
CAUTION:
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PROCEDURE
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3.REMOVE NO. 1 FUEL PIPE 23811H

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a.
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Remove the bolt, union bolt and gasket and disconnect the No. 1 fuel pipe from the cylinder head cover
sub-assembly and exhaust fuel addition injector assembly.
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Disconnect the No. 4 fuel pipe and remove the No. 1 fuel pipe.
4.DISCONNECT NO. 4 WATER BY-PASS HOSE 16281
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CAUTION:
engine is hot.
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5.DISCONNECT NO. 5 WATER BY-PASS HOSE 16282

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CAUTION:
engine is hot.
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a. Slide the clamp and disconnect the No. 5 water by-pass hose from the No. 1 injector holder.
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6.REMOVE NO. 1 INJECTOR HOLDER 23295D

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CAUTION:
engine is hot.

a.
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Remove the connector from the exhaust fuel addition injector assembly.
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Remove the 3 nuts and No. 1 injector holder from the exhaust manifold.
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7.REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 17168

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Remove the 3 nuts and No. 2 exhaust manifold heat insulator from the No. 1 injector holder.
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8.REMOVE INJECTOR HOLDER 23295C

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Remove the 2 bolts and injector holder from the No. 1 injector holder.
9.REMOVE NO. 2 NOZZLE HOLDER CLAMP 23695B
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Using a T40 "TORX" socket wrench, remove the bolt and No. 2 nozzle holder clamp from the No. 1 injector
holder.
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10.REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY 23710B

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a.
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Remove the exhaust fuel addition injector assembly from the No. 1 injector holder.

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Remove the gasket from the No. 1 injector holder.
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Remove the E-ring from the exhaust fuel addition injector assembly.
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Remove the No. 3 fuel injector back-up ring, O-ring, No. 2 fuel injector back-up ring and No. 1 fuel injector
back-up ring from the exhaust fuel addition injector assembly.
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1GD-FTV EMISSION CONTROL EXHAUST GAS TEMPERATURE SENSOR COMPONENTS
ILLUSTRATION
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*3 NO. 3 EXHAUST GAS TEMPERATURE SENSOR *4 NO. 1 ENGINE COVER SUB-ASSEMBLY

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1GD-FTV EMISSION CONTROL EXHAUST GAS TEMPERATURE SENSOR INSPECTION
PROCEDURE
1.INSPECT EXHAUST GAS TEMPERATURE SENSOR 89425

Tester Specified
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Condition
89.3 to 159.8
1-2 20°C (68°F)
kΩ
HINT:
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The temperature indicated in "Condition" is the temperature of the exhaust gas temperature sensor.
If the result is not as specified, replace the exhaust gas temperature sensor.
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2.INSPECT NO. 2 EXHAUST GAS TEMPERATURE SENSOR 89425A

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Tester Specified
Condition
89.3 to 159.8
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1-2 20°C (68°F)
kΩ
HINT:
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The temperature indicated in "Condition" is the temperature of the No. 2 exhaust gas temperature sensor.
If the result is not as specified, replace the No. 2 exhaust gas temperature sensor.
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3.INSPECT NO. 3 EXHAUST GAS TEMPERATURE SENSOR 89425B

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Tester Specified
Condition
89.3 to 159.8
1-2 20°C (68°F)
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kΩ
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HINT:
The temperature indicated in "Condition" is the temperature of the No. 3 exhaust gas temperature sensor.
If the result is not as specified, replace the No. 3 exhaust gas temperature sensor.
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1GD-FTV EMISSION CONTROL EXHAUST GAS TEMPERATURE SENSOR INSTALLATION
PROCEDURE
1.INSTALL EXHAUST GAS TEMPERATURE SENSOR 89425
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*a Torque Wrench Fulcrum Length
Using a 14 mm union nut wrench, install the No. 3 exhaust gas temperature sensor to the exhaust manifold
converter sub-assembly.
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Torque:
Specified tightening torque : 30 N*m (306 kgf*cm, 22 ft.*lbf)
NOTICE:
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If the No. 3 exhaust gas temperature sensor is dropped, replace the new one.
HINT:
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· The connector color of the No. 3 exhaust gas temperature sensor is gray.
· Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION
· When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum
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length of 180 mm (7.09 in.)): 26.3 N*m (268 kgf*cm, 19 ft.*lbf)

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Using a 14 mm union nut wrench, install the No. 2 exhaust gas temperature sensor to the exhaust manifold
Torque:
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NOTICE:
If the No. 2 exhaust gas temperature sensor is dropped, replace the new one.
HINT:
· The connector color of the No. 2 exhaust gas temperature sensor is black.
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Using a 14 mm union nut wrench, install the exhaust gas temperature sensor to the exhaust manifold
Torque:
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NOTICE:
If the exhaust gas temperature sensor is dropped, replace the new one.
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HINT:
· The connector color of the exhaust gas temperature sensor is white.
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d.
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*a White
*b Black
*c Gray

Attach the 3 colored connectors to the pipe clamp in the positions shown in the illustration.
e. Close the clamp of the pipe clamp, and install the bolt.
Torque:
f. Connect the No. 3 exhaust gas temperature sensor to the No. 1 vacuum pipe.
Torque:
g. Connect the 3 connectors to the 3 exhaust gas temperature sensor.
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1GD-FTV EMISSION CONTROL EXHAUST GAS TEMPERATURE SENSOR REMOVAL
CAUTION:
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PROCEDURE
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2.REMOVE EXHAUST GAS TEMPERATURE SENSOR 89425

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CAUTION:
engine is hot.
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a.
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Disconnect the 3 connectors from the 3 exhaust gas temperature sensors.
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Remove the nut and disconnect the No. 3 exhaust gas temperature sensor from the No. 1 vacuum pipe.
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Remove the bolt and open the clamp of the pipe clamp.
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d. Detach the 3 connectors from the pipe clamp.
e.
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Using a 14 mm union nut wrench, remove the exhaust gas temperature sensor from the exhaust manifold
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Using a 14 mm union nut wrench, remove the No. 2 exhaust gas temperature sensor from the exhaust
manifold converter sub-assembly.
g.
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Using a 14 mm union nut wrench, remove the No. 3 exhaust gas temperature sensor from the exhaust
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1GD-FTV EMISSION CONTROL FUEL TANK CAP INSPECTION
PROCEDURE
1.INSPECT FUEL TANK CAP ASSEMBLY 77310A
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*1 Gasket
Visually check that the fuel tank cap assembly and gasket are not deformed or damaged.
If necessary, replace the fuel tank cap assembly or gasket.
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1GD-FTV EMISSION CONTROL MONOLITHIC CONVERTER(w/ DPF) COMPONENTS
ILLUSTRATION
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*A for 2WD *B for 4WD and Pre-Runner

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*1 AIR CLEANER CAP AND HOSE *2 AIR CLEANER CASE SUB-ASSEMBLY

AIR CLEANER FILTER ELEMENT SUB-
*3 *4 FRONT FENDER SEAL
ASSEMBLY
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ILLUSTRATION

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*1 DIFFERENTIAL PRESSURE SENSOR *2 ENGINE COVER BRACKET

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*5 NO. 3 EXHAUST GAS TEMPERATURE SENSOR *6 NO. 1 VACUUM PIPE
*7 NO. 2 VACUUM PIPE *8 PIPE CLAMP
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ILLUSTRATION
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*A for RHD - -
ASSEMBLY
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*5 NO. 1 TURBO INSULATOR *6 NO. 2 EXHAUST PIPE SUPPORT STAY
*7 NO. 2 INTERMEDIATE SHAFT SUB-ASSEMBLY *8 UPPER ARM BUSH HEAT INSULATOR
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N*m (kgf*cm, ft.*lbf): Specified torque ● Precoated part

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1GD-FTV EMISSION CONTROL MONOLITHIC CONVERTER(w/ DPF) INSTALLATION
PROCEDURE
a. Set a new gasket and the exhaust manifold converter sub-assembly to the turbocharger sub-assembly.
b. Temporarily install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold
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converter sub-assembly with the 3 bolts.
c.
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*1 Exhaust Pipe Clamp
*2 Exhaust Manifold Converter
*3 Turbocharger Sub-assembly
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*4 Gasket
Install a new exhaust pipe clamp to the exhaust manifold converter sub-assembly with a new nut.
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Torque:
18 N*m (184 kgf*cm, 13 ft.*lbf)
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d. Tighten the 3 bolts and install the exhaust pipe support stay to the cylinder block sub-assembly and
exhaust manifold converter sub-assembly.
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Torque:
38 N*m (387 kgf*cm, 28 ft.*lbf)
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2.INSTALL NO. 2 EXHAUST PIPE SUPPORT STAY 17118

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a. Install the No. 2 exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold
converter sub-assembly with the bolt and 2 new nuts.
Torque:
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38 N*m (387 kgf*cm, 28 ft.*lbf)
a. Install the No. 1 turbo insulator to the exhaust manifold and turbocharger sub-assembly with the 3 bolts.
Torque:

a. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.
Torque:
5.INSTALL AIR FUEL RATIO SENSOR 89467B
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6.INSTALL UPPER ARM BUSH HEAT INSULATOR 48691
a. Install the upper arm bush heat insulator to the body with the 2 bolts.
Torque:
32 N*m (326 kgf*cm, 24 ft.*lbf)
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7.INSTALL NO. 2 INTERMEDIATE SHAFT SUB-ASSEMBLY (for RHD) 45203
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Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>INSTALLATION

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a. Install the engine cover bracket to the cylinder head sub-assembly with the 2 bolts.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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b. Attach the 2 clamps and connect the engine wire to the cylinder head sub-assembly.
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9.INSTALL PIPE CLAMP 17578B

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a. Install the pipe clamp to the engine cover bracket with the 3 bolts.
Torque:
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10.TEMPORARILY INSTALL NO. 2 VACUUM PIPE 25734
a. Install a new clamp to the pipe clamp.

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b. Temporarily install the No. 2 vacuum pipe to the exhaust manifold converter sub-assembly.
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11.TEMPORARILY INSTALL NO. 1 VACUUM PIPE 25733A
a. Temporarily install the No. 1 vacuum pipe to the exhaust manifold converter sub-assembly.
b. Install a new clamp to the No. 1 vacuum pipe and No. 2 vacuum pipe with the nut.
Torque:
6.0 N*m (61 kgf*cm, 53 in.*lbf)

12.TIGHTEN NO. 2 VACUUM PIPE 25734
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Using a 17 mm union nut wrench, tighten the No. 2 vacuum pipe.
Torque:
HINT:
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13.TIGHTEN NO. 1 VACUUM PIPE 25733A
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Using a 17 mm union nut wrench, tighten the No. 1 vacuum pipe.

Torque:
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HINT:

14.INSTALL EXHAUST GAS TEMPERATURE SENSOR 89425

SENSOR>INSTALLATION
15.INSTALL DIFFERENTIAL PRESSURE SENSOR 89481B

SENSOR>INSTALLATION
16.INSTALL AIR CLEANER CASE SUB-ASSEMBLY 17701
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17.INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 17801

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18.INSTALL AIR CLEANER CAP AND HOSE
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19.INSTALL FRONT FENDER SEAL 53882F

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a. for 2WD:
Install the front fender seal to the body with 5 new clips.
b. for 4WD and Pre-Runner:

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Install the front fender seal to the body with 6 new clips.
20.INSTALL FUEL ADDITION INJECTOR ASSEMBLY

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21.INSTALL FRONT EXHAUST PIPE ASSEMBLY 17410

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Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST PIPE>INSTALLATION

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1GD-FTV EMISSION CONTROL MONOLITHIC CONVERTER(w/ DPF) REMOVAL
CAUTION:
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PROCEDURE
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2.REMOVE FRONT EXHAUST PIPE ASSEMBLY 17410

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Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST PIPE>REMOVAL
3.REMOVE FUEL ADDITION INJECTOR ASSEMBLY

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INJECTOR>REMOVAL
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4.REMOVE FRONT FENDER SEAL 53882F

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a. for 2WD:
Remove the 5 clips and front fender seal from the body.
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b. for 4WD and Pre-Runner:

Remove the 6 clips and front fender seal from the body.
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5.REMOVE AIR CLEANER CAP AND HOSE

6.REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 17801


7.REMOVE AIR CLEANER CASE SUB-ASSEMBLY 17701

8.REMOVE DIFFERENTIAL PRESSURE SENSOR 89481B
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>DIFFERENTIAL PRESSURE SENSOR>REMOVAL
9.REMOVE EXHAUST GAS TEMPERATURE SENSOR 89425

SENSOR>REMOVAL
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10.REMOVE NO. 1 VACUUM PIPE 25733A
CAUTION:
engine is hot.
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Remove the nut and clamp from the No. 1 vacuum pipe and No. 2 vacuum pipe.
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b.
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Using a 17 mm union nut wrench, remove the No. 1 vacuum pipe from the exhaust manifold converter sub-
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assembly.
11.REMOVE NO. 2 VACUUM PIPE 25734
CAUTION:
engine is hot.

a.
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Using a 17 mm union nut wrench, remove the No. 2 vacuum pipe from the exhaust manifold converter sub-
assembly.
b.
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Remove the clamp from the pipe clamp.
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12.REMOVE PIPE CLAMP 17578B

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CAUTION:
engine is hot.
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a.
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Remove the 3 bolts and pipe clamp from the engine cover bracket.
13.REMOVE ENGINE COVER BRACKET 12631A
CAUTION:
engine is hot.

a.
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Detach the 2 clamp and disconnect the engine wire from the engine cover bracket.
b.
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Remove the 2 bolts and engine cover bracket from the cylinder head sub-assembly.
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14.REMOVE NO. 2 INTERMEDIATE SHAFT SUB-ASSEMBLY (for RHD) 45203

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Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>REMOVAL
15.REMOVE UPPER ARM BUSH HEAT INSULATOR 48691

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CAUTION:
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engine is hot.
a.
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Remove the 2 bolt and upper arm bush heat insulator from the body.
16.REMOVE AIR FUEL RATIO SENSOR 89467B

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>AIR FUEL RATIO SENSOR>REMOVAL
CAUTION:
engine is hot.
a.
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Remove the 3 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold.
18.REMOVE NO. 1 TURBO INSULATOR
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CAUTION:
engine is hot.
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a.
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Remove the 3 bolts and No. 1 turbo insulator from the exhaust manifold and turbocharger sub-assembly.
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19.REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY 17118

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CAUTION:
engine is hot.

a.
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Remove the bolt, 2 nuts and No. 2 exhaust pipe support stay from the cylinder block sub-assembly and
20.REMOVE EXHAUST PIPE SUPPORT STAY 17118
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CAUTION:
engine is hot.
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Remove the 3 bolts and exhaust pipe support stay from the cylinder block sub-assembly and exhaust
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21.REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 25051
CAUTION:
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engine is hot.
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a.
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Remove the nut, exhaust pipe clamp and exhaust manifold converter sub-assembly from the turbocharger
sub-assembly.
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1GD-FTV EMISSION CONTROL MONOLITHIC CONVERTER(w/o DPF) COMPONENTS
ILLUSTRATION
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*1 EXHAUST MANIFOLD CONVERTER SUB- *2 EXHAUST PIPE SUPPORT STAY

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ASSEMBLY
*5 NO. 2 EXHAUST PIPE SUPPORT STAY *6 GASKET
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*7 EXHAUST PIPE CLAMP - -
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1GD-FTV EMISSION CONTROL MONOLITHIC CONVERTER(w/o DPF) INSTALLATION
PROCEDURE
a. Set a new gasket and the exhaust manifold converter sub-assembly to the turbocharger sub-assembly.
b. Temporarily install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold
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converter sub-assembly with the 3 bolts.
c.
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*1 Exhaust Pipe Clamp
*2 Exhaust Manifold Converter Sub-assembly
*3 Turbocharger Sub-assembly
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*4 Gasket
Install a new exhaust pipe clamp to the exhaust manifold converter sub-assembly with a new nut.
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Torque:
18 N*m (184 kgf*cm, 13 ft.*lbf)
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d. Tighten the 3 bolts and install the exhaust pipe support stay to the cylinder block sub-assembly and
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Torque:
38 N*m (387 kgf*cm, 28 ft.*lbf)
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2.INSTALL NO. 2 EXHAUST PIPE SUPPORT STAY 17118

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a. Install the No. 2 exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold
converter sub-assembly with 2 new nuts and the bolt.
Torque:
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38 N*m (387 kgf*cm, 28 ft.*lbf)
a. Install the No. 1 turbo insulator to the exhaust manifold and turbocharger sub-assembly with the 3 bolts.
Torque:
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MMTN.html?PUB_TYPE=RM&MODE=1 Page 1 of 2

a. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.
Torque:
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Print Exit
1GD-FTV EMISSION CONTROL MONOLITHIC CONVERTER(w/o DPF) REMOVAL
CAUTION:
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PROCEDURE
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CAUTION:
engine is hot.
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3.REMOVE NO. 1 TURBO INSULATOR 17271
CAUTION:
engine is hot.
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MMTM.html?PUB_TYPE=RM&MODE=1 Page 1 of 3

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CAUTION:
engine is hot.
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CAUTION:
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engine is hot.
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CAUTION:
engine is hot.
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sub-assembly.

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1GD-FTV EMISSION CONTROL MONOLITHIC CONVERTER(w/o DPF) REMOVAL
CAUTION:
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PROCEDURE
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CAUTION:
engine is hot.
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a.
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CAUTION:
engine is hot.

a.
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CAUTION:
engine is hot.
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CAUTION:
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CAUTION:
engine is hot.
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sub-assembly.

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Slide the hose clamp and disconnect the No. 1 turbo water hose from the engine water pump assembly.
4.REMOVE ENGINE WATER PUMP ASSEMBLY 16100
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Remove the 8 bolts, engine water pump assembly and gasket.

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https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000MV8F.html?PUB_TYPE=RM&MODE=1 Page 2 of 2


· After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet
· The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or
dropped.
or dropped.
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PROCEDURE
1.REMOVE ENGINE ASSEMBLY
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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE UNIT>REMOVAL

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4.REMOVE ENGINE WIRE 82121
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5.REMOVE INTERCOOLER AIR TUBE 17363K

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8.REMOVE DIFFERENTIAL PRESSURE SENSOR (w/ DPF) 89481B

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9.REMOVE EXHAUST GAS TEMPERATURE SENSOR (w/ DPF) 89425

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SENSOR>REMOVAL
10.REMOVE NO. 1 VACUUM PIPE (w/ DPF) 25733A
Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHIC CONVERTER(w/ DPF)>REMOVAL
11.REMOVE NO. 2 VACUUM PIPE (w/ DPF) 25734

12.REMOVE PIPE CLAMP (w/ DPF) 17578B
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15.REMOVE DIESEL TURBO PRESSURE SENSOR 89421C

SENSOR>REMOVAL
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Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EGR COOLER>REMOVAL
19.REMOVE CONNECTING WIRE 27148A

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22.REMOVE NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY 16209

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23.REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC 25800
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24.REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 11409
Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>INTAKE MANIFOLD>REMOVAL
25.REMOVE NO. 2 FUEL PIPE 23812D
26.REMOVE WIRING HARNESS CLAMP BRACKET

27.REMOVE MANIFOLD STAY 17118
28.REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY 22803
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL SUPPLY PUMP>REMOVAL
29.REMOVE FUEL PUMP MOTOR WIRE 23243B
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30.REMOVE NO. 2 FUEL HOSE 23273H
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32.REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ DPF) 23804D
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33.REMOVE NO. 3 FUEL PIPE (w/ DPF) 23815D

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34.REMOVE FUEL INLET PIPE SUB-ASSEMBLY 23804C

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35.REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY 23770

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36.REMOVE INTAKE MANIFOLD 17111

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Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>REMOVAL
38.REMOVE NO. 1 FUEL PIPE (w/ DPF) 23811H

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INJECTOR>REMOVAL
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39.REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY 23760
41.REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY 23701

42.REMOVE HOSE BRACKET 44781
43.REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning 88431

System)
44.REMOVE IDLER PULLEY ASSEMBLY (w/o Air Conditioning System) 16630D
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45.REMOVE PCV PIPE (for Cold Area Specification Vehicles) 12229
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46.REMOVE NO. 5 WATER BY-PASS HOSE (w/ DPF) 16282
47.DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ DPF)
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16281
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48.REMOVE NO. 1 INJECTOR HOLDER (w/ DPF) 23295D
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INJECTOR>REMOVAL
49.REMOVE AIR FUEL RATIO SENSOR (w/ DPF) 89467B

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· w/ DPF:
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DPF)>REMOVAL
· w/o DPF:
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DPF)>REMOVAL
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· w/ DPF:
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DPF)>REMOVAL
· w/o DPF:
DPF)>REMOVAL
52.REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY
· w/ DPF:


DPF)>REMOVAL
· w/o DPF:
DPF)>REMOVAL
53.REMOVE EXHAUST PIPE SUPPORT STAY
· w/ DPF:
DPF)>REMOVAL
· w/o DPF:
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DPF)>REMOVAL
· w/ DPF:
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DPF)>REMOVAL
· w/o DPF:
DPF)>REMOVAL
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55.REMOVE PCV HOSE (except Cold Area Specification Vehicles) 12261
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58.DISCONNECT NO. 1 AND NO. 2 TURBO WATER HOSE 16284

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59.REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous 87101

Heater)
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60.REMOVE TURBOCHARGER STAY 17293

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61.REMOVE TURBO OIL OUTLET PIPE 15474

62.REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY 15407



65.REMOVE WATER OUTLET SUB-ASSEMBLY 16304
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68.REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY 16603
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Remove the bolt and No. 1 idler pulley sub-assembly from the generator bracket sub-assembly.
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69.REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 16620

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a.
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Remove the 3 bolts and V-ribbed belt tensioner assembly from the timing chain cover sub-assembly.

70.REMOVE VISCOUS HEATER CRANKSHAFT PULLEY (w/ Viscous Heater) 88451B
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>FRONT CRANKSHAFT OIL SEAL>REMOVAL
71.REMOVE CRANKSHAFT PULLY COVER 13496
72.REMOVE CRANKSHAFT PULLEY 13471
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73.REMOVE NO. 1 WATER HOSE CLAMP BRACKET (w/ DPF) 16575C
74.REMOVE NO. 1 ENGINE HANGER 12281A
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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE UNIT>DISASSEMBLY
75.REMOVE GENERATOR BRACKET SUB-ASSEMBLY 12501
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76.REMOVE INJECTOR ASSEMBLY 23670

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77.REMOVE NOZZLE HOLDER GASKET 23682
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78.REMOVE CAMSHAFT POSITION SENSOR 11401G

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Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>CAMSHAFT POSITION SENSOR>REMOVAL
79.REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 11201

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Bolt
Nut

Nozzle Holder Clamp Seat
Remove the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and cylinder head cover sub-assembly from the
cylinder head sub-assembly.
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*1 Cylinder Head Cover Gasket
*2 No. 2 Cylinder Head Cover Gasket
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*3 Camshaft Bearing Cap Oil Hole Gasket
Remove the cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil
hole gaskets from the cylinder head cover sub-assembly.
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80.REMOVE OIL PAN COVER SILENCER 12144
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Remove the 5 bolts and oil pan cover silencer from the oil pan sub-assembly.
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81.REMOVE ENGINE OIL LEVEL SENSOR 89491

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Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL LEVEL SENSOR>REMOVAL
82.REMOVE OIL PAN SUB-ASSEMBLY 12101

a.
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Bolt
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Nut
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Remove the 23 bolts and 2 nuts.
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Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and cylinder block sub-
assembly, cut off the applied sealer and remove the oil pan sub-assembly.
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NOTICE:
· Be careful not to damage the contact surfaces of the cylinder block sub-assembly and oil pan sub-
assembly.
· Be careful not to damage the cylinder block sub-assembly flange.
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Click hereEngine / Hybrid System>1GD-FTV COOLING>WATER PUMP>REMOVAL
84.SET NO. 1 CYLINDER TO TDC/COMPRESSION
85.REMOVE TIMING CHAIN COVER PLATE 11324
https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000M7T3.html?PUB_TYPE=RM&MODE=1 Page 10 of 15

86.REMOVE SUPPLY PUMP ASSEMBLY 22100
87.REMOVE INJECTION PUMP INSULATOR 22815A
88.REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 11302
a.
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Remove the 20 bolts from the timing chain cover sub-assembly.
b. Using a screwdriver wrapped in protective tape, remove the timing chain cover sub-assembly by prying the
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points in the illustration.

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*a Protective Tape - -
NOTICE:
Do not damage the contacting surfaces of the timing chain cover sub-assembly and timing chain case
assembly.

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Remove the timing chain case gasket from the timing chain case assembly.
89.REMOVE FRONT CRANKSHAFT OIL SEAL 11303A
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*a Protective Tape
*b Wooden Block
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Using a screwdriver and wooden block, pull out the front crankshaft oil seal.
NOTICE:
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Do not damage the surface of the front crankshaft oil seal press fit hole.
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90.INSPECT BACKLASH OF OIL PUMP GEAR TO OIL PUMP DRIVE GEAR
a.
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Using a dial indicator, measure the backlash.

Standard gear backlash:
0.02 to 0.3 mm (0.000787 to 0.0118 in.)

Maximum gear backlash:

0.42 mm (0.0165 in.)
If the gear backlash is more than the maximum, replace the timing chain case assembly or oil pump drive
gear.
91.REMOVE OIL PUMP DRIVE GEAR 13519
a.
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Remove the oil pump drive gear from the crankshaft.
92.REMOVE TIMING CHAIN GUIDE
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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>CAMSHAFT>REMOVAL
93.REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY 13550

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94.REMOVE NO. 2 CHAIN TENSIONER SLIPPER

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13562
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95.REMOVE NO. 2 CHAIN VIBRATION DAMPER

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96.REMOVE NO. 2 CHAIN SUB-ASSEMBLY 13507

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98.REMOVE NO. 1 CHAIN TENSIONER SLIPPER 13559

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99.REMOVE NO. 1 CHAIN VIBRATION DAMPER 13561
100.REMOVE CRANKSHAFT TIMING SPROCKET, INJECTION PUMP DRIVE GEAR 13506

WITH NO. 1 CHAIN SUB-ASSEMBLY

101.REMOVE CAMSHAFT TIMING SPROCKET 13523
102.REMOVE TIMING CHAIN CASE ASSEMBLY 11310
a.
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Remove the 15 bolts from the timing chain case assembly.
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b. Using a screwdriver wrapped in protective tape, remove the timing chain case assembly by prying the
points in the illustration.
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*a Protective Tape - -
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NOTICE:
Do not damage the contacting surfaces of the timing chain case assembly, cylinder head sub-assembly
and cylinder block sub-assembly.

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Remove the 4 O-rings from the cylinder head sub-assembly and cylinder block sub-assembly.
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Print Exit
1GD-FTV ENGINE MECHANICAL CAMSHAFT COMPONENTS
ILLUSTRATION
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*7 RADIATOR RESERVE TANK ASSEMBLY *8 VANE PUMP OIL RESERVOIR ASSEMBLY

*9 OIL RETURN HOSE *10 NO. 3 AIR TUBE
ILLUSTRATION
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000LWOQ.html?PUB_TYPE=RM&MODE=1 Page 1 of 8

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*A for Automatic Transmission - -

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*7 SUCTION HOSE SUB-ASSEMBLY *8 FAN WITH FLUID COUPLING ASSEMBLY
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*9 FAN PULLEY *10 FAN AND GENERATOR V BELT

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ILLUSTRATION

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*A for Cold Area Specification Vehicles *B except Cold Area Specification Vehicles
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*C w/ DPF - -
*1 DIESEL THROTTLE BODY ASSEMBLY *2 ENGINE WIRE
*3 FUEL FILTER ASSEMBLY *4 GAS FILTER
*5 NO. 1 FUEL PIPE *6 NO. 2 ENGINE COVER BRACKET
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*9 TURBO PRESSURE SENSOR *10 GASKET
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*11 EMISSION CONTROL VALVE WIRE *12 NO. 11 WATER BY-PASS HOSE
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ILLUSTRATION
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VALVE ASSEMBLY
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*15 STUD BOLT - -

ILLUSTRATION
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*1 HARNESS BRACKET *2 INJECTOR ASSEMBLY

*3 NO. 1 INJECTION PIPE SUB-ASSEMBLY *4 NO. 2 INJECTION PIPE SUB-ASSEMBLY
*5 NOZZLE HOLDER GASKET *6 NOZZLE LEAKAGE PIPE ASSEMBLY
*7 WIRING HARNESS CLAMP BRACKET *8 GASKET
*9 UNION BOLT *10 NO. 5 FUEL HOSE
*11 WASHER *12 NOZZLE HOLDER CLAMP
*13 NOZZLE HOLDER CLAMP BOLT *14 O-RING

*15 INJECTION NOZZLE SEAT - -

N*m (kgf*cm, ft.*lbf) : Specified torque
ft.*lbf)
* For use with SST Engine oil
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ILLUSTRATION
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*3 OIL FILLER CAP SUB-ASSEMBLY *4 NOZZLE HOLDER CLAMP SEAT

*5 CYLINDER HEAD COVER GASKET *6 CAMSHAFT BEARING CAP OIL HOLE GASKET
*7 NO. 2 CYLINDER HEAD COVER GASKET *8 GASKET
*9 OIL PUMP RELIEF VALVE PLUG - -

ILLUSTRATION
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*1 CAMSHAFT OIL SEAL RETAINER *2 NO. 1 CAMSHAFT

*3 NO. 2 CAMSHAFT *4 NO. 3 CAMSHAFT BEARING CAP
*5 TIMING CHAIN GUIDE *6 VACUUM PUMP ASSEMBLY
*7 NO. 1 CAMSHAFT BEARING CAP *8 NO. 2 CAMSHAFT BEARING CAP
*9 O-RING *10 NO. 2 CHAIN SUB-ASSEMBLY
*11 CAMSHAFT TIMING SPROCKET - -


ft.*lbf)
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1GD-FTV ENGINE MECHANICAL CAMSHAFT COMPONENTS
ILLUSTRATION
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*9 OIL RETURN HOSE *10 NO. 3 AIR TUBE
ILLUSTRATION

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*A for Automatic Transmission - -

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*7 SUCTION HOSE SUB-ASSEMBLY *8 FAN WITH FLUID COUPLING ASSEMBLY
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ILLUSTRATION

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*A for Cold Area Specification Vehicles *B except Cold Area Specification Vehicles
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*C w/ DPF - -
*1 DIESEL THROTTLE BODY ASSEMBLY *2 ENGINE WIRE
*3 FUEL FILTER ASSEMBLY *4 GAS FILTER
*5 NO. 1 FUEL PIPE *6 NO. 2 ENGINE COVER BRACKET
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*9 TURBO PRESSURE SENSOR *10 GASKET
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*11 EMISSION CONTROL VALVE WIRE *12 NO. 11 WATER BY-PASS HOSE
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ILLUSTRATION
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VALVE ASSEMBLY
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*15 STUD BOLT - -

ILLUSTRATION
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*5 NOZZLE HOLDER GASKET *6 NOZZLE LEAKAGE PIPE ASSEMBLY
*7 WIRING HARNESS CLAMP BRACKET *8 GASKET
*9 UNION BOLT *10 NO. 5 FUEL HOSE
*11 WASHER *12 NOZZLE HOLDER CLAMP
*13 NOZZLE HOLDER CLAMP BOLT *14 O-RING

*15 INJECTION NOZZLE SEAT - -

ft.*lbf)
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ILLUSTRATION
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*3 OIL FILLER CAP SUB-ASSEMBLY *4 NOZZLE HOLDER CLAMP SEAT

*5 CYLINDER HEAD COVER GASKET *6 CAMSHAFT BEARING CAP OIL HOLE GASKET
*7 NO. 2 CYLINDER HEAD COVER GASKET *8 GASKET
*9 OIL PUMP RELIEF VALVE PLUG - -

ILLUSTRATION
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*1 CAMSHAFT OIL SEAL RETAINER *2 NO. 1 CAMSHAFT

*3 NO. 2 CAMSHAFT *4 NO. 3 CAMSHAFT BEARING CAP
*5 TIMING CHAIN GUIDE *6 VACUUM PUMP ASSEMBLY
*9 O-RING *10 NO. 2 CHAIN SUB-ASSEMBLY
*11 CAMSHAFT TIMING SPROCKET - -


ft.*lbf)
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1GD-FTV ENGINE MECHANICAL CAMSHAFT INSTALLATION
NOTICE:
Injector assembly (including shuffling the · No. 1 injection pipe sub-assembly
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injector assemblies between the cylinders) · No. 2 injection pipe sub-assembly

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· Fuel inlet pipe sub-assembly
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dropped.
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PROCEDURE
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1.INSTALL CAMSHAFT
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*1 Valve Rocker Arm Sub-assembly

*2 Valve Stem Cap
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*3 Valve Lash adjuster assembly
Check that the valve rocker arm sub-assembly is firmly set to the valve lash adjuster assembly.
b. Apply a light coat of engine oil to the camshaft journals of the cylinder head sub-assembly and the thrust
portion of the camshaft.
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000LWOS.html?PUB_TYPE=RM&MODE=1 Page 1 of 10

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*a Paint Mark
*b Timing Mark
Align the paint mark of the No. 2 chain sub-assembly and timing mark of the camshaft timing sprocket, and
install the camshaft timing sprocket to the No. 2 chain sub-assembly.
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HINT:
Make sure the timing mark of the camshaft timing sprocket face the front side.
d.
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Align the knock pin of the No. 1 camshaft to the groove of the sprocket and install the No. 1 camshaft to
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the camshaft timing sprocket, and set the bolt.
e.
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*a Paint Mark
*b Timing Mark

HINT:
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HINT:
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*a Glove
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Glove is at the rear end of the No. 2 camshaft.

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*a Paint Mark
*b Timing Mark
Check the timing mark of the camshaft timing sprocket and paint mark of the No. 2 chain sub-assembly.
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Set the No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps to the cylinder head sub-assembly
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i. Temporarily install the 20 bolts.
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Bolt A
Bolt B

Uniformly tighten the 20 bolts in several steps in the order shown in the illustration.
Torque:
for bolt A : 10 N*m (102 kgf*cm, 7 ft.*lbf)
for bolt B : 21 N*m (214 kgf*cm, 15 ft.*lbf)
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*1 No. 1 Camshaft
*2 No. 2 Camshaft
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Hold the hexagonal portion of the No. 1 camshaft and No. 2 camshaft with a wrench, and tighten the 2
bolts.
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Torque:
81 N*m (826 kgf*cm, 60 ft.*lbf)
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NOTICE:
Be careful not to damage the cylinder head sub-assembly with the wrench.
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l. Remove the pin from the No. 2 chain tensioner assembly.
m. Install a new gasket and the oil pump relief valve plug to the timing chain cover.
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Torque:
46 N*m (469 kgf*cm, 34 ft.*lbf)
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a. Install the timing chain guide to the cylinder head sub-assembly with the bolt.
Torque:

3.INSTALL CAMSHAFT OIL SEAL RETAINER 11382C
Click hereBrake>BRAKE SYSTEM (OTHER)>VACUUM PUMP(for 1GD-FTV, 2GD-FTV)>INSTALLATION
4.TEMPORARILY INSTALL VACUUM PUMP ASSEMBLY 29300
5.INSTALL NO. 3 CAMSHAFT BEARING CAP
a. Clean and degrease the contact surfaces of the cylinder head sub-assembly and No. 3 camshaft bearing
cap.
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b.
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*a Seal Packing
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Apply seal packing to the specified areas as shown in the illustration.
Seal packing:
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3.0 mm (0.118 in.)
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NOTICE:
· Do not allow seal packing to contact the oil passage of the No. 3 camshaft bearing cap.
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· After applying seal packing, install the No. 3 camshaft bearing cap within 3 minutes and tighten
the bolts within 10 minutes.
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c. Install the No. 3 camshaft bearing cap with the 2 bolts.

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Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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d. Wipe off excess seal packing from between No. 3 camshaft bearing cap and cylinder head sub-assembly.
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6.INSTALL VACUUM PUMP ASSEMBLY 29300
Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL PUMP>INSTALLATION

10.TEMPORARILY INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE
SUB-ASSEMBLY
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12.TIGHTEN NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE SUB-
ASSEMBLY
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14.INSTALL HARNESS BRACKET

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16.INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR
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29.INSTALL NO. 1 FUEL PIPE (w/ DPF)
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39.INSTALL RADIATOR RESERVE TANK ASSEMBLY 16470
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47.INSTALL FRONT BUMPER
Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER(for Steel Type Bumper)>INSTALLATION

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49.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION
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53.INSPECT FOR FUEL LEAK
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1GD-FTV ENGINE MECHANICAL CAMSHAFT INSTALLATION
NOTICE:
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dropped.
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PROCEDURE
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1.INSTALL CAMSHAFT
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*1 Valve Rocker Arm Sub-assembly

*2 Valve Stem Cap
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Check that the valve rocker arm sub-assembly is firmly set to the valve lash adjuster assembly.

c.
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*a Paint Mark
*b Timing Mark
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HINT:
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e.
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*a Paint Mark
*b Timing Mark

HINT:
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*a Glove
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*a Paint Mark
*b Timing Mark
Check the timing mark of the camshaft timing sprocket and paint mark of the No. 2 chain sub-assembly.
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Bolt A
Bolt B

Uniformly tighten the 20 bolts in several steps in the order shown in the illustration.
Torque:
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*1 No. 1 Camshaft
*2 No. 2 Camshaft
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Hold the hexagonal portion of the No. 1 camshaft and No. 2 camshaft with a wrench, and tighten the 2
bolts.
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Torque:
81 N*m (826 kgf*cm, 60 ft.*lbf)
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NOTICE:
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l. Remove the pin from the No. 2 chain tensioner assembly.
m. Install a new gasket and the oil pump relief valve plug to the timing chain cover.
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Torque:
46 N*m (469 kgf*cm, 34 ft.*lbf)
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a. Install the timing chain guide to the cylinder head sub-assembly with the bolt.
Torque:

4.TEMPORARILY INSTALL VACUUM PUMP ASSEMBLY 29300
a. Clean and degrease the contact surfaces of the cylinder head sub-assembly and No. 3 camshaft bearing
cap.
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b.
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*a Seal Packing
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Seal packing:
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3.0 mm (0.118 in.)
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NOTICE:
· Do not allow seal packing to contact the oil passage of the No. 3 camshaft bearing cap.
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· After applying seal packing, install the No. 3 camshaft bearing cap within 3 minutes and tighten
the bolts within 10 minutes.
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c. Install the No. 3 camshaft bearing cap with the 2 bolts.

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Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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10.TEMPORARILY INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE
SUB-ASSEMBLY
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12.TIGHTEN NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE SUB-
ASSEMBLY
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16.INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR
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29.INSTALL NO. 1 FUEL PIPE (w/ DPF)
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39.INSTALL RADIATOR RESERVE TANK ASSEMBLY 16470
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47.INSTALL FRONT BUMPER

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1GD-FTV ENGINE MECHANICAL CAMSHAFT REMOVAL
parts are removed, installed, or replaced during the camshaft removal/installation are shown below.
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w/ Stop and Start System: Drive the vehicle until stop
Battery terminal is and start control is
Stop and start system
disconnected/reconnected permitted (approximately 5
to 40 minutes)
· Injector
w/o DPF
compensation code
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Replacement of injector registration ( )
Engine starting
assembly · Pilot quantity w/ DPF
learning ( )
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· Replacement of diesel
· Replacement of electric
EGR control valve
assembly w/o DPF
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· Replacement of ( )
w/ DPF
assembly
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turbocharger sub-
assembly or turbocharger
variable nozzle motor
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CAUTION:
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engine is hot.
NOTICE:

https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000LWOR.html?PUB_TYPE=RM&MODE=1 Page 1 of 10


· Common rail assembly · No. 1 injection pipe sub-assembly
· Cylinder block sub-assembly · No. 2 injection pipe sub-assembly
· Cylinder head sub-assembly · Fuel inlet pipe sub-assembly
dropped.
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PROCEDURE
1. PRECAUTION
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NOTICE:
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the
battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice
before proceeding with work.
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2.DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

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NOTICE:
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5.REMOVE FRONT BUMPER

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13.REMOVE RADIATOR RESERVE TANK ASSEMBLY 16470
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16.REMOVE FAN SHROUD

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INJECTOR>REMOVAL

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34.REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

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38.REMOVE HARNESS BRACKET

40.REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE SUB-ASSEMBLY
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43.REMOVE CAMSHAFT POSITION SENSOR 11301M
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Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL PUMP>REMOVAL
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*a Timing Mark
*b Paint Mark
Align the timing mark of the crankshaft pulley and timing chain cover by rotating the crankshaft clockwise.
b. Make sure that the timing mark of the camshaft timing sprocket is at the top.
HINT:
If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark is at
the top (set the No. 1 piston to TDC/compression).

c. Place paint marks on the No. 2 chain sub-assembly.
46.REMOVE NO. 3 CAMSHAFT BEARING CAP
a.
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Remove the 2 bolts and No. 3 camshaft bearing cap from the cylinder head sub-assembly.
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47.REMOVE VACUUM PUMP ASSEMBLY 29300
Click hereBrake>BRAKE SYSTEM (OTHER)>VACUUM PUMP(for 1GD-FTV, 2GD-FTV)>REMOVAL

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48.REMOVE CAMSHAFT OIL SEAL RETAINER 11382C

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49.REMOVE TIMING CHAIN GUIDE 13566B
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Remove the bolt and timing chain guide from the cylinder head sub-assembly.
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50.REMOVE CAMSHAFT

a.
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Remove the oil pump relief valve plug and gasket from timing chain cover.
b.
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*a Stopper Plate
*b Pin
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Insert a pin into stopper plate hole of the No. 2 chain tensioner assembly and lock the No. 2 chain
tensioner assembly.
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*1 No. 1 Camshaft
*2 No. 2 Camshaft
Hold the hexagonal portion of the camshaft with a wrench and loosen the 2 bolts from the No. 1 camshaft
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and No. 2 camshaft.
NOTICE:
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Using several steps, remove the 20 bolts, No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps
from the cylinder head sub-assembly.

e.
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Raise the No. 1 camshaft and remove the bolt from the No. 1 camshaft.
f. Raise the No. 2 camshaft and remove the bolt from the No. 2 camshaft.
g.
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Remove the No. 2 camshaft from the camshaft timing sprocket.
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Remove the camshaft timing sprocket from the No. 2 chain sub-assembly.
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Suspend the No. 2 chain sub-assembly with a string or equivalent.

HINT:
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Be careful not to drop the No. 2 chain sub-assembly inside the timing chain cover assembly.
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Print Exit
1GD-FTV ENGINE MECHANICAL CAMSHAFT REMOVAL
parts are removed, installed, or replaced during the camshaft removal/installation are shown below.
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w/ Stop and Start System: Drive the vehicle until stop
Battery terminal is and start control is
Stop and start system
disconnected/reconnected permitted (approximately 5
to 40 minutes)
· Injector
w/o DPF
compensation code
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Engine starting
learning ( )
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· Replacement of electric
EGR control valve
assembly w/o DPF
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w/ DPF
assembly
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turbocharger sub-
assembly or turbocharger
variable nozzle motor
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CAUTION:
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engine is hot.
NOTICE:



· Cylinder block sub-assembly · No. 2 injection pipe sub-assembly
· Cylinder head sub-assembly · Fuel inlet pipe sub-assembly
dropped.
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PROCEDURE
1. PRECAUTION
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NOTICE:
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5.REMOVE FRONT BUMPER

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13.REMOVE RADIATOR RESERVE TANK ASSEMBLY 16470
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16.REMOVE FAN SHROUD

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INJECTOR>REMOVAL

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34.REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

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40.REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY AND NO. 2 INJECTION PIPE SUB-ASSEMBLY
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43.REMOVE CAMSHAFT POSITION SENSOR 11301M
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*a Timing Mark
*b Paint Mark
Align the timing mark of the crankshaft pulley and timing chain cover by rotating the crankshaft clockwise.
b. Make sure that the timing mark of the camshaft timing sprocket is at the top.
HINT:

c. Place paint marks on the No. 2 chain sub-assembly.
a.
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Remove the 2 bolts and No. 3 camshaft bearing cap from the cylinder head sub-assembly.
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Remove the bolt and timing chain guide from the cylinder head sub-assembly.
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50.REMOVE CAMSHAFT

a.
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Remove the oil pump relief valve plug and gasket from timing chain cover.
b.
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*a Stopper Plate
*b Pin
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Insert a pin into stopper plate hole of the No. 2 chain tensioner assembly and lock the No. 2 chain
tensioner assembly.
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*1 No. 1 Camshaft
*2 No. 2 Camshaft
Hold the hexagonal portion of the camshaft with a wrench and loosen the 2 bolts from the No. 1 camshaft
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and No. 2 camshaft.
NOTICE:
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Using several steps, remove the 20 bolts, No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps
from the cylinder head sub-assembly.

e.
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Raise the No. 1 camshaft and remove the bolt from the No. 1 camshaft.
f. Raise the No. 2 camshaft and remove the bolt from the No. 2 camshaft.
g.
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Suspend the No. 2 chain sub-assembly with a string or equivalent.

HINT:
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Be careful not to drop the No. 2 chain sub-assembly inside the timing chain cover assembly.
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Print Exit
1GD-FTV ENGINE MECHANICAL CYLINDER BLOCK COMPONENTS
ILLUSTRATION
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*1 NO. 1 CONNECTING ROD BEARING *2 NO. 2 CONNECTING ROD BEARING
*3 CRANKSHAFT *4 CYLINDER BLOCK WATER DRAIN COCK SUB-

ASSEMBLY
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*5 NO. 1 OIL NOZZLE SUB-ASSEMBLY *6 CONNECTING ROD SUB-ASSEMBLY

*7 PISTON RING SET *8 PISTON
*9 PISTON PIN *10 NO. 1 COMPRESSION RING
*11 NO. 2 COMPRESSION RING *12 OIL RING RAIL
*13 OIL RING EXPANDER *14 PISTON PIN HOLE SNAP RING
*15 CONNECTING ROD CAP *16 CONNECTING ROD BOLT
*17 CYLINDER BLOCK WATER DRAIN COCK PLUG *18 UPPER CRANKSHAFT THRUST WASHER
*19 LOWER CRANKSHAFT THRUST WASHER *20 NO. 1 CRANKSHAFT BEARING
*21 NO. 2 CRANKSHAFT BEARING *22 CRANKSHAFT BEARING CAP
*23 CRANKSHAFT BEARING CAP SET BOLT - -

moving/turning/stopping": N*m (kgf*cm,
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ft.*lbf)
● Non-reusable part Precoated part
*T1 1st: 40 (408, 30) *T2 1st: 95 (969, 70)

2nd: Turn 90° 2nd: Turn 90°
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ILLUSTRATION
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*1 RING PIN *2 STRAIGHT PIN

*3 STUD BOLT - -
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Print Exit
1GD-FTV ENGINE MECHANICAL CYLINDER BLOCK COMPONENTS
ILLUSTRATION
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*1 NO. 1 CONNECTING ROD BEARING *2 NO. 2 CONNECTING ROD BEARING
*3 CRANKSHAFT *4 CYLINDER BLOCK WATER DRAIN COCK SUB-

ASSEMBLY
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*5 NO. 1 OIL NOZZLE SUB-ASSEMBLY *6 CONNECTING ROD SUB-ASSEMBLY

*7 PISTON RING SET *8 PISTON
*9 PISTON PIN *10 NO. 1 COMPRESSION RING
*11 NO. 2 COMPRESSION RING *12 OIL RING RAIL
*13 OIL RING EXPANDER *14 PISTON PIN HOLE SNAP RING
*15 CONNECTING ROD CAP *16 CONNECTING ROD BOLT
*17 CYLINDER BLOCK WATER DRAIN COCK PLUG *18 UPPER CRANKSHAFT THRUST WASHER
*19 LOWER CRANKSHAFT THRUST WASHER *20 NO. 1 CRANKSHAFT BEARING
*21 NO. 2 CRANKSHAFT BEARING *22 CRANKSHAFT BEARING CAP
*23 CRANKSHAFT BEARING CAP SET BOLT - -

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ft.*lbf)
● Non-reusable part Precoated part
*T1 1st: 40 (408, 30) *T2 1st: 95 (969, 70)

2nd: Turn 90° 2nd: Turn 90°
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ILLUSTRATION
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*3 STUD BOLT - -
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Print Exit
1GD-FTV ENGINE MECHANICAL CYLINDER BLOCK DISASSEMBLY
PROCEDURE
1.INSPECT CONNECTING ROD SUB-ASSEMBLY THRUST CLEARANCE
a.
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Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back
and forth.
Standard thrust clearance:
0.10 to 0.45 mm (0.00394 to 0.0177 in.)
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Maximum thrust clearance:
0.45 mm (0.0177 in.)
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If the thrust clearance is more than the maximum, replace the connecting rod sub-assembly. If necessary,
replace the crankshaft.
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2.INSPECT CONNECTING ROD SUB-ASSEMBLY OIL CLEARANCE
a.
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Remove the 2 connecting rod bolts.
b. Using the 2 removed connecting rod bolts, move the connecting rod cap back and forth to remove the
connecting rod cap from the connecting rod sub-assembly.
HINT:
Keep the connecting rod bearing and connecting rod cap together.
c. Clean the crank pin and connecting rod bearing.
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000LWPL.html?PUB_TYPE=RM&MODE=1 Page 1 of 8

d. Check the crank pin and connecting rod bearing for pitting and scratches.
If the crank pin or connecting rod bearing is damaged, replace the connecting rod bearings. If necessary,
e.
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*a Plastigage
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Lay a strip of Plastigage on the crank pin.
f. Install the connecting rod cap to the connecting rod sub-assembly.

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>CYLINDER BLOCK>REASSEMBLY
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NOTICE:
Do not turn the crankshaft.
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g. Remove the 2 connecting rod bolts and connecting rod cap from the connecting rod sub-assembly.
HINT:
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h. Measure the Plastigage at its widest point.

Standard oil clearance:
0.042 to 0.048 mm (0.00165 to 0.00189 in.)
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Maximum oil clearance:

0.054 mm (0.00213 in.)
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NOTICE:
Remove the Plastigage completely after the measurement.
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If the oil clearance is more than the maximum, replace the connecting rod bearing. If necessary, grind or
HINT:
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If using a standard connecting rod bearing, replace it with one that has the same number. If the number
of the connecting rod bearing cannot be determined, select the correct connecting rod bearing by adding
together the numbers imprinted on the crankshaft and connecting rod cap, and then selecting the
connecting rod bearing with the same number as the total. There are 5 sizes of standard connecting rod
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bearings, marked 2, 3, 4, 5 and 6.

EXAMPLE:
Connecting rod cap (A) "3" + Crankshaft (B) "1" = Total number 4 (Use connecting rod bearing (C) "4")
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Use
Connecting Crankshaft Connecting
Rod Cap (A) (B) Rod Bearing
(C)
1 2
1 2 3
3 4
1 3
2 4
2

3 5
1 4
3 2 5
3 6
Standard Connecting Rod Sub-assembly Big End Inside Diameter (A):

58.014 to 58.020 mm
Mark 1
(2.2840 to 2.2842 in.)
58.020 to 58.026 mm
Mark 2
(2.2842 to 2.2845 in.)
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58.026 to 58.032 mm
Mark 3
(2.2845 to 2.2847 in.)
Standard Crank Pin Diameter (B):

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54.994 to 55.000 mm
Mark 1
(2.1651 to 2.1654 in.)
54.988 to 54.994 mm
Mark 2
(2.1649 to 2.1651 in.)
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54.982 to 54.988 mm
Mark 3
(2.1646 to 2.1649 in.)
Standard Sized Connecting Rod Bearing Center Wall Thickness (C):

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1.486 to 1.489 mm
Mark 2
(0.0585 to 0.0586 in.)
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1.489 to 1.492 mm
Mark 3
(0.0586 to 0.0587 in.)
1.492 to 1.495 mm
Mark 4
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(0.0587 to 0.0589 in.)

1.495 to 1.498 mm
Mark 5
(0.0589 to 0.0590 in.)
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1.498 to 1.501 mm
Mark 6
(0.0590 to 0.0591 in.)
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*1 No. 1 Connecting Rod Bearing *2 No. 2 Connecting Rod Bearing
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*a Plastigage *b Front Side
Connecting Rod Sub-assembly Big End Inside
Connecting Rod Bearing:
*c Diameter: *d
Mark 2, 3, 4, 5 or 6
Mark 1, 2 or 3
Crank Pin Diameter:
*e *f No. 1
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Mark 1, 2 or 3
*g No. 2 *h No. 3
*i No. 4 - -
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i. Completely remove the Plastigage from the crank pin.

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3.REMOVE PISTON AND CONNECTING ROD SUB-ASSEMBLY

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a.
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Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. Push out the piston and connecting rod sub-assembly with connecting rod bearing through the top of the
cylinder block sub-assembly to remove them.
HINT:
· Keep the connecting rod sub-assembly and connecting rod cap together.
· Arrange the piston and connecting rod sub-assemblies in the correct order.
· Be sure to arrange the removed piston and connecting rod sub-assemblies in such a way that they
can be reinstalled exactly as before.
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4.REMOVE CONNECTING ROD BEARING 13041
a. Remove the No. 1 connecting rod bearings and No. 2 connecting rod bearings from the connecting rod sub-
assemblies and connecting rod caps.
HINT:
Arrange the removed parts in the correct order.
5.REMOVE PISTON RING SET 13011
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HINT:
Arrange the piston rings in the correct order.
a.
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Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the
piston.
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b. Using a piston ring expander, remove the oil ring rail from the piston.
c. Remove the oil ring expander from the piston by hand.

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6.REMOVE PISTON WITH PIN SUB-ASSEMBLY 13101

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*1 Piston Pin Hole Snap Ring
Using a small screwdriver, pry out the front side piston pin hole snap ring from the piston.
b. Gradually heat the piston to approximately 80°C (176°F).

CAUTION:
Be sure to wear protective gloves.
c. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin from the piston. Then remove the
connecting rod sub-assembly.
HINT:
· The piston and piston pin are a matched set.
· Be sure to organize the removed pistons, piston pins, piston rings, connecting rod sub-assemblies
and connecting rod bearings in such a way that the parts can be reinstalled exactly as before.
· Arrange the pistons, piston pins, connecting rod sub-assemblies and connecting rod bearings in
the correct order.
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7.INSPECT CRANKSHAFT THRUST CLEARANCE
a.
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Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth
with a screwdriver.
0.04 to 0.24 mm (0.00157 to 0.00945 in.)
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0.24 mm (0.00945 in.)
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If the thrust clearance is more than the maximum, replace the upper crankshaft thrust washers and lower
crankshaft thrust washers. If necessary, replace the crankshaft.
Standard crankshaft thrust washer thickness:
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2.2 to 2.8 mm (0.0866 to 0.110 in.)

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8.REMOVE CRANKSHAFT 13411

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a.
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Using several steps, uniformly loosen and remove the 10 crankshaft bearing cap set bolts in the sequence
shown in the illustration.
b.
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Using the removed crankshaft bearing cap set bolts, pry the crankshaft bearing cap back and forth and
remove the crankshaft bearing caps, No. 2 crankshaft bearings and lower crankshaft thrust washers (No. 5
crankshaft journal only).
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HINT:
· Keep the No. 2 crankshaft bearing and crankshaft bearing cap together.
· Be sure to organize the crankshaft bearing caps and lower crankshaft thrust washers (No. 5
crankshaft journal only) in such a way that they can be reinstalled exactly as before.
c.
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Remove the crankshaft from the cylinder block sub-assembly.
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d.
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Remove the 2 upper crankshaft thrust washers (No. 5 cylinder block sub-assembly journal only) from the
cylinder block sub-assembly.
HINT:
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Arrange the upper crankshaft thrust washers in the correct order.

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e.
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Remove the 5 No. 1 crankshaft bearings from the cylinder block sub-assembly.
HINT:
Arrange the No. 1 crankshaft bearings in the correct order.
f. Check each crankshaft journal, No. 1 crankshaft bearings and No. 2 crankshaft bearings for pitting and
scratches.
If the journal or crankshaft bearing is damaged, replace the crankshaft bearings. If necessary, replace the
crankshaft.
9.REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 15708
a.
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Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder
block sub-assembly.
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10.REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 11415
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Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.
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b. Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.
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11.REMOVE STUD BOLT
NOTICE:
If a stud bolt is deformed or its threads are damaged, replace it.

Print Exit
1GD-FTV ENGINE MECHANICAL CYLINDER BLOCK DISASSEMBLY
PROCEDURE
a.
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Using a dial indicator, measure the thrust clearance while moving the connecting rod sub-assembly back
and forth.
0.10 to 0.45 mm (0.00394 to 0.0177 in.)
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0.45 mm (0.0177 in.)
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If the thrust clearance is more than the maximum, replace the connecting rod sub-assembly. If necessary,
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2.INSPECT CONNECTING ROD SUB-ASSEMBLY OIL CLEARANCE
a.
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Remove the 2 connecting rod bolts.
b. Using the 2 removed connecting rod bolts, move the connecting rod cap back and forth to remove the
connecting rod cap from the connecting rod sub-assembly.
HINT:
c. Clean the crank pin and connecting rod bearing.

d. Check the crank pin and connecting rod bearing for pitting and scratches.
If the crank pin or connecting rod bearing is damaged, replace the connecting rod bearings. If necessary,
e.
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*a Plastigage
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Lay a strip of Plastigage on the crank pin.
f. Install the connecting rod cap to the connecting rod sub-assembly.

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>CYLINDER BLOCK>REASSEMBLY
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NOTICE:
Do not turn the crankshaft.
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g. Remove the 2 connecting rod bolts and connecting rod cap from the connecting rod sub-assembly.
HINT:
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h. Measure the Plastigage at its widest point.

0.042 to 0.048 mm (0.00165 to 0.00189 in.)
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Maximum oil clearance:

0.054 mm (0.00213 in.)
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NOTICE:
Remove the Plastigage completely after the measurement.
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If the oil clearance is more than the maximum, replace the connecting rod bearing. If necessary, grind or
HINT:
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If using a standard connecting rod bearing, replace it with one that has the same number. If the number
of the connecting rod bearing cannot be determined, select the correct connecting rod bearing by adding
together the numbers imprinted on the crankshaft and connecting rod cap, and then selecting the
connecting rod bearing with the same number as the total. There are 5 sizes of standard connecting rod
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bearings, marked 2, 3, 4, 5 and 6.

EXAMPLE:
Connecting rod cap (A) "3" + Crankshaft (B) "1" = Total number 4 (Use connecting rod bearing (C) "4")
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Use
Connecting Crankshaft Connecting
Rod Cap (A) (B) Rod Bearing
(C)
1 2
1 2 3
3 4
1 3
2 4
2

3 5
1 4
3 2 5
3 6
Standard Connecting Rod Sub-assembly Big End Inside Diameter (A):

58.014 to 58.020 mm
Mark 1
(2.2840 to 2.2842 in.)
58.020 to 58.026 mm
Mark 2
(2.2842 to 2.2845 in.)
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58.026 to 58.032 mm
Mark 3
(2.2845 to 2.2847 in.)
Standard Crank Pin Diameter (B):

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54.994 to 55.000 mm
Mark 1
(2.1651 to 2.1654 in.)
54.988 to 54.994 mm
Mark 2
(2.1649 to 2.1651 in.)
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54.982 to 54.988 mm
Mark 3
(2.1646 to 2.1649 in.)
Standard Sized Connecting Rod Bearing Center Wall Thickness (C):

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1.486 to 1.489 mm
Mark 2
(0.0585 to 0.0586 in.)
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1.489 to 1.492 mm
Mark 3
(0.0586 to 0.0587 in.)
1.492 to 1.495 mm
Mark 4
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(0.0587 to 0.0589 in.)

1.495 to 1.498 mm
Mark 5
(0.0589 to 0.0590 in.)
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1.498 to 1.501 mm
Mark 6
(0.0590 to 0.0591 in.)
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*1 No. 1 Connecting Rod Bearing *2 No. 2 Connecting Rod Bearing
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*a Plastigage *b Front Side
Connecting Rod Sub-assembly Big End Inside
Connecting Rod Bearing:
*c Diameter: *d
Mark 2, 3, 4, 5 or 6
Mark 1, 2 or 3
Crank Pin Diameter:
*e *f No. 1
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Mark 1, 2 or 3
*g No. 2 *h No. 3
*i No. 4 - -
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i. Completely remove the Plastigage from the crank pin.

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3.REMOVE PISTON AND CONNECTING ROD SUB-ASSEMBLY

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a.
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Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. Push out the piston and connecting rod sub-assembly with connecting rod bearing through the top of the
cylinder block sub-assembly to remove them.
HINT:
· Keep the connecting rod sub-assembly and connecting rod cap together.
· Arrange the piston and connecting rod sub-assemblies in the correct order.
· Be sure to arrange the removed piston and connecting rod sub-assemblies in such a way that they
can be reinstalled exactly as before.

4.REMOVE CONNECTING ROD BEARING 13041
a. Remove the No. 1 connecting rod bearings and No. 2 connecting rod bearings from the connecting rod sub-
assemblies and connecting rod caps.
HINT:
5.REMOVE PISTON RING SET 13011
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HINT:
Arrange the piston rings in the correct order.
a.
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Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring from the
piston.
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b. Using a piston ring expander, remove the oil ring rail from the piston.
c. Remove the oil ring expander from the piston by hand.

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6.REMOVE PISTON WITH PIN SUB-ASSEMBLY 13101

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Using a small screwdriver, pry out the front side piston pin hole snap ring from the piston.
b. Gradually heat the piston to approximately 80°C (176°F).

CAUTION:
c. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin from the piston. Then remove the
connecting rod sub-assembly.
HINT:
· The piston and piston pin are a matched set.
· Be sure to organize the removed pistons, piston pins, piston rings, connecting rod sub-assemblies
and connecting rod bearings in such a way that the parts can be reinstalled exactly as before.
· Arrange the pistons, piston pins, connecting rod sub-assemblies and connecting rod bearings in
the correct order.
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Using a dial indicator, measure the crankshaft thrust clearance while prying the crankshaft back and forth
with a screwdriver.
0.04 to 0.24 mm (0.00157 to 0.00945 in.)
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0.24 mm (0.00945 in.)
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If the thrust clearance is more than the maximum, replace the upper crankshaft thrust washers and lower
crankshaft thrust washers. If necessary, replace the crankshaft.
Standard crankshaft thrust washer thickness:
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2.2 to 2.8 mm (0.0866 to 0.110 in.)

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8.REMOVE CRANKSHAFT 13411

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a.
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Using several steps, uniformly loosen and remove the 10 crankshaft bearing cap set bolts in the sequence
b.
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Using the removed crankshaft bearing cap set bolts, pry the crankshaft bearing cap back and forth and
remove the crankshaft bearing caps, No. 2 crankshaft bearings and lower crankshaft thrust washers (No. 5
crankshaft journal only).
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HINT:
· Keep the No. 2 crankshaft bearing and crankshaft bearing cap together.
· Be sure to organize the crankshaft bearing caps and lower crankshaft thrust washers (No. 5
crankshaft journal only) in such a way that they can be reinstalled exactly as before.
c.
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Remove the crankshaft from the cylinder block sub-assembly.
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Remove the 2 upper crankshaft thrust washers (No. 5 cylinder block sub-assembly journal only) from the
cylinder block sub-assembly.
HINT:
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Arrange the upper crankshaft thrust washers in the correct order.

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e.
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Remove the 5 No. 1 crankshaft bearings from the cylinder block sub-assembly.
HINT:
Arrange the No. 1 crankshaft bearings in the correct order.
f. Check each crankshaft journal, No. 1 crankshaft bearings and No. 2 crankshaft bearings for pitting and
scratches.
If the journal or crankshaft bearing is damaged, replace the crankshaft bearings. If necessary, replace the
crankshaft.
9.REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY 15708
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Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder
block sub-assembly.
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10.REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 11415
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Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.
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b. Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.
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11.REMOVE STUD BOLT
NOTICE:

Print Exit
1GD-FTV ENGINE MECHANICAL CYLINDER BLOCK REASSEMBLY
PROCEDURE
1.INSTALL STUD BOLT
NOTICE:
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a. Using an E6 "TORX" socket wrench, install the stud bolt labeled A to the cylinder block sub-assembly.
Torque:
for stud bolt A : 6.0 N*m (61 kgf*cm, 53 in.*lbf)
b. Using an E8 "TORX" socket wrench, install the stud bolts labeled B, D and E to the cylinder block sub-
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assembly.
Torque:
for stud bolt B, D and E : 10 N*m (102 kgf*cm, 7 ft.*lbf)
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c. Using an E10 "TORX" socket wrench, install the stud bolt labeled C to the cylinder block sub-assembly.
Torque:
for stud bolt C : 19 N*m (194 kgf*cm, 14 ft.*lbf)
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*a Engine Lower Side *b Engine LH Side

*c Engine RH Side *d 9.0 mm (0.354 in.)
*e 19 mm (0.748 in.) *f 16 mm (0.630 in.)
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*g 44 mm (1.73 in.) *h 23 mm (0.906 in.)

*i 15 mm (0.591 in.) *j 40 mm (1.57 in.)
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*k 20 mm (0.787 in.) *l 10 mm (0.394 in.)

*m 32 mm (1.26 in.) *n 13 mm (0.511 in.)
*o 73 mm (2.87 in.) - -
2.INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 11415

a.
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Install a new cylinder block water drain cock sub-assembly to the cylinder block sub-assembly.
Torque:
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25 N*m (255 kgf*cm, 18 ft.*lbf)
HINT:
Install the cylinder block water drain cock sub-assembly so that the installation angle is within the range
indicated by the illustration.
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b. Install a new cylinder block water drain cock plug to the cylinder block water drain cock sub-assembly.
Torque:
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12.7 N*m (130 kgf*cm, 9 ft.*lbf)
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3.INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY 15708

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a. Using a 5 mm hexagon wrench, install the 4 No. 1 oil nozzle sub-assemblies with the 4 bolts to the cylinder
block sub-assembly.
Torque:
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4.INSTALL PISTON WITH PIN SUB-ASSEMBLY 13101
a.
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*a Service Hole Cutout Portion
Using a small screwdriver, install a new piston pin hole snap ring on one side of the piston pin hole.
HINT:
· Be sure that the end gap of the piston pin hole snap ring is not aligned with the service hole
cutout portion of the piston.
· If the new piston pin is difficult to insert, heat the piston to approximately 80°C (176°F).
CAUTION:
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b. Coat the piston pin with engine oil.
c.
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*a Front Mark (Arrow)

*b Front Mark (Protrusion)
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Align the front marks of the piston and connecting rod sub-assembly, install the connecting rod sub-
assembly to the piston and push in the piston pin with your thumb.
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d. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth
on the piston pin.
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e.
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*a Service Hole Cutout Portion

Using a small screwdriver, install a new piston pin hole snap ring on one side of the piston pin hole.
HINT:
Be sure that the end gap of the piston pin hole snap ring is not aligned with the service hole cutout
portion of the piston.
5.INSTALL PISTON RING SET 13011
a. Install the oil ring expander to the piston by hand.
b.
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*a Coil Joint
*b Oil Ring Rail End Gap
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Using a piston ring expander, install the oil ring rail to the piston.
HINT:
Make sure the end gap of the oil ring rail and the coil joint are on opposite sides.
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c.
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*a No. 1 Compression Ring Code Mark

*b No. 2 Compression Ring Code Mark

Using a piston ring expander, install the No. 1 compression ring and No. 2 compression ring to the piston so
that the code marks are positioned as shown in the illustration.
Code Mark:
Item Code Mark
No. 1 Compression
G1 or 1G
Ring
No. 2 Compression
N2 or 2N
Ring
HINT:
Install the No. 1 compression ring and No. 2 compression ring with the code mark facing upward.
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*1 No. 1 Compression Ring
*3 Oil Ring Expander
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*4 Oil Ring Rail
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Position the piston rings so that the ring ends are as shown in the illustration.
NOTICE:
Do not align the ring ends.
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6.INSTALL CRANKSHAFT BEARING
HINT:
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· No. 1 crankshaft bearings have an oil groove and oil hole. No. 2 crankshaft bearings do not.
· There are different types of crankshaft bearings for the No. 1 and No. 5 journal. Therefore, be sure to
install crankshaft bearings with the same colors as the ones that were removed.
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Crankshaft Bearing Color:

No. 1 No. 2
Journal
Crankshaft Crankshaft
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Position
Bearing Color Bearing Color
Silver or Silver or
No. 1
Brown Brown
No. 2 Silver Silver
No. 3 Silver Silver
No. 4 Silver Silver
Silver or Silver or
No. 5
Brown Brown

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*a Width
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Install the No. 1 crankshaft bearing to the cylinder block sub-assembly as shown in the illustration.
Standard width:
4.25 mm (0.167 in.)
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NOTICE:
· Clean the contact surface of the No. 1 crankshaft bearing and cylinder block sub-assembly.
· Apply oil to the inner surface of each No. 1 crankshaft bearing (the surface which contacts the
crankshaft), but not to the outer surface (the surface which contacts the cylinder block sub-
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assembly).
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b.
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Install the No. 2 crankshaft bearing to the crankshaft bearing cap.

NOTICE:
· Clean the contact surface of the No. 2 crankshaft bearing and crankshaft bearing cap.
· Apply oil to the inner surface of each No. 2 crankshaft bearing (the surface which contacts the
crankshaft), but not to the outer surface (the surface which contacts the crankshaft bearing cap).

c. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and crankshaft
bearing edge.
Dimension A - B or B - A:
0 to 0.7 mm (0 to 0.0276 in.)
7.INSTALL CRANKSHAFT 13411
a. Apply engine oil to the crankshaft bearing, and then install the crankshaft to the cylinder block sub-
assembly.
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*1 Lower Crankshaft Thrust Washer
*2 Upper Crankshaft Thrust Washer
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Apply engine oil to the 2 upper crankshaft thrust washers and 2 lower crankshaft thrust washers.
HINT:
Check the crankshaft thrust washers, as there are different types as shown in the illustration.
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c.
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*a Groove
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Push the crankshaft in one direction and install one upper crankshaft thrust washer to the No. 5 cylinder
block sub-assembly journal position with the oil groove facing outward.
d. Push the crankshaft in the opposite direction and install the other upper crankshaft thrust washer to the
No. 5 cylinder block sub-assembly journal position with the oil groove facing outward.

e.
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*a Groove
Install the 2 lower crankshaft thrust washers to the crankshaft bearing cap (No. 5 crankshaft journal) with
the grooves facing outward.
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*a Front Mark (Protrusion)

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Install the 5 crankshaft bearing caps to the cylinder block sub-assembly, making sure that the front marks
(protrusions) and crankshaft bearing cap number of the crankshaft bearing caps are as shown in the
illustration.
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g. Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap set bolts.
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h. Install the crankshaft bearing cap set bolts.

HINT:
· The crankshaft bearing cap set bolts are tightened in 2 progressive steps.
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· If a crankshaft bearing cap set bolt is broken or deformed, replace it.

i.
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Step 1:
Using several steps, install and uniformly tighten the 10 crankshaft bearing cap set bolts in the sequence
Torque:
95 N*m (969 kgf*cm, 70 ft.*lbf)
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HINT:
If any of the crankshaft bearing cap set bolts does not meet the torque specification, replace the
crankshaft bearing cap set bolt.
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j. Step 2:
i. Mark the front of the crankshaft bearing cap set bolts with paint.
ii. Tighten the crankshaft bearing cap set bolts by 90°.

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iii. Check that the painted marks are now at a 90° angle to the front.
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k. Check that the crankshaft turns smoothly.
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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>CYLINDER BLOCK>DISASSEMBLY

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9.INSTALL CONNECTING ROD BEARING 13041

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HINT:
Check that the No. 1 and No. 2 connecting rod bearing colors are correct, as the colors differ.
Bearing Color:
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Connecting Rod
Item
Bearing Color
No. 1 Connecting Rod
Brown
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Bearing
No. 2 Connecting Rod
Silver
Bearing
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a. Clean the backside of the connecting rod bearing and the connecting rod bearing surface of the connecting
rod sub-assembly and connecting rod cap.
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b.
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*1 No. 1 Connecting Rod Bearing
*2 No. 2 Connecting Rod Bearing
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Install the No. 1 connecting rod bearings to the connecting rod sub-assembly.
c. Install the No. 2 connecting rod bearings to the connecting rod cap.
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d. Using a vernier caliper, measure the distance between the connecting rod cap edge and connecting rod
bearing edge.
Dimension A - B or B - A:
0 to 0.7 mm (0 to 0.0276 in.)
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10.INSTALL PISTON AND CONNECTING ROD SUB-ASSEMBLY
a. Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings.
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b.
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*3 Oil Ring Expander
*4 Oil Ring Rail
Position the piston rings so that the piston ring ends are as shown in the illustration.
NOTICE:

Do not align the piston ring ends.
c.
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Using a piston ring compressor and hammer handle, press a piston with connecting rod sub-assembly into
each cylinder with the front mark (arrow) of the piston facing forward.
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d. Place the connecting rod cap on the connecting rod sub-assembly.
i.
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*a Pin
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Align the pin holes of the connecting rod cap with the pins of the connecting rod sub-assembly, and
then install the connecting rod cap.
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ii.
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Front
Check that the front mark (protrusion) of the connecting rod cap is facing forward.
iii.
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*b Matchmark
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Check that the matchmarks of the connecting rod sub-assembly and connecting rod cap are aligned.
e. Apply a light coat of engine oil to the threads and under the heads of the connecting rod bolts.
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f. Install the connecting rod bolts.

HINT:
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The connecting rod bolts are tightened in 2 progressive steps.
i.
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Step 1:
Install and alternately tighten the connecting rod bolts of each connecting rod cap in several steps.
Torque:
40 N*m (408 kgf*cm, 30 ft.*lbf)
ii. Mark the front side of each connecting rod bolt with paint.

iii. Step 2:
Tighten the connecting rod bolts 90°.
iv. Check that the paint marks are now at a 90° angle to the front.
g. Check that the crankshaft turns smoothly.
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>CYLINDER BLOCK>DISASSEMBLY
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1GD-FTV ENGINE MECHANICAL CYLINDER BLOCK REPLACEMENT
PROCEDURE
1.REPLACE STRAIGHT PIN
NOTICE:
It is not necessary to remove the straight pin unless it is being replaced.
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a. Remove the straight pin from the cylinder block sub-assembly.
b. Using a plastic-faced hammer, tap in a new straight pin to the cylinder block sub-assembly.
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*a Engine Front Side *b Engine Rear Side

*c 36 mm (1.42 in.) *d 10 mm (0.394 in.)
*e 18 mm (0.709 in.) *f 6.0 mm (0.236 in.)
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*g 11 mm (0.433 in.) *h 22 mm (0.866 in.)

*i 8.0 mm (0.315 in.) *j Protrusion Height
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Standard Protrusion Height:

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18 to 20 mm (0.709 to
Straight Pin A
0.787 in.)
8.0 to 10 mm (0.315
Straight Pin B
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to 0.394 in.)
4.0 to 6.0 mm (0.157
Straight Pin C
to 0.236 in.)
10 to 12 mm (0.394 to
Straight Pin D
0.472 in.)
2.REPLACE RING PIN
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NOTICE:
It is not necessary to remove the ring pin unless it is being replaced.
a. Remove the ring pin from the cylinder block sub-assembly.
b. Using a plastic-faced hammer, tap in a new ring pin to the cylinder block sub-assembly.
Standard protrusion height:
5.5 to 7.5 mm (0.217 to 0.295 in.)
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*a Protrusion Height
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1GD-FTV ENGINE MECHANICAL CYLINDER BLOCK REPLACEMENT
PROCEDURE
NOTICE:
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a. Remove the straight pin from the cylinder block sub-assembly.
b. Using a plastic-faced hammer, tap in a new straight pin to the cylinder block sub-assembly.
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*a Engine Front Side *b Engine Rear Side

*c 36 mm (1.42 in.) *d 10 mm (0.394 in.)
*e 18 mm (0.709 in.) *f 6.0 mm (0.236 in.)
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*g 11 mm (0.433 in.) *h 22 mm (0.866 in.)

*i 8.0 mm (0.315 in.) *j Protrusion Height
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Standard Protrusion Height:

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18 to 20 mm (0.709 to
Straight Pin A
0.787 in.)
8.0 to 10 mm (0.315
Straight Pin B
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to 0.394 in.)
4.0 to 6.0 mm (0.157
Straight Pin C
to 0.236 in.)
10 to 12 mm (0.394 to
Straight Pin D
0.472 in.)
2.REPLACE RING PIN
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NOTICE:
a. Remove the ring pin from the cylinder block sub-assembly.
b. Using a plastic-faced hammer, tap in a new ring pin to the cylinder block sub-assembly.
5.5 to 7.5 mm (0.217 to 0.295 in.)
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1GD-FTV ENGINE MECHANICAL CYLINDER HEAD COMPONENTS
ILLUSTRATION
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*1 EXHAUST VALVE *2 EXHAUST VALVE GUIDE BUSH

*3 INTAKE VALVE *4 INTAKE VALVE GUIDE BUSH
*5 NO. 1 STRAIGHT SCREW PLUG WITH HEAD *6 VALVE SPRING SEAT
*7 VALVE STEM CAP *8 VALVE STEM OIL SEAL
*9 VALVE SPRING RETAINER LOCK *10 VALVE SPRING RETAINER
*11 VALVE COMPRESSION SPRING - -
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Precoated part - -
ILLUSTRATION
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*3 STUD BOLT - -
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1GD-FTV ENGINE MECHANICAL CYLINDER HEAD DISASSEMBLY
PROCEDURE
1.REMOVE VALVE STEM CAP 13716
a. Remove the 16 valve stem caps from the cylinder head sub-assembly.
HINT:
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2.REMOVE INTAKE VALVE 13711
a.
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Using SST and wooden blocks, compress the valve compression spring and remove the valve spring
retainer locks from the valve spring retainer.
SST
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09202-70020
09202-00021
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b. Remove the valve spring retainer, valve compression spring and intake valve from the cylinder head sub-
assembly.
HINT:
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3.REMOVE EXHAUST VALVE 13715

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a.
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Using SST and wooden blocks, compress the valve compression spring and remove the valve spring
retainer locks from the valve spring retainer.
SST
09202-70020
09202-00021
b. Remove the valve spring retainer, valve compression spring and exhaust valve from the cylinder head sub-
assembly.
HINT:
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4.REMOVE VALVE STEM OIL SEAL 13711E
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Using needle-nose pliers, remove the valve stem oil seals from the valve guide bush.
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5.REMOVE VALVE SPRING SEAT 13734A

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Using compressed air and a magnet hand, remove the valve spring seat from the cylinder head sub-
assembly by blowing air onto it.
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6.REMOVE NO. 1 STRAIGHT SCREW PLUG WITH HEAD 11117E

a.
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Using a 6 mm hexagon wrench, remove the 4 No. 1 straight screw plug with heads from the cylinder head
sub-assembly.
7.REMOVE STUD BOLT
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1GD-FTV ENGINE MECHANICAL CYLINDER HEAD INSPECTION
PROCEDURE
1.INSPECT CYLINDER HEAD SUB-ASSEMBLY 11101
a.
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*a Cylinder Block Sub-assembly Side

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*b Intake Manifold Side

*c Exhaust Manifold Side
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Using a precision straightedge and feeler gauge, measure the warpage of the surface where the cylinder
head sub-assembly contacts the cylinder block sub-assembly, and the surfaces where the cylinder head
sub-assembly contacts each manifold.
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Maximum Warpage:
Cylinder Block Sub-
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0.05 mm (0.00197 in.)

assembly Side
Intake Manifold Side 0.10 mm (0.00394 in.)
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Exhaust Manifold Side 0.10 mm (0.00394 in.)
If the warpage is more than the maximum, replace the cylinder head sub-assembly.
b. Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks.
If there are cracks, replace the cylinder head sub-assembly.
2.INSPECT VALVE COMPRESSION SPRING 13711M
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a.
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Using a vernier caliper, measure the free length of the valve compression spring.
Standard free length:
52.4 mm (2.06 in.)
If the free length is not as specified, replace the valve compression spring.
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*a Deviation
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Using a steel square, measure the deviation of the valve compression spring.
Maximum deviation:
1.8 mm (0.0709 in.)
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Maximum angle (reference):

2°
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If the deviation is more than the maximum, replace the valve compression spring.
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3.INSPECT INTAKE VALVE 13711
a. Using a gasket scraper, chip off any carbon from the intake valve head.
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NOTICE:
Be careful not to damage the intake valve face.
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b. Using a wire brush, thoroughly clean the intake valve.
c. Using a vernier caliper, measure the overall length of the intake valve.
Standard overall length:
99.98 mm (3.94 in.)
Minimum overall length:

99.48 mm (3.92 in.)
If the length is less than the minimum, replace the intake valve.
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d. Using a micrometer, measure the diameter of the intake valve stem.

Standard valve stem diameter:
5.970 to 5.985 mm (0.2350 to 0.2356 in.)
If the intake valve stem diameter is not as specified, check the oil clearance.
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*a Margin Thickness
Using a vernier caliper, measure the intake valve head margin thickness.
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Standard margin thickness:
1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Minimum margin thickness:

0.5 mm (0.0197 in.)
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If the margin thickness is less than the minimum, replace the intake valve.
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4.INSPECT EXHAUST VALVE 13715
a. Using a gasket scraper, chip off any carbon from the exhaust valve head.
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NOTICE:
Be careful not to damage the exhaust valve face.
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b. Using a wire brush, thoroughly clean the exhaust valve.

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c. Using a vernier caliper, measure the overall length of the exhaust valve.
Standard overall length:
99.39 mm (3.91 in.)
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Minimum overall length:

98.89 mm (3.89 in.)
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If the length is less than the minimum, replace the exhaust valve.
d. Using a micrometer, measure the diameter of the exhaust valve stem.

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Standard valve stem diameter:

5.960 to 5.975 mm (0.2346 to 0.2352 in.)
If the exhaust valve stem diameter is not as specified, check the oil clearance.

e.
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*a Margin Thickness
Using a vernier caliper, measure the exhaust valve head margin thickness.
Standard margin thickness:
1.0 to 1.4 mm (0.0394 to 0.0551 in.)
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Minimum margin thickness:
0.5 mm (0.0197 in.)
If the margin thickness is less than the minimum, replace the exhaust valve.
5.INSPECT VALVE GUIDE BUSH OIL CLEARANCE
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Using a caliper gauge, measure the inside diameter of the valve guide bush.
Standard valve guide bush inside diameter:
6.010 to 6.030 mm (0.2366 to 0.2374 in.)
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b. Subtract the valve stem diameter measurement from the valve guide bush inside diameter measurement.
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Standard Oil Clearance:

0.025 to 0.060 mm
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Intake Side (0.000984 to 0.00236

in.)
0.035 to 0.070 mm
Exhaust Side (0.00138 to 0.00276
in.)
Maximum Oil Clearance:

Intake Side 0.11 mm (0.00433 in.)

Exhaust Side 0.12 mm (0.00472 in.)
If the clearance is more than the maximum, replace the valve and valve guide bush.
6.INSPECT INTAKE VALVE SEAT
a. Apply a light coat of Prussian blue to the intake valve face.
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*a Width
Lightly press the intake valve face against the intake valve seat.
HINT:
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Do not rotate the intake valve while pressing the intake valve.
c. Check the intake valve face and intake valve seat.

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i. Check that Prussian blue appears around the entire intake valve face and that the intake valve face is
concentric. If not, replace the intake valve.
ii. Check that Prussian blue appears around the entire intake valve seat and that the guide and intake
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valve face are concentric. If not, resurface the intake valve seat.
iii. Check that the intake valve seat contacts the middle of the intake valve face with the width between
1.2 to 1.6 mm (0.0472 to 0.0630 in.).
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7.INSPECT EXHAUST VALVE SEAT
a. Apply a light coat of Prussian blue to the exhaust valve face.

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b.
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*a Width

Lightly press the exhaust valve face against the exhaust valve seat.
HINT:
Do not rotate the exhaust valve while pressing the exhaust valve.
c. Check the exhaust valve face and exhaust valve seat.

i. Check that Prussian blue appears around the entire exhaust valve face and that the exhaust valve face
is concentric. If not, replace the exhaust valve.
ii. Check that Prussian blue appears around the entire exhaust valve seat and that the guide and exhaust
valve face are concentric. If not, resurface the exhaust valve seat.
iii. Check that the exhaust valve seat contacts the middle of the exhaust valve face with the width between
1.6 to 2.0 mm (0.0630 to 0.0787 in.).
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8.INSPECT CAMSHAFT THRUST CLEARANCE
a. Install the No. 2 camshaft and camshaft to the cylinder head sub-assembly.
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Using a dial indicator, measure the camshaft thrust clearance and No. 2 camshaft thrust clearance while
moving the camshaft back and forth.
0.060 to 0.200 mm (0.00236 to 0.00787 in.)
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0.25 mm (0.00984 in.)
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If the thrust clearance is more than the maximum, replace the cylinder head sub-assembly. If the thrust
surface is damaged, replace the camshaft or No. 2 camshaft.
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c. Remove the No. 2 camshaft and camshaft from the cylinder head sub-assembly.
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9.INSPECT CAMSHAFT OIL CLEARANCE

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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE UNIT>INSPECTION

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1GD-FTV ENGINE MECHANICAL CYLINDER HEAD PRECAUTION
HINT:
· Any digits beyond the 0.01 mm (1/1000 in.) place for standard, minimum and maximum values should
be used as a reference only.
· When both standard and maximum or minimum values are listed for an inspection, use the standard
value as a reference only and base any judgments on the maximum and minimum values.
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1GD-FTV ENGINE MECHANICAL CYLINDER HEAD REASSEMBLY
PROCEDURE
1.INSTALL STUD BOLT
NOTICE:
If a stud bolt is deformed or the threads are damaged, replace it.
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a. Using an E6 "TORX" socket wrench, install the stud bolts labeled A to the cylinder head sub-assembly.
Torque:
for stud bolt A : 6.0 N*m (61 kgf*cm, 53 in.*lbf)
b. Install the stud bolts labeled B to the cylinder head sub-assembly.
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Torque:
for stud bolt B : 10 N*m (102 kgf*cm, 7 ft.*lbf)
c. Using an E10 "TORX" socket wrench, install the stud bolts labeled C and D to the cylinder head sub-
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assembly.
Torque:
for stud bolt C : 19 N*m (194 kgf*cm, 14 ft.*lbf)
for stud bolt D : 20 N*m (204 kgf*cm, 15 ft.*lbf)
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*a Cylinder Head Cover Sub-assembly Side *b Exhaust Manifold Side

*c Intake Manifold Side *d 12 mm (0.472 in.)
*e 37 mm (1.46 in.) *f 34 mm (1.34 in.)
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*g 23 mm (0.906 in.) *h 15 mm (0.591 in.)

*i 25 mm (0.984 in.) *j 65 mm (2.56 in.)
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*k 40 mm (1.57 in.) - -
2.INSTALL NO. 1 STRAIGHT SCREW PLUG WITH HEAD 11117E
a. Using a 6 mm hexagon wrench, install 4 new No. 1 straight screw plug with heads to the cylinder head sub-
assembly.
Torque:
25 N*m (255 kgf*cm, 18 ft.*lbf)
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3.INSTALL VALVE SPRING SEAT 13734A
a. Install the valve spring seats to the cylinder head sub-assembly.
4.INSTALL VALVE STEM OIL SEAL 13711E
a. Apply a light coat of engine oil to a new valve stem oil seals.
b.
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*1 Valve Stem Oil Seal

*a CORRECT
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*b INCORRECT
Using SST, push in the intake valve stem oil seals and exhaust valve stem oil seals to the valve guide bush.
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SST
09201-41020
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NOTICE:
Failure to use SST will cause the valve stem oil seal to be damaged or improperly seated.
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5.INSTALL INTAKE VALVE 13711

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a.
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*a 30 mm (1.18 in.) or more
Apply plenty of engine oil to the tip area of the intake valve shown in the illustration.
b. Install the intake valve, valve compression spring and valve spring retainer to the cylinder head sub-
assembly.
NOTICE:
Install the same parts in the same combination to their original locations.
c.
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Using SST and wooden blocks, compress the valve compression spring and install the valve spring retainer
locks to the valve spring retainer.
SST
09202-70020
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09202-00021
d. Using a plastic-faced hammer, lightly tap the intake valve stem tip to ensure a proper fit.
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NOTICE:
Be careful not to damage the valve spring retainer.
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6.INSTALL EXHAUST VALVE 13715

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a.
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*a 30 mm (1.18 in.) or more
Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration.
b. Install the exhaust valve, valve compression spring and valve spring retainer to the cylinder head sub-
assembly.
NOTICE:
Install the same parts in the same combination to their original locations.

c.
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Using SST and wooden blocks, compress the valve compression spring and install the valve spring retainer
locks to the valve spring retainer.
SST
09202-70020
09202-00021
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d. Using a plastic-faced hammer, lightly tap the exhaust valve stem tip to ensure a proper fit.
NOTICE:
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Be careful not to damage the valve spring retainer.
7.INSTALL VALVE STEM CAP 13716

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a. Apply a light coat of engine oil to the valve stem caps.
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b. Install the 16 valve stem caps to the cylinder head sub-assembly.
NOTICE:
· Install the valve stem cap at the same place it was removed from.
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· Do not drop the valve stem caps into the cylinder head sub-assembly.
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1GD-FTV ENGINE MECHANICAL CYLINDER HEAD REPAIR
PROCEDURE
1.REPAIR INTAKE VALVE SEAT
NOTICE:
· Repair the seat while checking the seating position.
· Keep the lip free from foreign matter.
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· Take off the cutter gradually to make the intake valve seat smooth.
a.
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*a Width
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If the seating is too high on the intake valve face, use 25° and 45° cutters to correct the intake valve seat.
b.
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*a Width
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If the seating is too low on the intake valve face, use 70° and 45° cutters to correct the intake valve seat.
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c. Check that the intake valve seat contact is in the middle of the intake valve face and has the following
width.
Standard width:
1.2 to 1.6 mm (0.0472 to 0.0630 in.)
2.REPAIR EXHAUST VALVE SEAT
NOTICE:
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· Repair the seat while checking the seating position.

· Take off the cutter gradually to make the exhaust valve seat smooth.
a.
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*a Width
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If the seating is too high on the exhaust valve face, use 25° and 45° cutters to correct the exhaust valve
seat.
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*a Width
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If the seating is too low on the exhaust valve face, use 75° and 45° cutters to correct the exhaust valve
seat.
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c. Check that the seat contact is in the middle of the exhaust valve face and has the following width.
Standard width:
1.6 to 2.0 mm (0.0630 to 0.0787 in.)
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1GD-FTV ENGINE MECHANICAL CYLINDER HEAD REPLACEMENT
PROCEDURE
1.REPLACE INTAKE VALVE GUIDE BUSH
a. Heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F).

CAUTION:
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b. Place the cylinder head sub-assembly on wooden blocks.
c.
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Using SST and a hammer, tap out the intake valve guide bush from the cylinder head sub-assembly.
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SST
09201-10000 (09201-01060)
09950-70010 (09951-07100)
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d. Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head sub-
assembly.
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If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 11.006 mm
(0.433 in.), machine the intake valve guide bush bore diameter to between 11.035 and 11.056 mm (0.434
and 0.435 in.).
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If the intake valve guide bush bore diameter of the cylinder head sub-assembly is more than 11.056 mm
(0.435 in.), replace the cylinder head sub-assembly.
e. Select a new intake valve guide bush (STD or O/S 0.05).

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Intake Valve Guide Bush:

Bush Size Specified Condition
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11.033 to 11.044 mm
Use STD
(0.4344 to 0.4348 in.)
11.083 to 11.094 mm
Use O/S 0.05
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(0.4363 to 0.4368 in.)
f. Heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F).

CAUTION:
g. Place the cylinder head sub-assembly on wooden blocks.
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h.
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Using SST and a hammer, tap in a new intake valve guide bush to the specified protrusion height.
SST
09201-10000 (09201-01060)
09950-70010 (09951-07100)
Standard protrusion height (H):
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15.5 to 15.9 mm (0.610 to 0.626 in.)
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*a Sharp 6.0 mm Reamer
Using a sharp 6.0 mm reamer, ream the intake valve guide bush to obtain the standard specified clearance
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between the intake valve guide bush and intake valve stem.
0.025 to 0.060 mm (0.000984 to 0.00236 in.)
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2.REPLACE EXHAUST VALVE GUIDE BUSH
a. Heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F).

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CAUTION:
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b. Place the cylinder head sub-assembly on wooden blocks.
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c.
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Using SST and a hammer, tap out the exhaust valve guide bush from the cylinder head sub-assembly.
SST
09201-10000 (09201-01060)
09950-70010 (09951-07100)
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d. Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head sub-
assembly.
If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 11.006 mm
(0.433 in.), machine the exhaust valve guide bush bore diameter to between 11.035 and 11.056 mm
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(0.434 and 0.435 in.).
If the exhaust valve guide bush bore diameter of the cylinder head sub-assembly is more than 11.056 mm
(0.435 in.), replace the cylinder head sub-assembly.
e. Select a new exhaust valve guide bush (STD or O/S 0.05).

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Exhaust Valve Guide Bush:
Bush Size Specified Condition
11.033 to 11.044 mm
Use STD
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(0.4344 to 0.4348 in.)
11.083 to 11.094 mm
Use O/S 0.05
(0.4363 to 0.4368 in.)
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f. Heat the cylinder head sub-assembly to approximately 80 to 100°C (176 to 212°F).

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CAUTION:
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g. Place the cylinder head sub-assembly on wooden blocks.

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h.
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Using SST and a hammer, tap in a new exhaust valve guide bush to the specified protrusion height.
SST
09201-10000 (09201-01060)

09950-70010 (09951-07100)
Standard protrusion height (H):

15.5 to 15.9 mm (0.610 to 0.626 in.)
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*a Sharp 6.0 mm Reamer
Using a sharp 6.0 mm reamer, ream the exhaust valve guide bush to obtain the standard specified
clearance between the exhaust valve guide bush and exhaust valve stem.
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0.035 to 0.070 mm (0.00138 to 0.00276 in.)
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3.REPLACE RING PIN
NOTICE:
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a. Remove the ring pin from the cylinder head sub-assembly.

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b.
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Using a plastic-faced hammer, tap in new ring pins to the cylinder head sub-assembly.
3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTICE:
a. Remove the straight pin from the cylinder head sub-assembly.
b.
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Using a plastic-faced hammer, tap in new straight pins to the cylinder head sub-assembly.
2.0 to 4.0 mm (0.0787 to 0.157 in.)
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1GD-FTV ENGINE MECHANICAL CYLINDER HEAD GASKET COMPONENTS
ILLUSTRATION
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*1 CYLINDER HEAD GASKET *2 CYLINDER HEAD SET BOLT

*3 CYLINDER HEAD SUB-ASSEMBLY *4 NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
*5 VALVE LASH ADJUSTER ASSEMBLY *6 CYLINDER HEAD SET BOLT SPACER
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ft.*lbf)
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1st: 150 (1530, 111) 85 (867, 63)

*T1 2nd: Turn 90° *T2 2nd: Turn 90°
3rd: Turn 90° 3rd: Turn 90°
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1GD-FTV ENGINE MECHANICAL CYLINDER HEAD GASKET INSTALLATION
NOTICE:
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dropped.
or dropped.
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PROCEDURE
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1.INSTALL CYLINDER HEAD GASKET 11115

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a. Check the piston protrusions for each cylinder.

i. Clean the cylinder block sub-assembly with solvent.
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ii. Set the piston of the cylinder to be measured to slightly before TDC.
iii.
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*a Measuring Tip
*b Protrusion
Place a dial indicator on the cylinder block sub-assembly, and position the measuring tip as shown in
the illustration.
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iv. Set the dial indicator at 0 mm (0 in.)

HINT:
Make sure that the measuring tip is square to the cylinder block gasket surface and piston head when
taking the measurements.
b. Find where the piston head protrudes most by slowly turning the crankshaft clockwise and
counterclockwise.
c.
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*a Measuring Point
Measure the piston protrusion of each cylinder at the 2 points shown in the illustration.
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d. For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.
Standard piston protrusion:
0.355 to 0.605 mm (0.0140 to 0.0238 in.)
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HINT:
When installing the piston and connecting rod assembly, if the protrusion is not as specified, remove the
piston and connecting rod assembly and reinstall them.
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e.
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Select a new cylinder head gasket.

HINT:
New cylinder head gaskets are available in 5 sizes, and are marked A, B, C, D or E.
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New Cylinder Head Gasket Thickness

Mark Specified Condition
1.15 to 1.25 mm
A
(0.0453 to 0.0492 in.)
1.20 to 1.30 mm
B
(0.0472 to 0.0512 in.)
1.25 to 1.35 mm
C
(0.0492 to 0.0531 in.)
1.30 to 1.40 mm
D
(0.0512 to 0.0551 in.)
1.35 to 1.45 mm
E
(0.0531 to 0.0571 in.)
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i. Select the largest piston protrusion value from the measurements made. Then select a new appropriate
cylinder head gasket according to the table below.
Gasket Size
0.355 to 0.405 0.405 to 0.455 0.455 to 0.505 0.505 to 0.555 0.555 to 0.605
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Piston
mm (0.0140 to mm (0.0159 to mm (0.0179 to mm (0.0199 to mm (0.0219 to
protrusion
0.0159 in.) 0.0179 in.) 0.0199 in.) 0.0219 in.) 0.0238 in.)
Gasket to be
A B C D E
used
f.
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Clean and degrease the contact surfaces of the cylinder head sub-assembly and cylinder block sub-
assembly.
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Place the cylinder head gasket on the cylinder block sub-assembly.

NOTICE:
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Make sure the cylinder head gasket is installed facing the proper direction.
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2.INSTALL CYLINDER HEAD SUB-ASSEMBLY 11101

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HINT:
· If any cylinder head set bolt is broken or deformed, replace the cylinder head set bolt and cylinder head
set bolt spacer.
· The cylinder head set bolts are tightened in 3 progressive steps.
a. Clean and degrease the contact surfaces of the cylinder head sub-assembly and cylinder block sub-
assembly.
b. Place the cylinder head sub-assembly on the cylinder head gasket.

c. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
d.
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Bolt A
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Bolt B
passes in the sequence shown in the illustration.

Torque: ke
Install and uniformly tighten the 10 cylinder head set bolts and 6 cylinder head set bolt spacers in several
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Standard Bolt Length
Bolt A 180 mm (7.09 in.)
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Bolt B 127 mm (5.00 in.)
If any of the cylinder head set bolts does not meet the specification, replace it.
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e. Mark the front of each cylinder head set bolt with paint.
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f. Further tighten the cylinder head set bolts by 90° in the sequence shown in the illustration above.
g. Finally, tighten the cylinder head set bolts by an additional 90°.

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h. Check that the painted marks are now facing rearward.

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3.INSTALL VALVE LASH ADJUSTER ASSEMBLY 13750

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4.INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 13801
5.INSTALL TIMING CHAIN COVER ASSEMBLY 11310
6.INSTALL CAMSHAFT

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1GD-FTV ENGINE MECHANICAL CYLINDER HEAD GASKET REMOVAL
parts are removed, installed, or replaced during the cylinder head gasket removal/installation are shown below.
Replacement Part or Effects/Inoperative when
Procedure not Performed
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w/o DPF
· Learning values save ( )
· Learning values write Engine starting w/ DPF
( )
for RC61:
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Performing iMT · iMT system
Replacement of ECM
installation · DTCs are output ( )
information reset
See the Service
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Code registration Bulletin for the
Engine start function
(Immobiliser system) registration
method.
· Injector
w/o DPF
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compensation code
registration ( )
Engine starting
· Pilot quantity w/ DPF
Replacement of engine learning ( )
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assembly
w/o DPF
Clear Crank Time ( )
Engine starting
Compensation Data w/ DPF
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( )
Crank time compensation w/o DPF
data compensation amount
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Replacement of crankshaft Clear Crank Time ( )

is same as before
position sensor plate Compensation Data w/ DPF
replacement, affecting crank
time compensation data ( )
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· Injector
w/o DPF
compensation code
Engine starting
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learning ( )
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throttle body
assembly
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· Replacement of
electric EGR control
valve assembly w/o DPF
w/ DPF
assembly
turbocharger sub-
assembly or
turbocharger variable
nozzle motor
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for AC60E:
Replacement of · Large shift shock
automatic Reset memory · Engine overruns
transmission
assembly
( )
for AC60E: The value of the Data List
Replacement of ATF thermal degradation item "ATF Thermal
automatic estimate reset Degradation Estimate" is not
transmission fluid estimated correctly
for AC60F:
Replacement of
· Large shift shock
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transmission
assembly
( )
for AC60F: The value of the Data List
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w/ Automatic Headlight
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Beam Level Control
System:
The vehicle height
changes due to
replacement of Headlight leveling ECU
Headlight leveling function
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suspension assembly initialization ( )
components or after
performing such
operations as
removal and
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reinstallation
· Clearing zero point

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for 4WD:
calibration data
Front wheel
· Yaw rate and VSC malfunctioning
alignment ( )
acceleration sensor
adjustment
zero point calibration
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CAUTION:
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engine is hot.
NOTICE:



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dropped.
or dropped.
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PROCEDURE
1.REMOVE CAMSHAFT
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2.REMOVE TIMING CHAIN COVER ASSEMBLY 11310

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3.REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 13801

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13750
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4.REMOVE VALVE LASH ADJUSTER ASSEMBLY

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5.REMOVE CYLINDER HEAD SUB-ASSEMBLY 11101

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a.
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Uniformly loosen the 10 cylinder head set bolts in several passes in the sequence shown in the illustration.
Then remove the 10 cylinder head set bolts and 6 cylinder head set bolt spacers.
NOTICE:

· Cylinder head sub-assembly warpage or cracking could result from removing bolts in the incorrect
order.
· Be careful not to drop the cylinder head set bolt spacers into the cylinder head sub-assembly.
b. Lift the cylinder head sub-assembly from the ring pins on the cylinder block sub-assembly, and place the
cylinder head sub-assembly on wooden blocks on a bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylinder head sub-assembly and cylinder block sub-
assembly.
HINT:
If the cylinder head sub-assembly is difficult to lift, use a screwdriver to pry between the cylinder head
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sub-assembly and cylinder block sub-assembly.
6.REMOVE CYLINDER HEAD GASKET 11115
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Click hereEngine / Hybrid System>1KD-FTV ENGINE MECHANICAL>CYLINDER HEAD GASKET>REMOVAL
7.INSPECT CYLINDER HEAD SET BOLT 11101A
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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE UNIT>INSPECTION

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1GD-FTV ENGINE MECHANICAL DRIVE BELT COMPONENTS
ILLUSTRATION
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*A w/ Viscous Heater *B for 4WD and Pre-Runner

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*1 FAN AND GENERATOR V BELT *2 NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

*3 VISCOUS HEATER V BELT - -
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Print Exit
1GD-FTV ENGINE MECHANICAL DRIVE BELT INSTALLATION
PROCEDURE
1.INSTALL FAN AND GENERATOR V BELT 16361A
a. Set the fan and generator V belt onto each part.

HINT:
When installing the fan and generator V belt, attach the fan and generator V belt to the No. 1 idler pulley
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sub-assembly last.
b. While turning the V-ribbed belt tensioner assembly clockwise, remove the pin.
c. Check that the fan and generator V belt fits properly in the ribbed grooves.
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NOTICE:
Make sure that the fan and generator V belt is set properly on each pulley.
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2.INSTALL VISCOUS HEATER V BELT (w/ Viscous Heater) 88359
a. Install the viscous heater V belt.

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Turn the bolt and adjust the tension of the viscous heater V belt.
c.
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Tighten the 2 bolts and nut.

Torque:
39 N*m (398 kgf*cm, 29 ft.*lbf)
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d. Check the tension of the viscous heater V belt.
3.INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for 4WD and Pre- 51410
Runner)
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1GD-FTV ENGINE MECHANICAL DRIVE BELT ON-VEHICLE INSPECTION
CAUTION:
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the engine running.
PROCEDURE
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1.INSPECT FAN AND GENERATOR V BELT 16361A
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Check the belt for wear, cracks or other signs of damage.

If any of the following defects is found, replace the fan and generator V belt.
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· The fan and generator V belt is cracked.

· The fan and generator V belt is worn out to the extent that the cords are exposed.
· The fan and generator V belt has chunks missing from the ribs.
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b.
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*a CORRECT
*b INCORRECT
Check that the fan and generator V belt fits properly in the ribbed grooves.
HINT:
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Check with your hand to confirm that the fan and generator V belt has not slipped out of the grooves on
the bottom of the pulley. If it has slipped out, replace the fan and generator V belt. Install a new fan and
generator V belt correctly.
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2.INSPECT VISCOUS HEATER V BELT (w/ Viscous Heater) 88359
a.
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Check the viscous heater V belt for wear, cracks or other signs of damage.
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If any of the following defects is found, replace the viscous heater V belt.
· The viscous heater V belt is cracked.
· The viscous heater V belt is worn out to the extent that the cords are exposed.
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· The viscous heater V belt has chunks missing from the ribs.
b.
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*a CORRECT

*b INCORRECT
Check that the viscous heater V belt fits properly in the ribbed grooves.
HINT:
Check with your hand to confirm that the viscous heater V belt has not slipped out of the grooves on the
bottom of the pulley. If it has slipped out, replace the viscous heater V belt. Install a new viscous heater
V belt correctly.
c. Inspect the viscous heater V belt tension or deflection value.

NOTICE:
· Check and adjust the viscous heater V belt when engine is cold.
· Check the viscous heater V belt tension at the specified point.
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· Perform the V belt tension and deflection value check after idling the engine for a few minutes.
After this, rotate the crankshaft pulley 2 times and adjust to the middle of the range of values
given for "New belt".
· With the exception of new belts, when reinstalling a belt used for 5 minutes or more, adjust to the
middle of the range of values given for "Used belt".
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Using a belt tension gauge, check the viscous heater V belt tension.
Standard Tension:
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Specified
Item Condition
Condition
382 to 618 N
Crankshaft
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(39 to 63 kgf,
New belt pulley after 2
85.9 to 138.9
rotations
lbf)
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282 to 478 N
Crankshaft
(29 to 49 kgf,
Used belt pulley after 2
63.4 to 107.5
rotations
lbf)
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If the belt tension is not specified, adjust the viscous heater V belt.
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ii. Check the viscous heater V belt deflection by pressing on the V belt at the point indicated in the
illustration with 98 N (10 kgf, 22 lbf) of force.
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Standard Drive Deflection:

Specified
Item Condition
Condition
Crankshaft 9 to 12 mm
New belt pulley after 2 (0.354 to
rotations 0.472 in.)
Crankshaft 11 to 14 mm
Used belt pulley after 2 (0.433 to
rotations 0.551 in.)

If the belt tension is not specified, adjust the viscous heater V belt.
3.INSPECT V-RIBBED BELT TENSIONER ASSEMBLY 16620
a. Remove the fan and generator V belt.

b.
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Check that nothing gets caught in the V-ribbed belt tensioner assembly by turning it clockwise and
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counterclockwise.
If a malfunction exists, replace the V-ribbed belt tensioner assembly.
c.
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*a Turn
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Turn the pulley, and check that the tensioner bearing moves smoothly and quietly.
If necessary, replace the tensioner pulley.
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d. Install the fan and generator V belt.

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1GD-FTV ENGINE MECHANICAL DRIVE BELT REMOVAL
PROCEDURE
1.REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for 4WD and Pre- 51410
Runner)
2.REMOVE VISCOUS HEATER V BELT (w/ Viscous Heater) 88359
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Loosen the 2 bolts and nut.
b.
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Turn the bolt to loosen the viscous heater V belt and reduce the tension. Then remove the viscous heater V
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belt.
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3.REMOVE FAN AND GENERATOR V BELT 16361A

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a.
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*a Service Hole
*b Pin
While turning the V-ribbed belt tensioner assembly clockwise, align the service holes of the V-ribbed belt
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tensioner assembly, and then insert a pin with a diameter of 5.0 mm (0.197 in.) into the service holes to fix
the V-ribbed belt tensioner assembly in place.
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b. Remove the fan and generator V belt.

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1GD-FTV ENGINE MECHANICAL ENGINE ON-VEHICLE INSPECTION
CAUTION:
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the engine running.
HINT:
The type of ignition switch used on this model differs according to the specifications of the vehicle. For the
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expressions listed in this section, refer to the "Ignition Switch Expressions" precaution.
Click hereEngine / Hybrid System>1GD-FTV STARTING>STARTING SYSTEM>PRECAUTION
PROCEDURE
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1.INSPECT ENGINE COOLANT

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2.INSPECT ENGINE OIL

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3.INSPECT BATTERY 28800

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Click herePower Source / Network>1GD-FTV BATTERY / CHARGING>CHARGING SYSTEM>ON-VEHICLE

INSPECTION
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4.INSPECT V-RIBBED BELT TENSIONER ASSEMBLY 16620
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>DRIVE BELT>ON-VEHICLE INSPECTION

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5.CHECK VALVE LASH ADJUSTER NOISE 13750
a. Rev the engine several times. Check that the engine does not emit unusual noises.
If unusual noises occur, warm up the engine and idle it for more than 30 minutes. Then perform the
inspection above again.
If any defects or problems are found during the inspection above, perform a valve lash adjuster inspection.
6.INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 17801
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a. Remove the air cleaner filter element sub-assembly from the air cleaner case.
b. Check that the air cleaner filter element sub-assembly is not excessively dirty.
If the air cleaner filter element sub-assembly is excessively dirty, replace the air cleaner filter element sub-
assembly.
If cleaning the air cleaner filter element sub-assembly. blow compressed air to clean it.
NOTICE:
· Do not start the engine with the air cleaner filter element sub-assembly removed, as this may
damage the engine.
· When using an air cleaner filter element sub-assembly that uses compressed air, wear safety
glasses and a dust mask in order to protect your health.
HINT:
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When an excessive amount of dirt is present, replace the air cleaner filter element sub-assembly.
c. Reinstall the air cleaner filter element sub-assembly to the air cleaner case.
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7.INSPECT ENGINE IDLE SPEED
a. Warm up and stop the engine.
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b. When using the GTS:
HINT:
· For more information about the GTS, refer to its operator's manual.
· If the GTS is not available, use a tachometer as a substitute.
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i. Connect the GTS to the DLC3.
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ii. Start the engine and idle it.
iii. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.
Powertrain > Engine and ECT > Data List
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Tester Display
Engine Speed
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Execute
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*a Front view of DLC3
When not using the GTS:

i. Connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.
SST
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09843-18040
ii. Start the engine and idle it.
d. Inspect the engine idle speed.

Standard idle speed:
800 to 900 rpm
NOTICE:
· Turn all the electrical systems and A/C off.
· When checking the idle speed, move the shift lever to neutral.
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e. Turn the ignition switch off.
f. Disconnect the GTS or tachometer tester probe from the DLC3.
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8.INSPECT MAXIMUM ENGINE SPEED
a. Start the engine.
b.
c.
Fully depress the accelerator pedal.
Check the maximum engine speed.

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Maximum engine speed:
4450 to 4750 rpm
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9.INSPECT COMPRESSION
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a. Warm up and stop the engine.
b. Remove the 4 injector assemblies.

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c. Inspect the cylinder compression pressure.

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i.
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*1 Bolt
*2 Washer
*3 Nozzle Holder Clamp
*a SST (Attachment I)
*b New O-Ring
*c New Injection Nozzle Seat
*d New Nozzle Holder Gasket
Install a new nozzle holder gasket, new injection nozzle seat, new O-ring, SST (attachment I), nozzle
holder clamp and washer to the cylinder head cover sub-assembly with the bolt.
SST
09992-19015 (09992-10120)
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Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
ii.
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*a SST (Compression Gauge)
*b SST (Joint)
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Connect SST (gauge assembly), SST (packing set) and SST (L-joint) to SST (attachment I).
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SST
09992-19015 (09992-10010, 09992-10020, 09992-10030)
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iii. While cranking the engine, measure the compression pressure.

Standard compression pressure:
2700 kPa (27.5 kgf/cm2, 392 psi) or higher
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Minimum pressure:
2200 kPa (22.4 kgf/cm2, 319 psi)
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Difference between each cylinder:

500 kPa (5.1 kgf/cm2, 73 psi) or less
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NOTICE:
· Use a fully-charged battery so the engine speed can be increased to 280 rpm or more.
· Inspect the other cylinders in the same way.
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· Measure the compression as quickly as possible.
iv. If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the
injector holes, and then inspect it again.
If adding oil increases the compression pressure, the piston rings and/or cylinder bore may be worn or
damaged.
If the pressure stays low, the valve may be stuck or seated improperly, or there may be leakage from
the gasket.

d. Remove SST.
e. Install the 4 injector assemblies.

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1GD-FTV ENGINE MECHANICAL ENGINE ASSEMBLY COMPONENTS
ILLUSTRATION
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*A w/ Viscous Heater *B for Automatic Transmission

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*C for 4WD and Pre-Runner - -

*1 HOOD SUB-ASSEMBLY *2 NO. 1 ENGINE COVER SUB-ASSEMBLY
*3 NO. 1 ENGINE UNDER COVER ASSEMBLY *4 NO. 2 ENGINE UNDER COVER
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*5 RADIATOR ASSEMBLY *6 RADIATOR RESERVE TANK ASSEMBLY

*7 VANE PUMP OIL RESERVOIR ASSEMBLY *8 WASHER HOSE
*9 NO. 1 RADIATOR HOSE *10 NO. 2 RADIATOR HOSE
*11 FAN SHROUD *12 FAN WITH FLUID COUPLING ASSEMBLY
*15 VISCOUS HEATER V BELT *16 NO. 1 OIL COOLER OUTLET TUBE
*17 NO. 1 OIL COOLER INLET TUBE - -
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ILLUSTRATION
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*A for LHD - -
*1 ENGINE WIRE *2 ECM
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*3 GLOVE COMPARTMENT DOOR ASSEMBLY - -
ILLUSTRATION

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*A for RHD - -
*1 ENGINE WIRE *2 ECM
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*3 GLOVE COMPARTMENT DOOR ASSEMBLY - -

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ILLUSTRATION
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AIR CLEANER FILTER ELEMENT SUB-

*1 AIR CLEANER CAP AND HOSE *2
ASSEMBLY
*3 FUEL FILTER ASSEMBLY *4 INTERCOOLER AIR TUBE
*5 NO. 1 AIR HOSE *6 NO. 1 FUEL HOSE
*7 NO. 2 FUEL HOSE *8 NO. 4 AIR HOSE
*9 OIL RETURN HOSE *10 ENGINE WIRE

ILLUSTRATION
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*1 BATTERY *2 BATTERY CLAMP SUB-ASSEMBLY

*3 BATTERY TRAY *4 WATER HOSE SUB-ASSEMBLY
*5 NO. 1 RELAY BLOCK UPPER *6 NO. 1 RELAY BLOCK SIDE
*7 NO. 2 ENGINE WIRE *8 WIRE TO WIRE
*9 ENGINE ROOM MAIN WIRE - -

ILLUSTRATION
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*A w/ Viscous Heater - -
*1 COOLER COMPRESSOR ASSEMBLY *2 GENERATOR ASSEMBLY
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*3 VANE PUMP ASSEMBLY *4 VISCOUS HEATER WITH MAGNET CLUTCH

ASSEMBLY
*5 WATER HOSE SUB-ASSEMBLY *6 SUCTION HOSE SUB-ASSEMBLY
*7 STUD BOLT - -

ILLUSTRATION
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*1 FRONT EXHAUST PIPE ASSEMBLY *2 GASKET
*3 COMPRESSION SPRING - -
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*A for 2WD and Pre-Runner *B for 4WD

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*1 PROPELLER SHAFT GUARD - -

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ILLUSTRATION
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*C for RC61 - -
PROPELLER WITH CENTER BEARING SHAFT
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*1 FRONT PROPELLER SHAFT ASSEMBLY *2

ASSEMBLY
*3 DIFFERENTIAL TORSIONAL DAMPER *4 TRANSFER CASE PROTECTOR LOWER
*5 PROPELLER SHAFT GUARD - -
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ft.*lbf)
Do not apply lubricants - -

ILLUSTRATION
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*A for Manual Transmission *B w/ Console Box Lid

*C for R151 - -
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*1 UPPER CONSOLE PANEL ASSEMBLY *2 SHIFT LEVER KNOB SUB-ASSEMBLY

*3 SHIFT LEVER BOOT ASSEMBLY *4 FLOOR SHIFT LEVER ASSEMBLY
*5 CONSOLE BOX ASSEMBLY *6 FLOOR SHIFT LEVER COVER
ILLUSTRATION
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*A for Manual Transmission *B w/o Console Box Lid
*1 FRONT CONSOLE BOX COVER *2 FRONT CONSOLE BOX
*3 REAR CONSOLE BOX SUB-ASSEMBLY *4 SHIFT LEVER KNOB SUB-ASSEMBLY
*5 SHIFT LEVER BOOT ASSEMBLY *6 FLOOR SHIFT LEVER ASSEMBLY
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ILLUSTRATION
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*A for LHD *B for Manual Transmission

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*C for 4WD - -
*1 STEERING SLIDING YOKE *2 POWER STEERING LINK ASSEMBLY
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N*m (kgf*cm, ft.*lbf) : Specified torque - -

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ILLUSTRATION
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*A for RHD *B for Manual Transmission

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*C for 4WD - -
*1 STEERING SLIDING YOKE *2 POWER STEERING LINK ASSEMBLY
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ILLUSTRATION
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*A for Manual Transmission *B for 4WD

*1 FRONT DIFFERENTIAL CARRIER ASSEMBLY *2 FRONT DRIVE SHAFT ASSEMBLY LH
*3 FRONT DRIVE SHAFT ASSEMBLY RH *4 FRONT PROPELLER SHAFT ASSEMBLY
*5 OIL TEMPERATURE SENSOR *6 FRONT DIFFERENTIAL BREATHER HOSE
*7 FRONT DRIVE SHAFT HOLE SNAP RING *8 FRONT NO. 1 DIFFERENTIAL SUPPORT
*9 FRONT NO. 2 DIFFERENTIAL SUPPORT *10 FRONT NO. 3 DIFFERENTIAL SUPPORT
*11 DIFFERENTIAL MOUNT NUT *12 UPPER DIFFERENTIAL MOUNT STOPPER
*13 LOWER DIFFERENTIAL MOUNT STOPPER *14 DIFFERENTIAL BREATHER TUBE BRACKET
*15 WIRE HARNESS - -


ft.*lbf)
● Non-reusable part Differential oil
MP grease Do not apply lubricants
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ILLUSTRATION
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*A for R151 - -
*1 MANUAL TRANSMISSION UNIT ASSEMBLY *2 STIFFENER PLATE RH
*3 STIFFENER PLATE LH *4 STARTER ASSEMBLY
*5 CLUTCH RELEASE CYLINDER ASSEMBLY *6 REAR ENGINE MOUNTING INSULATOR

*7 NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY - -
ILLUSTRATION
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*A for RC61 - -
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ILLUSTRATION
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*A for RC61F - -
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N*m (kgf*cm, ft.*lbf): Specified torque Do not apply lubricants to the threads
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ILLUSTRATION

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*A for AC60E - -
*1 AUTOMATIC TRANSMISSION ASSEMBLY *2 DRIVE PLATE AND TORQUE CONVERTER

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CLUTCH SETTING BOLT

*3 OUTLET OIL COOLER TUBE *4 INLET OIL COOLER TUBE
*5 STIFFENER PLATE RH *6 NO. 4 CYLINDER BLOCK INSULATOR
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*7 NO. 2 END PLATE *8 STIFFENER PLATE LH

*9 STARTER ASSEMBLY *10 TRANSMISSION CONTROL CABLE BRACKET
*11 REAR ENGINE MOUNTING INSULATOR *12 NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
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*a BLACK: x 1 - -
SILVER: x 5
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ILLUSTRATION

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*A for AC60F - -
DRIVE PLATE AND TORQUE CONVERTER
*1 AUTOMATIC TRANSMISSION ASSEMBLY *2
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CLUTCH SETTING BOLT

*3 OUTLET OIL COOLER TUBE *4 INLET OIL COOLER TUBE
*5 STIFFENER PLATE RH *6 NO. 4 CYLINDER BLOCK INSULATOR
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*7 NO. 2 END PLATE *8 STIFFENER PLATE LH

*9 STARTER ASSEMBLY *10 TRANSMISSION CONTROL CABLE BRACKET
*11 REAR ENGINE MOUNTING INSULATOR *12 NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
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*a BLACK: x 1 - -
SILVER: x 5
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N*m (kgf*cm, ft.*lbf): Specified torque Do not apply lubricants to the threads
ILLUSTRATION

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*A for Automatic Transmission *B for Manual Transmission

*1 CLUTCH COVER ASSEMBLY *2 CLUTCH DISC ASSEMBLY
*3 FLYWHEEL SUB-ASSEMBLY *4 REAR END PLATE
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*5 PUMP IMPELLER DRIVE PLATE *6 REAR DRIVE PLATE SPACER

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ILLUSTRATION

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*1 FRONT ENGINE MOUNTING INSULATOR *2 FRONT ENGINE MOUNTING INSULATOR RH

*3 NO. 1 ENGINE HANGER UPPER *4 NO. 2 ENGINE HANGER
*5 UNION TO CONNECTOR TUBE HOSE - -
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Print Exit
1GD-FTV ENGINE MECHANICAL ENGINE ASSEMBLY INSTALLATION
PROCEDURE
1.INSTALL FRONT ENGINE MOUNTING INSULATOR 12361
a. Install the 2 front engine mounting insulators to the 2 front engine mounting brackets with the 2 nuts.
Torque:
64 N*m (653 kgf*cm, 47 ft.*lbf)
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2.INSTALL FRONT ENGINE MOUNTING INSULATOR RH 12391
a. Install the front engine mounting insulator RH to the front engine mounting insulator sub-assembly with
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the bolt.
Torque:
13 N*m (133 kgf*cm, 10 ft.*lbf)
3.INSTALL ENGINE WIRE
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a. Install the engine wire to the engine assembly.
4.INSTALL ENGINE HANGER

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5.REMOVE ENGINE ASSEMBLY TO ENGINE STAND

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NOTICE:
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· Pay attention to the angle of the sling device as the engine assembly or engine hangers may be
damaged or deformed if the angle is incorrect.
· With the exception of installing the engine assembly to an engine stand or removing the engine
assembly from an engine stand, do not perform any work on the engine assembly while it is suspended,
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as doing so is dangerous.
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a. Attach the engine sling device and hang the engine assembly with the chain block.
b. Remove the engine assembly from the engine stand.

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6.INSTALL ENGINE ASSEMBLY

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a. Slowly lower the engine assembly into the engine compartment.
b. Install the engine assembly to the body with the 4 bolts and 4 nuts.
Torque:
42 N*m (428 kgf*cm, 31 ft.*lbf)
HINT:
· Make sure to tighten the side with the nut.
· When installing a bolt with a claw (stopper), make sure that the claw (stopper) does not damage

the body of the vehicle.
c. Remove the 3 bolts, No. 1 engine hanger upper and No. 2 engine hanger.
7.INSTALL REAR END PLATE 11355
a. Install the rear end plate to the cylinder block with the bolt.
Torque:
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8.INSTALL FLYWHEEL SUB-ASSEMBLY 13405
a. Clean the bolt holes.
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b.
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Using SST, hold the crankshaft pulley.

SST
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09213-58014 (91551-80840)
09330-00021
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c. for Manual Transmission:

Install the flywheel sub-assembly to the crankshaft with the 8 bolts.
Torque:
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178 N*m (1815 kgf*cm, 131 ft.*lbf)

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*1 Flywheel Sub-assembly
*2 Pump Impeller Drive Plate
*3 Rear Drive Plate Spacer
*a Engine Side
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*b Transmission Side
for Automatic Transmission:

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Install the flywheel sub-assembly, the pump impeller drive plate and the rear drive plate spacer to the
crankshaft with the 8 bolts.
NOTICE:
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· Align either hole in the pump impeller drive plate and either hole in the rear drive plate spacer
with the knock pin of the flywheel sub-assembly, and then install the flywheel sub-assembly, the
pump impeller drive plate and the rear drive plate spacer to the crankshaft.
· Do not start the engine for at least 1 hour after installation.
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HINT:
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As the rear drive plate spacer and pump impeller drive plate are not reversible, be sure to install them in
the direction shown in the illustration.
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e.
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Install and uniformly tighten and tighten the 8 bolts in several steps in the sequence shown in the
illustration.
Torque:
178 N*m (1815 kgf*cm, 131 ft.*lbf)
f. w/o Viscous Heater:

Install the crankshaft pulley cover to the crankshaft pulley with the 4 bolts.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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g. w/ Viscous Heater:
Install the crankshaft pulley cover and viscous heater crankshaft pulley to the crankshaft pulley with the 4
bolts.
Torque:
24.5 N*m (250 kgf*cm, 18 ft.*lbf)
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9.INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission) 31250
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· for R151:
Click hereDrivetrain>CLUTCH>CLUTCH UNIT(for R151)>INSTALLATION
· for RC61:
Click hereDrivetrain>CLUTCH>CLUTCH UNIT(for RC60, RC61)>INSTALLATION
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10.INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission) 31210
· for R151:
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· for RC61:
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11.INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transmission) 31210
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· for R151:
· for RC61:
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12.INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic 35000

Transmission)
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· for AC60E:
Click hereDrivetrain>AC60E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSMISSION
ASSEMBLY(for 1GD-FTV, 2GD-FTV)>INSTALLATION
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· for AC60F:
Click hereDrivetrain>AC60F AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSMISSION
13.INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for 32101A
Automatic Transmission)
· for AC60E:

· for AC60F:
14.INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission) 33030
· for R151:
Click hereDrivetrain>R151 MANUAL TRANSMISSION / TRANSAXLE>MANUAL TRANSMISSION
ASSEMBLY>INSTALLATION
· for RC61:
Click hereDrivetrain>RC60 / RC61 MANUAL TRANSMISSION / TRANSAXLE>MANUAL TRANSMISSION
· for RC61F:
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Click hereDrivetrain>RC60F / RC61F MANUAL TRANSMISSION / TRANSAXLE>MANUAL TRANSMISSION
15.INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 37100
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Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>PROPELLER SHAFT ASSEMBLY(for TMT
Made)>INSTALLATION
16.INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) 37140
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Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>FRONT DRIVE SHAFT ASSEMBLY>INSTALLATION

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18.INSTALL VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous 87120G
Heater)
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a. Install the viscous heater with magnet clutch assembly to the No. 1 viscous heater bracket.
Torque:
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39 N*m (398 kgf*cm, 29 ft.*lbf)

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b. Connect the connector to the viscous heater with magnet clutch assembly.
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a. Install the water hose sub-assembly to the viscous heater with magnet clutch assembly, No. 2 water pipe
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and water outlet sub-assembly, and slide the 4 clamps to secure the 2 hoses.
b. Connect the water hose sub-assembly to the water inlet with the bolt.
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Torque:
5.4 N*m (55 kgf*cm, 48 in.*lbf)
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20.CONNECT COOLER COMPRESSOR ASSEMBLY 88320
a. Temporarily install the cooler compressor assembly to the compressor mounting bracket with the 2 stud
bolts.
b. Using an E8 "TORX" socket wrench, tighten the 2 stud bolts.

Torque:

c. Install the 2 bolts and 2 nuts.

Torque:
24.5 N*m (250 kgf*cm, 18 ft.*lbf)
d. Connect the connector to the cooler compressor assembly.
e. Connect the suction hose sub-assembly to the water inlet and timing chain cover with the 2 bolts.
Torque:
5.4 N*m (55 kgf*cm, 48 in.*lbf)
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21.INSTALL GENERATOR ASSEMBLY 27020
Click herePower Source / Network>1GD-FTV BATTERY / CHARGING>GENERATOR(for 80A Type)>INSTALLATION
22.CONNECT UNION TO CONNECTOR TUBE HOSE 44774
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a. Connect the union to connector tube hose to the No. 1 hose to hose tube, and slide the clamp to secure the
hose.
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23.CONNECT VANE PUMP ASSEMBLY 44320
a. Connect the vane pump assembly to the generator bracket with the 2 bolts.
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Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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b. Connect the connector to the power steering oil pressure switch.
24.CONNECT WATER HOSE SUB-ASSEMBLY

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a. Connect the water hose sub-assembly to the air conditioning unit assembly, slide the 2 clamps secure the 2
hoses.
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25.INSTALL BATTERY TRAY 74431

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26.INSTALL BATTERY 28800

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27.INSTALL BATTERY CLAMP SUB-ASSEMBLY 74404B

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a. Install the battery clamp sub-assembly to the battery with the 2 nuts.
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Torque:
5.4 N*m (55 kgf*cm, 48 in.*lbf)
28.CONNECT WIRE HARNESS
a. Connect the engine room main wire to the battery positive cable with the nut.
Torque:
7.1 N*m (72 kgf*cm, 63 in.*lbf)

b. Attach the clamp and connect the No. 2 engine wire with the 2 bolts.
Torque:
14 N*m (143 kgf*cm, 10 ft.*lbf)
c. Connect the 2 connectors to the engine room relay block sub-assembly.
d. Connect the wire to wire to the engine room relay block sub-assembly with the nut.
Torque:
12.5 N*m (127 kgf*cm, 9 ft.*lbf)
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e. Attach the 2 clips and install the No. 1 relay block cover side to the engine room relay block sub-assembly.
f. Attach the 3 clips and install the No. 1 relay block cover upper to the engine room relay block sub-
assembly.
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29.CONNECT NO. 2 FUEL HOSE 23273H
a. Connect the No. 2 fuel hose to the No. 3 nozzle leakage pipe assembly, and slide the clamp to secure the
hose.
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b. Attach the clamp to the No. 2 fuel hose.
30.CONNECT NO. 1 FUEL HOSE 23271H

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a. Connect the No. 1 fuel hose to the No. 2 fuel pipe, and slide the clamp to secure the hose.
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b. Attach the clamp to the No. 1 fuel hose.
23300
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31.INSTALL FUEL FILTER ASSEMBLY
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL FILTER>REPLACEMENT

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a. Install the intercooler air tube to the diesel throttle body assembly, and slide the clamp to secure the hose.
Torque:
6.5 N*m (66 kgf*cm, 58 in.*lbf)
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b. Connect the connector to the intake air temperature sensor.

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33.INSTALL NO. 4 AIR TUBE 17344E

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a. Install the No. 4 air hose to the No. 2 air tube and intercooler air tube, and slide the 2 clamps to secure the
hose.
Torque:
6.5 N*m (66 kgf*cm, 58 in.*lbf)
b. Connect the oil return hose to the engine oil level dipstick guide assembly, and slide the clamp to secure
the hose.

34.INSTALL NO. 1 AIR HOSE 17341F
a. Install the No. 1 air hose to the compressor outlet elbow and No. 1 air tube, and slide the 2 clamps to
secure the 2 hoses.
Torque:
6.5 N*m (66 kgf*cm, 58 in.*lbf)
36.INSTALL AIR CLEANER CAP AND HOSE
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a. Attach the 4 clips and install the air cleaner cap and hose.
b. Tighten the hose clamp.

Torque:
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4.0 N*m (41 kgf*cm, 35 in.*lbf)
c. Attach the 2 clamp and connect the connector to the mass air flow meter.
a.
37.CONNECT ENGINE WIRE
Pass the engine wire into the cabin. ke 82121

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b. Attach the grommet to the body.
HINT:
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Make sure the direction of grommet is shown in the illustration.

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c. Attach the clamp to connect the engine wire to the bracket.
d. Attach the clamp and connect the 4 connectors to the glow plug controller.
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e. Connect the connector to the engine room main wire.
f. Attach the 2 clamps and connect the 3 connectors to the instrument panel wire.
g. Install the ECM.

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECM>INSTALLATION

39.INSTALL HOOD SUB-ASSEMBLY 53301
a. Install the hood sub-assembly to the 2 hood hinge assemblies with the 4 bolts.
Torque:
13 N*m (133 kgf*cm, 10 ft.*lbf)
b. Connect the washer nozzle hose to the hood sub-assembly.
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40.ADD ENGINE OIL
41.ADD MANUAL TRANSMISSION OIL (for Manual Transmission)
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· for R151:
OIL>REPLACEMENT
· for RC61:
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OIL>REPLACEMENT
· for RC61F:
OIL>REPLACEMENT
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42.ADD AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)
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· for AC60E:
FLUID>ADJUSTMENT
· for AC60F:
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FLUID>ADJUSTMENT
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NOTICE:
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48.INSPECT ENGINE IDLE SPEED AND MAXIMUM SPEED
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE>ON-VEHICLE INSPECTION
50.INSTALL NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner) 51442
Torque:
28 N*m (286 kgf*cm, 21 ft.*lbf)
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Torque:
for M6 bolt : 11.5 N*m (117 kgf*cm, 8 ft.*lbf)
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for M8 bolt : 28 N*m (286 kgf*cm, 21 ft.*lbf)
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Print Exit
1GD-FTV ENGINE MECHANICAL ENGINE ASSEMBLY REMOVAL
parts are removed, installed, or replaced during the engine assembly removal/installation are shown below.
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· Learning values save
· Learning values write Engine starting ( )
for RC61:
Replacement of ECM installation · DTCs are output ( )
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information reset
See the Service

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method.
· Injector
compensation code
registration
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Engine starting ( )
Replacement of engine · Pilot quantity
assembly learning
Clear Crank Time

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Engine starting ( )
Compensation Data
Crank time compensation
data compensation amount
Replacement of crankshaft Clear Crank Time
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is same as before ( )
position sensor plate Compensation Data
replacement, affecting crank
time compensation data
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· Injector
compensation code
Replacement of injector registration Engine starting ( )
assembly · Pilot quantity
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learning
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throttle body
assembly
· Replacement of
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valve assembly
· Replacement of
turbocharger sub- Perform initialization - ( )
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assembly
· Replacement of
turbocharger sub-
assembly or
nozzle motor
for AC60E:
Replacement of · Large shift shock
automatic · Engine overruns
Reset memory
transmission

assembly
( )

for AC60F:
Replacement of
transmission
assembly
( )
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Beam Level Control
System:
The vehicle height
changes due to
replacement of
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Headlight leveling ECU
suspension Headlight leveling function ( )
assembly initialization
components or after
performing such
operations as
removal and
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reinstallation

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for 4WD:
calibration data
Front wheel
alignment ( )
acceleration sensor
adjustment
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CAUTION:
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engine is hot.
PROCEDURE
1. PRECAUTION
NOTICE:

NOTICE:
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4.REMOVE NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner) 51442
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5.DRAIN ENGINE OIL
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7.DRAIN MANUAL TRANSMISSION OIL (for Manual Transmission)

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· for R151:
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OIL>REPLACEMENT
· for RC61:
OIL>REPLACEMENT
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· for RC61F:
OIL>REPLACEMENT
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8.DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)

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· for AC60:
Click hereDrivetrain>AC60E AUTOMATIC TRANSMISSION / TRANSAXLE>TRANSMISSION WIRE>REMOVAL
· for AC60F:
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Click hereDrivetrain>AC60F AUTOMATIC TRANSMISSION / TRANSAXLE>TRANSMISSION WIRE>REMOVAL
53301
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9.REMOVE HOOD SUB-ASSEMBLY
a. Disconnect the washer nozzle hose from the hood sub-assembly.

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b. Remove the 4 bolts and hood sub-assembly from the 2 hood hinge assemblies.

a. Remove the ECM.

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECM>REMOVAL
b.
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*A for LHD
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*B for RHD
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Detach the 2 clamps and disconnect the 3 connectors from the instrument panel wire.
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c.
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*A for LHD
*B for RHD
Disconnect the connector from the engine room main wire.

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*A for LHD

*B for RHD
Detach the clamp and disconnect the 4 connectors from the glow plug controller.
e.
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*A for LHD
*B for RHD
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Detach the clamp and disconnect the engine wire from the bracket.
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*A for LHD
*B for RHD
Detach the grommet and pull out the engine wire from the cabin.
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13.REMOVE AIR CLEANER CAP AND HOSE

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a.
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Detach the 2 clamps and disconnect the connector from the mass air flow meter.
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b.
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Loosen the hose clamp.
c. Detach the 4 clips and remove the air cleaner cap and hose.
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15.REMOVE NO. 1 AIR HOSE 17341F
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Slide the 2 clamps and remove the No. 1 air hose from the compressor outlet elbow and air tube.
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a.
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Slide the clamp and disconnect the oil return hose from the engine oil level dipstick guide assembly.

b.
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Slide the 2 clamps and remove the No. 4 air hose from the No. 2 air tube and intercooler air tube.
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a.
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Disconnect the connector from the intake air temperature sensor.

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b.
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Slide the clamp and remove intercooler air tube from the diesel throttle body assembly.
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18.REMOVE FUEL FILTER ASSEMBLY 23300
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL FILTER>REPLACEMENT

a.
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Detach the clamp from the No. 1 fuel hose.
b. Slide the clamp and disconnect the No. 1 fuel hose from the No. 2 fuel pipe.
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a.
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Detach the clamp from the No. 2 fuel hose.
b. Slide the clamp and disconnect the No. 2 fuel hose from the No. 3 nozzle leakage pipe assembly.
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21.DISCONNECT WIRE HARNESS

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a.
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Detach the 3 clips and remove the No. 1 relay block cover upper from the engine room relay block.

b.
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Detach the 2 clips and remove the No. 1 relay block cover side from the engine room relay block sub-
assembly.
c.
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Remove the nut and disconnect the wire to wire from the engine room relay block sub-assembly.
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d.
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Disconnect the 2 connectors from the engine room relay block sub-assembly.
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e.
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Detach the clamp and remove the 2 bolts and disconnect the No. 2 engine wire.
f.
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Remove the nut and disconnect the engine room main wire from the battery positive cable.
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22.REMOVE BATTERY CLAMP SUB-ASSEMBLY 74404B
a. Loosen the 2 nuts and remove the battery clamp sub-assembly from the battery.
23.REMOVE BATTERY
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24.REMOVE BATTERY TRAY 74431
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25.DISCONNECT WATER HOSE SUB-ASSEMBLY
a.
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Slide the 2 clamps and disconnect the water hose sub-assembly from the air conditioning unit assembly.
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26.DISCONNECT VANE PUMP ASSEMBLY 44320

a.
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Disconnect the connector from the power steering oil pressure switch.
b.
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Remove the 2 bolt and disconnect the vane pump assembly from the generator bracket.
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27.DISCONNECT UNION TO CONNECTOR TUBE HOSE 44774

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a.
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Slide the clamp and disconnect the union to connector tube hose from the No. 1 hose to hose tube.
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28.REMOVE GENERATOR ASSEMBLY 27020
Click herePower Source / Network>1GD-FTV BATTERY / CHARGING>GENERATOR(for 80A Type)>REMOVAL
29.DISCONNECT COOLER COMPRESSOR ASSEMBLY 88320

a.
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Remove the 2 bolts and disconnect the suction hose sub-assembly from the water inlet and timing chain
cover.
b.
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Disconnect the connector from the cooler compressor assembly.
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c. Remove the 2 bolt and 2 nuts.

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d.
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Using an E8 "TORX" socket wrench, remove the 2 stud bolts and disconnect the cooler compressor
assembly from the compressor mounting bracket.
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a.
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Remove the bolt and disconnect the water hose from the water inlet.
b.
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Slide the 4 clamps and remove the water hose sub-assembly from the viscous heater with magnet clutch
assembly, No. 2 water pipe and water outlet sub-assembly.
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31.REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous 87120G
Heater)
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a. Disconnect the connector from the viscous heater with magnet clutch assembly.
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b.
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Remove the 2 bolts, nut and viscous heater with magnet clutch assembly from the No. 1 viscous heater
bracket.
33.REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) 37140

Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>FRONT PROPELLER SHAFT ASSEMBLY(for TMT

Made)>REMOVAL
34.REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 37100
Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>PROPELLER SHAFT ASSEMBLY(for TMT Made)>REMOVAL
35.REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission) 33030
· for R151:
ASSEMBLY>REMOVAL
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· for RC61:
ASSEMBLY>REMOVAL
· for RC61F:
ASSEMBLY>REMOVAL
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36.REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for 32101A
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· AC60E:
ASSEMBLY(for 1GD-FTV, 2GD-FTV)>REMOVAL
· AC60F:
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37.REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission) 35000

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· for AC60E:
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· for AC60F:
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38.REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission) 31210

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· for R151:
Click hereDrivetrain>CLUTCH>CLUTCH UNIT(for R151)>REMOVAL
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· for RC61:
Click hereDrivetrain>CLUTCH>CLUTCH UNIT(for RC60, RC61)>REMOVAL
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39.REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission) 31250

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· for R151:
· for RC61:
40.REMOVE FLYWHEEL SUB-ASSEMBLY 13405

a.
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w/ Viscous Heater:
Remove the 4 bolts, viscous heater crankshaft pulley and crankshaft pulley cover from the crankshaft
pulley.
b.
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w/o Viscous Heater:
Remove the 4 bolts and crankshaft pulley cover from the crankshaft pulley.
c.
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Using SST, hold the crankshaft pulley.

SST
09213-58014 (91551-80840)
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09330-00021

d.
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for Manual Transmission:
Remove the 8 bolts and flywheel sub-assembly from the crankshaft.
e.
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Remove the 8 bolts, rear drive plate spacer, pump impeller drive plate and flywheel sub-assembly from the
crankshaft.
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41.REMOVE REAR END PLATE 11355
a.
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Remove the bolt and rear end plate from the cylinder block sub-assembly.
42.INSTALL ENGINE HANGER

a.
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*1 No. 1 Engine Hanger Upper
*2 No. 2 Engine Hanger
Install the No. 1 engine hanger upper and No. 2 engine hanger with the 3 bolts as shown in the illustration.
Torque:
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for No. 1 engine hanger upper : 29 N*m (296 kgf*cm, 21 ft.*lbf)
for No. 2 engine hanger : 26 N*m (265 kgf*cm, 19 ft.*lbf)
HINT:
No. 1 Engine Hanger 12284-11010 or
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Upper 12284-11020
12282-11080 or
No. 2 Engine Hanger
12282-11090
90119-T0073 or
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91552-81025 and
Bolt
90119-T0219 or,
91672-80835
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43.REMOVE ENGINE ASSEMBLY

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a. Attach an engine sling device and hang the engine assembly with a chain block.
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b.
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Remove the 4 bolts and 4 nuts from the body.
c. Remove the engine assembly by operating the engine sling device and chain block.
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NOTICE:
· Make sure that the engine assembly is clear of all wiring and hoses.
· While lowering the engine assembly from the vehicle, do not allow it to contact the vehicle.
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44.INSTALL ENGINE ASSEMBLY TO ENGINE STAND
NOTICE:
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· Pay attention to the angle of the sling device as the engine assembly or engine hangers may be
damaged or deformed if the angle is incorrect.
· With the exception of installing the engine assembly to an engine stand or removing the engine
assembly from an engine stand, do not perform any work on the engine assembly while it is suspended,
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as doing so is dangerous.
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a. Install the engine assembly to engine stand with the bolts.
b. Remove the 3 bolts, No. 1 engine hanger upper and No. 2 engine hanger.
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a. Remove the engine wire from the engine assembly.
46.REMOVE FRONT ENGINE MOUNTING INSULATOR RH 12391

a.
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Remove the bolt and front engine mounting insulator RH from the front engine mounting insulator.
47.REMOVE FRONT ENGINE MOUNTING INSULATOR 12361
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Remove the 2 nuts and 2 front engine mounting insulators from the 2 front engine mounting brackets.
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Print Exit
1GD-FTV ENGINE MECHANICAL ENGINE UNIT COMPONENTS
ILLUSTRATION
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*A w/ DPF - -
*1 DIFFERENTIAL PRESSURE SENSOR *2 NO. 1 EXHAUST GAS TEMPERATURE SENSOR
*3 NO. 2 EXHAUST GAS TEMPERATURE SENSOR *4 NO. 3 EXHAUST GAS TEMPERATURE SENSOR

*5 NO. 1 VACUUM PIPE *6 NO. 2 VACUUM PIPE

*7 PIPE CLAMP *8 CLAMP
ILLUSTRATION
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*1 DIESEL THROTTLE BODY ASSEMBLY *2 DIESEL TURBO PRESSURE SENSOR
*3 ENGINE COVER BRACKET *4 GAS FILTER
*5 HOSE BRACKET *6 INTERCOOLER AIR TUBE
*9 NO. 2 WATER BY-PASS PIPE *10 NO. 11 WATER BY-PASS HOSE

ILLUSTRATION
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*1 CONNECTING WIRE *2 EGR VALVE BRACKET
*3 ENGINE OIL LEVEL DIPSTICK GUIDE *4 ASSEMBLY WITH ELECTRIC EGR CONTROL
VALVE ASSEMBLY


*9 VACUUM CONTROL VALVE SET *10 ENGINE OIL LEVEL DIPSTICK
*13 STUD BOLT - -
Engine oil - -
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ILLUSTRATION
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*A w/ DPF - -
*3 MANIFOLD STAY *4 NO. 1 FUEL HOSE
*5 NO. 2 FUEL HOSE *6 NO. 2 FUEL PIPE
*9 WIRING HARNESS CLAMP BRACKET *10 FUEL PIPE CLAMP
*11 SUPPLY PUMP HOLLOW SCREW *12 UNION BOLT
*13 GASKET - -

ILLUSTRATION
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*A w/ DPF - -

*1 FUEL INLET PIPE SUB-ASSEMBLY *2 INTAKE MANIFOLD

*3 NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY *4 WIRING HARNESS CLAMP BRACKET
*5 INJECTION PIPE CLAMP *6 NO. 2 INJECTION PIPE CLAMP
*7 GASKET - -

ft.*lbf)
ILLUSTRATION
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*A w/ DPF - -
*1 COMMON RAIL ASSEMBLY *2 GLOW PLUG ASSEMBLY
*5 NO. 1 FUEL PIPE *6 NO. 1 GLOW PLUG CONNECTOR
*7 NOZZLE LEAKAGE PIPE ASSEMBLY *8 WIRING HARNESS CLAMP BRACKET
*9 UNION BOLT *10 SCREW GROMMET
*11 GASKET - -


ft.*lbf)
* For use with SST ● Non-reusable part
ILLUSTRATION
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*C w/ Air Conditioning System *D w/o Air Conditioning System
*1 ENGINE COOLANT TEMPERATURE SENSOR *2 FUEL FILTER ASSEMBLY

*3 NO. 1 COMPRESSOR MOUNTING BRACKET *4 NO. 1 IDLER PULLEY SUB-ASSEMBLY

*5 NO. 3 NOZZLE LEAKAGE PIPE *6 NO. 5 WATER BY-PASS PIPE SUB-ASSEMBLY
*7 GASKET - -
ILLUSTRATION
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*A w/ DPF - -
ASSEMBLY
*5 NO. 1 INJECTOR HOLDER *6 NO. 1 TURBO INSULATOR
*7 NO. 1 WATER HOSE CLAMP BRACKET *8 NO. 2 EXHAUST PIPE SUPPORT STAY
N*m (kgf*cm, ft.*lbf): Specified torque * For use with SST

ILLUSTRATION
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*A w/o DPF - -
*1 EXHAUST MANIFOLD CONVERTER SUB- *2 EXHAUST PIPE SUPPORT STAY

ASSEMBLY
*5 NO. 2 EXHAUST PIPE SUPPORT STAY *6 EXHAUST PIPE CLAMP
*7 GASKET - -
ILLUSTRATION
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*A except Cold Area Specification Vehicles *B for Cold Area Specification Vehicles
*C w/ Viscous Heater - -
*1 NO. 1 VISCOUS HEATER BRACKET SUB- *2 NO. 3 WATER BY-PASS PIPE

ASSEMBLY
*3 PCV HOSE *4 PCV PIPE

ILLUSTRATION
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*A w/ DPF - -
*1 ENGINE OIL PRESSURE SWITCH ASSEMBLY *2 EXHAUST MANIFOLD
*3 NO. 1 TURBO WATER HOSE *4 NO. 2 TURBO WATER HOSE
*5 TURBO OIL INLET PIPE SUB-ASSEMBLY *6 TURBO OIL OUTLET PIPE
*9 COLLAR *10 SPACER


ft.*lbf)
Toyota Genuine Adhesive 1344, Three Bond

● Non-reusable part
1344 or equivalent
Precoated part - -
ILLUSTRATION
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*A w/ DPF *B for Cold Area Specification Vehicles

*1 NO. 1 WATER BY-PASS PIPE *2 NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY
*3 THERMOSTAT *4 WATER INLET
*5 WATER OUTLET SUB-ASSEMBLY *6 GASKET
ILLUSTRATION
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*A w/o Viscous Heater *B w/ Viscous Heater

*1 CRANKSHAFT PULLEY *2 CRANKSHAFT PULLEY COVER
*3 NO. 1 IDLER PULLEY SUB-ASSEMBLY *4 VISCOUS HEATER CRANKSHAFT PULLEY

*5 V-RIBBED BELT TENSIONER ASSEMBLY *6 CRANKSHAFT PULLEY SET BOLT
ILLUSTRATION
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NO. 1 VACUUM TRANSMITTING PIPE SUB-

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*1 CAMSHAFT OIL SEAL RETAINER *2

ASSEMBLY
*3 VACUUM PUMP ASSEMBLY *4 O-RING

ft.*lbf)

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*1 FRONT NO. 1 ENGINE MOUNTING BRACKET *2 GENERATOR BRACKET SUB-ASSEMBLY

LH
*3 INJECTION PUMP INSULATOR *4 NO. 1 ENGINE HANGER
*5 NO. 2 CYLINDER BLOCK INSULATOR *6 NO. 3 CYLINDER BLOCK INSULATOR

*7 SUPPLY PUMP ASSEMBLY *8 TIMING CHAIN COVER PLATE

*9 NO. 1 FUEL PUMP BRACKET *10 SUPPLY PUMP SHAFT NUT

ft.*lbf)
ILLUSTRATION
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*1 FRONT NO. 1 ENGINE MOUNTING BRACKET *2 OIL COOLER ASSEMBLY

RH
*3 OIL FILTER BRACKET *4 OIL FILTER SUB-ASSEMBLY
*5 OIL FILTER UNION *6 WATER OUTLET PIPE GASKET
*7 O-RING - -


ft.*lbf)
ILLUSTRATION
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*3 INJECTOR ASSEMBLY *4 NOZZLE HOLDER GASKET
*5 OIL FILLER CAP GASKET *6 OIL FILLER CAP SUB-ASSEMBLY
*7 CYLINDER HEAD COVER GASKET *8 NO. 2 CYLINDER HEAD COVER GASKET
*9 CAMSHAFT BEARING CAP OIL HOLE GASKET *10 NOZZLE HOLDER CLAMP

*11 INJECTION NOZZLE SEAT *12 NOZZLE HOLDER CLAMP SEAT

*13 WASHER *14 O-RING

ft.*lbf)
ILLUSTRATION
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*1 CRANKSHAFT POSITION SENSOR *2 CRANKSHAFT POSITION SENSOR HARNESS

BRACKET
*3 ENGINE OIL LEVEL SENSOR *4 NO. 1 CYLINDER BLOCK INSULATOR
*5 NO. 5 CYLINDER BLOCK INSULATOR *6 OIL PAN COVER SILENCER
*7 OIL PAN SUB-ASSEMBLY *8 OIL STRAINER SUB-ASSEMBLY
*9 REAR ENGINE OIL SEAL *10 REAR ENGINE OIL SEAL RETAINER
*11 OIL PAN DRAIN PLUG *12 GASKET

ILLUSTRATION
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*1 CAMSHAFT TIMING SPROCKET (for Exhaust *2 CAMSHAFT TIMING SPROCKET (for Intake
Side) Side)
*3 FRONT CRANKSHAFT OIL SEAL *4 NO. 2 CHAIN SUB-ASSEMBLY
*7 NO. 2 CHAIN VIBRATION DAMPER *8 OIL PUMP RELIEF VALVE PLUG
*9 TIMING CHAIN COVER SUB-ASSEMBLY *10 TIMING CHAIN GUIDE
*11 TIMING CHAIN CASE GASKET *12 CAMSHAFT TIMING SPROCKET BOLT
*13 GASKET - -
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ILLUSTRATION
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*1 CRANKSHAFT TIMING SPROCKET *2 INJECTION PUMP DRIVE GEAR

*3 NO. 1 CHAIN SUB-ASSEMBLY *4 ENGINE WATER PUMP ASSEMBLY
*7 NO. 1 CHAIN VIBRATION DAMPER *8 OIL PUMP DRIVE GEAR
*9 TIMING CHAIN CASE ASSEMBLY *10 NO. 1 CHAIN TENSIONER ASSEMBLY BODY
*11 SPRING *12 PLUNGER

Engine oil - -
ILLUSTRATION
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*1 CAMSHAFT *2 CYLINDER HEAD GASKET

*3 CYLINDER HEAD SUB-ASSEMBLY *4 LOCK PLATE
*7 NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY *8 NO. 2 CAMSHAFT
*9 NO. 3 CAMSHAFT BEARING CAP *10 VALVE LASH ADJUSTER ASSEMBLY
*11 CYLINDER HEAD SET BOLT *12 CAMSHAFT BEARING CAP BOLT
*13 CYLINDER HEAD SET BOLT SPACER - -

ft.*lbf)
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1st: 150 (1530, 111) 1st: 85 (867, 63)

*T1 2nd: Turn 90° *T2 2nd: Turn 90°
3rd: Turn 90° 3rd: Turn 90°
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ILLUSTRATION
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*1 STRAIGHT PIN *2 STUD BOLT

*3 TIMING CHAIN COVER SUB-ASSEMBLY *4 TIMING CHAIN CASE ASSEMBLY
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Print Exit
1GD-FTV ENGINE MECHANICAL ENGINE UNIT DISASSEMBLY
PROCEDURE
1.REMOVE NO. 1 ENGINE HANGER 12281A
a.
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Remove the 2 bolts and No. 1 engine hanger from the cylinder head sub-assembly.
2.REMOVE NO. 2 CYLINDER BLOCK INSULATOR 12582

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Remove the No. 2 cylinder block insulator from the front No. 1 engine mounting bracket LH.
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3.REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH 12315

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a.
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Remove the 4 bolts and front No. 1 engine mounting bracket LH from the cylinder block sub-assembly.
4.REMOVE NO. 3 CYLINDER BLOCK INSULATOR 12583A
a.
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Remove the No. 3 cylinder block insulator from the cylinder block sub-assembly.
5.REMOVE GENERATOR BRACKET SUB-ASSEMBLY 12501
a.
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Remove the 4 bolts and generator bracket sub-assembly from the cylinder head sub-assembly and timing
chain case assembly.
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6.REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH 12311

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a.
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Remove the 4 bolts and front No. 1 engine mounting bracket RH from the cylinder block sub-assembly.

7.REMOVE OIL COOLER ASSEMBLY 15710
Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>ENGINE OIL COOLER>REMOVAL
9.REMOVE OIL FILTER UNION 15600A
a.
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Using a 27 mm deep socket wrench, remove the oil filter union from the oil filter bracket.
10.REMOVE OIL FILTER BRACKET 15677

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Remove the bolt, 2 nuts and oil filter bracket from the cylinder block sub-assembly.
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b. Remove the 2 O-rings from the cylinder block sub-assembly.

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13.REMOVE CAMSHAFT POSITION SENSOR 11401Q

14.REMOVE OIL FILLER CAP SUB-ASSEMBLY 12108
a. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.
15.REMOVE OIL FILLER CAP GASKET 12108A
a. Remove the oil filler cap gasket from the oil filler cap sub-assembly.
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17.REMOVE NO. 5 CYLINDER BLOCK INSULATOR 12585
a.
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18.REMOVE NO. 1 CYLINDER BLOCK INSULATOR 12581A

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19.REMOVE CRANKSHAFT POSITION SENSOR HARNESS BRACKET

a.
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Disconnect the crankshaft position sensor connector.
b. Remove the bolt and crankshaft position sensor harness bracket from the cylinder block sub-assembly.
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20.REMOVE CRANKSHAFT POSITION SENSOR 11401G
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>CRANKSHAFT POSITION SENSOR>REMOVAL
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21.REMOVE OIL PAN COVER SILENCER 12144
22.REMOVE ENGINE OIL LEVEL SENSOR 89491

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Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL LEVEL SENSOR>REMOVAL
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23.REMOVE OIL PAN SUB-ASSEMBLY 12101

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24.REMOVE OIL STRAINER SUB-ASSEMBLY 15104
a.
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Remove the 4 bolts, oil strainer sub-assembly and gasket from the cylinder block sub-assembly.
25.REMOVE REAR ENGINE OIL SEAL RETAINER 11381

a.
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Remove the 5 bolts.
b.
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Remove the rear engine oil seal retainer by prying between the rear engine oil seal retainer and cylinder
block sub-assembly with a screwdriver.
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NOTICE:
Be careful not to damage the contact surfaces of the cylinder block sub-assembly.
HINT:
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Tape the screwdriver tip before use.

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26.REMOVE REAR ENGINE OIL SEAL 11381A

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a.
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*a Wooden Block
Place the rear engine oil seal retainer on wooden blocks.
b. Using a screwdriver, tap out the rear engine oil seal from the rear engine oil seal retainer.
NOTICE:

Do not damage the surface of the rear engine oil seal press fit hole.
HINT:
Tape the screwdriver tip before use.
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a. Temporarily install the crankshaft pulley and crankshaft pulley set bolt to the crankshaft.
b.
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*a Timing Mark
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Align the timing mark of the crankshaft pulley and timing chain cover sub-assembly by rotating the
crankshaft clockwise.
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c. Make sure that the timing mark of the camshaft timing sprocket is at the top.
HINT:
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NOTICE:
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*A w/ DPF
*B w/o DPF
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Do not hold the supply pump assembly by the parts indicated by the arrows in the illustration.
a.
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*a Hold
Turn
Using SST, hold the crankshaft pulley and loosen the supply pump shaft nut.
SST
09213-58014 (91551-80840)
09330-00021
NOTICE:
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Do not excessively loosen the supply pump shaft nut, otherwise SST cannot be installed.
HINT:
Rotate the supply pump shaft nut once to loosen it.
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Install SST with the 3 bolts to the timing chain cover sub-assembly.
SST
09241-11010
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Torque:
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HINT:
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*a Engine Front Side
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*b Engine Rear Side
*c Hexagonal Portion
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· Make sure that the installation direction of SST is as shown in the illustration.
· Align the hexagonal portion of SST with the supply pump shaft nut to install SST.
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c.
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w/ DPF:
Remove the 2 bolts and No. 1 fuel pump bracket from the cylinder block sub-assembly and supply pump
assembly.

d.
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*A w/ DPF
*B w/o DPF
Loosen the 3 nuts to the ends of the stud bolts.

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NOTICE:
Do not completely remove the nuts. Otherwise, the supply pump assembly may fall off.
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Using SST, loosen the supply pump shaft nut and detach the supply pump assembly and injection pump
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drive gear.
f. Remove the 3 nuts from the stud bolts.
g. Remove the O-ring from the supply pump assembly.
h. Remove SST from the timing chain cover sub-assembly.

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Remove the supply pump shaft nut from the timing chain cover sub-assembly service hole.
j. Remove the crankshaft pulley set bolt and crankshaft pulley from the crankshaft.
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31.REMOVE INJECTION PUMP INSULATOR 22815A
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Remove the injection pump insulator from the cylinder block sub-assembly.
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32.REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 11302

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34.REMOVE OIL PUMP RELIEF VALVE PLUG 15133B

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Remove the oil pump relief valve plug and gasket from the timing chain cover sub-assembly.
35.INSPECT BACKLASH OF OIL PUMP GEAR TO OIL PUMP DRIVE GEAR
36.REMOVE OIL PUMP DRIVE GEAR 13519
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*a Stopper Plate
*b Plunger
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Allow the plunger to extend slightly, and then rotate the stopper plate clockwise to release the lock. Once
the lock is released, push the plunger into the No. 2 chain tensioner assembly.
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b.
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*a Pin
Move the stopper plate counterclockwise to set the lock, and then insert a pin into the stopper plate hole.

c.
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Remove the 2 bolts and No. 2 chain tensioner assembly from the timing chain case assembly.
39.REMOVE NO. 2 CHAIN TENSIONER SLIPPER
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Remove the bolt and No. 2 chain tensioner slipper from the timing chain case assembly.
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Remove the 2 bolts and No. 2 chain vibration damper from the timing chain case assembly.
41.REMOVE NO. 2 CHAIN SUB-ASSEMBLY 13507
a. Remove the No. 2 chain sub-assembly from the camshaft timing sprockets and injection pump drive gear.

NOTICE:
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*a No. 1 Chain Tensioner Assembly Body
*b Spring
*c Plunger
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· When the pin is removed from the No. 1 chain tensioner assembly, the plunger and spring may come off
of the No. 1 chain tensioner assembly body, but this is not a malfunction.
· Before installing the plunger and spring to the No. 1 chain tensioner assembly body, check that they are
free of foreign matter and not damaged.
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*a Pin
*b Plunger
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*c Plunger Groove
Fully insert the plunger, align the No. 1 chain tensioner assembly body hole with the plunger groove and
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insert the pin as shown in the illustration.

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Remove the 2 bolts, No. 1 chain tensioner assembly and gasket from the cylinder block sub-assembly.
43.REMOVE NO. 1 CHAIN TENSIONER SLIPPER 13559
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Remove the No. 1 chain tensioner slipper from the straight pin.
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Remove the bolt and No. 1 chain vibration damper from the cylinder block sub-assembly.
45.REMOVE CRANKSHAFT TIMING SPROCKET, INJECTION PUMP DRIVE GEAR 13506


a.
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Remove the crankshaft timing sprocket, injection pump drive gear with No. 1 chain sub-assembly from the
crankshaft and supply pump shaft.
46.REMOVE CAMSHAFT TIMING SPROCKET 13523
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a. for Exhaust Side:
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*a Hold
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Turn
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Hold hexagonal portion of the No. 2 camshaft with a wrench and remove the camshaft timing sprocket
bolt and camshaft timing sprocket from the No. 2 camshaft.
NOTICE:
Be careful not to damage the No. 2 camshaft or cylinder head sub-assembly with the wrench.
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b. for Intake Side:

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*a Hold
Turn
Hold hexagonal portion of the camshaft with a wrench and remove the camshaft timing sprocket bolt
and camshaft timing sprocket from the camshaft.
NOTICE:
Be careful not to damage the camshaft or cylinder head sub-assembly with the wrench.
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47.REMOVE TIMING CHAIN CASE ASSEMBLY 11310
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Remove the 2 camshaft bearing cap bolts and No. 3 camshaft bearing cap from the cylinder head sub-
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assembly.
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49.REMOVE NO. 1 AND NO. 2 CAMSHAFT BEARING CAP
a.
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Remove the 20 camshaft bearing cap bolts in the sequence shown in the illustration.
b. Remove the No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps from the cylinder head sub-
assembly.
HINT:

50.REMOVE CAMSHAFT 13511
a. Remove the camshaft from the cylinder head sub-assembly.
51.REMOVE NO. 2 CAMSHAFT 13512
a. Remove the No. 2 camshaft from the cylinder head sub-assembly.
52.REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 13801
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a. Remove the 16 No. 1 valve rocker arm sub-assemblies from the 16 valve lash adjuster assemblies.
53.REMOVE VALVE LASH ADJUSTER ASSEMBLY 13750
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a. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.
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54.REMOVE CYLINDER HEAD SUB-ASSEMBLY 11101
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>CYLINDER HEAD GASKET>REMOVAL
55.REMOVE CYLINDER HEAD GASKET 11115

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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>CYLINDER HEAD GASKET>REMOVAL
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56.REMOVE LOCK PLATE 13577D
a.
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Remove the bolt and lock plate from the cylinder block sub-assembly.
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57.REMOVE STUD BOLT
NOTICE:
58.REMOVE STRAIGHT PIN
NOTICE:

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Print Exit
1GD-FTV ENGINE MECHANICAL ENGINE UNIT INSPECTION
PROCEDURE
1.INSPECT NO. 1 CHAIN SUB-ASSEMBLY 13506
a.
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*a Measuring Point
Using a spring scale, pull the No. 1 chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in
the illustration.
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b. Using a vernier caliper, measure the length of 16 pins.
Maximum chain elongation:
144.7 mm (5.70 in.)
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HINT:
Perform the measurement at 3 random places.
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If the elongation is more than the maximum, replace the No. 1 chain sub-assembly.
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2.INSPECT NO. 2 CHAIN SUB-ASSEMBLY 13507
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*a Measuring Point
Using a spring scale, pull the No. 2 chain sub-assembly with a force of 147 N (15 kgf, 33.0 lbf) as shown in
the illustration.
b. Using a vernier caliper, measure the length of 16 pins.

Maximum chain elongation:

121.6 mm (4.79 in.)
HINT:
Perform the measurement at 3 random places.
If the elongation is more than the maximum, replace the No. 2 chain sub-assembly.
3.INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY 13540
NOTICE:
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*b Spring
*c Plunger
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*a Plunger
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Push the plunger and check that it moves smoothly.

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If necessary, replace the No. 1 chain tensioner assembly.
4.INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY 13550

a.
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*a Stopper Plate
*b Plunger
Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.
If necessary, replace the No. 2 chain tensioner assembly.
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5.INSPECT CAMSHAFT TIMING SPROCKET 13523
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a. Wrap the No. 2 chain sub-assembly around the camshaft timing sprocket.
b.
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Using a vernier caliper, measure the camshaft timing sprocket diameter with the No. 2 chain sub-assembly.
Minimum sprocket with chain diameter:
97.79 mm (3.85 in.)
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If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and camshaft timing
sprocket.
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HINT:
The vernier caliper must contact the No. 2 chain sub-assembly rollers for the measurement.
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6.INSPECT CRANKSHAFT TIMING SPROCKET 13521

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a. Wrap the No. 1 chain sub-assembly around the crankshaft timing sprocket.

b.
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Using a vernier caliper, measure the crankshaft timing sprocket diameter with the No. 1 chain sub-
assembly.
Minimum sprocket with chain diameter:
71.26 mm (2.81 in.)
If the diameter is less than the minimum, replace the No. 1 chain sub-assembly and crankshaft timing
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sprocket.
HINT:
7.INSPECT INJECTION PUMP DRIVE GEAR
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a. for No. 1 Chain Sub-assembly Side:
i. Wrap the No. 1 chain sub-assembly around the injection pump drive gear.
ii.
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Using a vernier caliper, measure the injection pump drive gear diameter with the No. 1 chain sub-
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assembly.
Minimum gear with chain diameter:
71.26 mm (2.81 in.)
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If the diameter is less than the minimum, replace the No. 1 chain sub-assembly and injection pump
drive gear.
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HINT:
b. for No. 2 Chain Sub-assembly Side:

i. Wrap the No. 2 chain sub-assembly around the injection pump drive gear.

ii.
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Using a vernier caliper, measure the injection pump drive gear diameter with the No. 2 chain sub-
assembly.
Minimum gear with chain diameter:
52.32 mm (2.06 in.)
If the diameter is less than the minimum, replace the No. 2 chain sub-assembly and injection pump
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drive gear.
HINT:
8.INSPECT NO. 1 CHAIN TENSIONER SLIPPER
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*a Depth
Measure the depth of wear of the No. 1 chain tensioner slipper.

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Maximum depth:
1.0 mm (0.0394 in.)
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If the depth is more than the maximum, replace the No. 1 chain tensioner slipper.
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9.INSPECT NO. 2 CHAIN TENSIONER SLIPPER

a.
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*a Depth
Measure the depth of wear of the No. 2 chain tensioner slipper.

Maximum depth:
1.0 mm (0.0394 in.)
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If the depth is more than the maximum, replace the No. 2 chain tensioner slipper.
10.INSPECT NO. 1 CHAIN VIBRATION DAMPER 13561
a.
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*a Depth
Measure the depth of wear of the No. 1 chain vibration damper.

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Maximum depth:
1.0 mm (0.0394 in.)
If the depth is more than the maximum, replace the No. 1 chain vibration damper.
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11.INSPECT NO. 2 CHAIN VIBRATION DAMPER 13562

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a.
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*a Depth
Measure the depth of wear of the No. 2 chain vibration damper.

Maximum depth:
1.0 mm (0.0394 in.)
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If the depth is more than the maximum, replace the No. 2 chain vibration damper.
12.INSPECT TIMING CHAIN GUIDE 13566B
a.
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*a Depth
Measure the depth of wear of the timing chain guide.

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Maximum depth:
1.0 mm (0.0394 in.)
If the depth is more than the maximum, replace the timing chain guide.
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13.INSPECT INTAKE MANIFOLD 17111

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a.
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Using a precision straightedge and feeler gauge, measure the warpage of the surface where the intake
manifold contacts the cylinder head sub-assembly.
Maximum warpage:
0.10 mm (0.00394 in.)
If the warpage is more than the maximum, replace the intake manifold.
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14.INSPECT EXHAUST MANIFOLD 17141
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Using a precision straightedge and feeler gauge, measure the warpage of the surface where the exhaust
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manifold contacts the cylinder head sub-assembly.

Maximum warpage:
0.10 mm (0.00394 in.)
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If the warpage is more than the maximum, replace the exhaust manifold.
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15.INSPECT CAMSHAFT 13511

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a. Inspect the camshaft runout.

i. Place the camshaft on V-blocks.
ii. Using a dial indicator, measure the circle runout at the center journal.
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Maximum circle runout:

0.03 mm (0.00118 in.)
If the circle runout is more than the maximum, replace the camshaft.
HINT:
Check the oil clearance after replacing the camshaft.
b. Inspect the cam lobes.

i. Using a micrometer, measure the cam lobe height.

Standard cam lobe height:

41.425 to 41.525 mm (1.631 to 1.635 in.)
Minimum cam lobe height:

41.375 mm (1.629 in.)
If the cam lobe height is less than the minimum, replace the camshaft.
c. Inspect the camshaft journals.

i. Using a micrometer, measure the journal diameter.
Standard Journal Diameter:
34.449 to 34.465 mm
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No. 1 journal
(1.356 to 1.357 in.)
22.990 to 23.007 mm
Other journals
(0.905 to 0.906 in.)
If the journal diameter is not as specified, check the oil clearance.
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16.INSPECT NO. 2 CAMSHAFT 13512
a. Inspect the No. 2 camshaft runout.

i. Place the No. 2 camshaft on V-blocks.
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Using a dial indicator, measure the circle runout at the center journal.
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Maximum circle runout:
0.03 mm (0.00118 in.)
If the circle runout is more than the maximum, replace the No. 2 camshaft.
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HINT:
Check the oil clearance after replacing the No. 2 camshaft.
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b. Inspect the cam lobes.

i. Using a micrometer, measure the cam lobe height.
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Standard cam lobe height:

41.694 to 41.794 mm (1.641 to 1.645 in.)
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Minimum cam lobe height:

41.644 mm (1.640 in.)
If the cam lobe height is less than the minimum, replace the No. 2 camshaft.
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c. Inspect the No. 2 camshaft journals.

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i. Using a micrometer, measure the journal diameter.

Standard Journal Diameter:
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34.449 to 34.465 mm
No. 1 journal
(1.356 to 1.357 in.)
22.990 to 23.007 mm
Other journals
(0.905 to 0.906 in.)
If the journal diameter is not as specified, check the oil clearance.

17.INSPECT CAMSHAFT OIL CLEARANCE
a. Clean the No. 1 camshaft bearing cap, No. 2 camshaft bearing caps, camshaft journals and No. 2 camshaft
journals.
b. Place the camshaft and No. 2 camshaft on the cylinder head sub-assembly.
c.
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*a Plastigage
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Lay a strip of Plastigage across each of the camshaft journals.
d. Install the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps to the cylinder head sub-assembly.
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NOTICE:
Do not turn the camshaft and No. 2 camshaft.
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e. Remove the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps from the cylinder head sub-
assembly.
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f.
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Measure the Plastigage at its widest point.

Standard Oil Clearance:
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0.040 to 0.077 mm
No. 1 journal (0.00157 to 0.00303
in.)
0.025 to 0.062 mm
Other journals (0.000984 to 0.00244
in.)
Maximum Oil Clearance:


0.117 mm (0.00461
No. 1 journal
in.)
0.102 mm (0.00402
Other journals
in.)
If the camshaft oil clearance is more than the maximum, replace the camshaft. If necessary, replace the
cylinder head sub-assembly.
g. Completely remove the Plastigage from the camshaft journals.
18.INSPECT CYLINDER HEAD SET BOLT 11101A
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a. w/ Washer:
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*a Measuring Area
*b Washer
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Using a vernier caliper, measure the thread outside diameter of the cylinder head set bolt.
Minimum diameter:
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11.4 mm (0.449 in.)
If the diameter is less than the minimum, replace the cylinder head set bolt.
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b. w/o Washer:
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*a Measuring Area
Using a vernier caliper, measure the thread outside diameter of the cylinder head set bolt.
Minimum diameter:
12.8 mm (0.504 in.)
If the diameter is less than the minimum, replace the cylinder head set bolt and cylinder head set bolt
spacer.

19.INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 13801
a. Turn the roller by hand and check that it turns smoothly.

If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.
20.INSPECT VALVE LASH ADJUSTER ASSEMBLY 13750
NOTICE:
· Keep the adjuster free from dirt and foreign matter.
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· Use only clean engine oil.
a. Place the valve lash adjuster assembly into a container full of new engine oil.
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*a CORRECT *b INCORRECT
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*c Taper Part *d Plunger

*e Low Pressure Chamber *f Check Ball
*g High Pressure Chamber - -
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b. Insert the tip of SST into the plunger and use the tip to press down on the check ball inside the plunger.
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SST
09276-75010
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c. Squeeze SST and the valve lash adjuster assembly together to move the plunger up and down 5 to 6 times.
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d. Check the movement of the plunger and bleed air.

OK:
Plunger moves up and down.
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NOTICE:
When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually
pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.
e. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.
OK:
Plunger is very difficult to move.
If the result is not as specified, replace the valve lash adjuster assembly.

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Print Exit
1GD-FTV ENGINE MECHANICAL ENGINE UNIT INSTALLATION
NOTICE:
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dropped.
or dropped.
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· The common rail assembly is a precision instrument. Do not use the common rail assembly if it is struck
or dropped.
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· Hold the common rail assembly itself during removal and installation. Do not hold the pressure discharge
valve or fuel pressure sensor, etc.
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PROCEDURE
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1.INSTALL NO. 1 WATER HOSE CLAMP BRACKET (w/ DPF) 16575C

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a. Install the No. 1 water hose clamp bracket with the bolt to the timing chain case assembly.
Torque:
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SEAL>INSTALLATION

SEAL>INSTALLATION

SEAL>INSTALLATION
NOTICE:
If the camshaft oil seal retainer is dropped, replace it with a new one.
a. Before installing a new camshaft oil seal retainer, clean the installation surface of the No. 3 camshaft
bearing cap and cylinder head sub-assembly and remove any foreign matter.
b.
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*1 Camshaft Oil Seal Retainer
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*a Depth
Using SST and a hammer, tap in a new camshaft oil seal retainer to the No. 3 camshaft bearing cap and
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cylinder head sub-assembly as shown in the illustration.

SST
09223-46011
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Standard depth:
0 to 0.8 mm (0 to 0.0315 in.)
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a.
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Coat 2 new O-rings with engine oil, and install them to the vacuum pump assembly.

b.
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Install the vacuum pump assembly so that the coupling teeth of the vacuum pump assembly labeled A and
the groove of the No. 2 camshaft labeled B can engage.
c. Install the vacuum pump assembly with the 3 bolts to the cylinder head sub-assembly.
Torque:
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21 N*m (214 kgf*cm, 15 ft.*lbf)
7.INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY 25706
a.
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Install the No. 1 vacuum transmitting pipe sub-assembly with the 3 bolts to the cylinder head sub-
assembly.
Torque:
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b. Connect the No. 1 vacuum transmitting hose to the vacuum pump assembly.
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9.INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY 16603

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a. Install the water inlet with the 3 bolts to the timing chain cover sub-assembly.
Torque:
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13 N*m (133 kgf*cm, 10 ft.*lbf)
12.INSTALL WATER OUTLET SUB-ASSEMBLY 16304
a. Install a new gasket and the water outlet sub-assembly with the 4 bolts and 2 nuts to the timing chain
cover sub-assembly.
Torque:

a. Install the No. 2 water by-pass pipe sub-assembly with the 2 bolts to the engine water pump assembly and
water inlet.
Torque:
b. Connect the No. 3 water by-pass hose to the water outlet sub-assembly, and slide the clamp to secure the
hose.
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14.INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 83530
Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL PRESSURE SWITCH>INSTALLATION
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17141
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16.TEMPORARILY INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-
ASSEMBLY

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Heater)
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a.
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Temporarily install the No. 1 viscous heater bracket sub-assembly with the 4 bolts to the cylinder block
sub-assembly and timing chain cover sub-assembly.
b. Tighten the 4 bolts in the sequence shown in the illustration to install the No. 1 viscous heater bracket sub-
assembly.
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Torque:
24.5 N*m (250 kgf*cm, 18 ft.*lbf)
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22.CONNECT NO. 1 AND NO. 2 TURBO WATER HOSE 16284

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a. Install a new gasket and the No. 1 water by-pass pipe with the 3 bolts to the timing chain cover sub-
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assembly.
Torque:
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HINT:
Make sure that the claw of the gasket faces the No. 1 water by-pass pipe.
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· w/ DPF:
DPF)>INSTALLATION
· w/o DPF:
DPF)>INSTALLATION
27.INSTALL NO. 2 EXHAUST PIPE SUPPORT STAY

· w/ DPF:
DPF)>INSTALLATION
· w/o DPF:
DPF)>INSTALLATION
· w/ DPF:
DPF)>INSTALLATION
· w/o DPF:
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DPF)>INSTALLATION
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· w/ DPF:
DPF)>INSTALLATION
· w/o DPF:
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DPF)>INSTALLATION
30.INSTALL AIR FUEL RATIO SENSOR (w/ DPF) 89467B

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31.INSTALL NO. 1 INJECTOR HOLDER (w/ DPF) 23295D

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32.CONNECT NO. 4 WATER BY-PASS HOSE (w/ DPF) 16281

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33.INSTALL NO. 5 WATER BY-PASS HOSE (w/ DPF) 16282
a. Attach the clamp and install the No. 5 water by-pass hose to the No. 1 water hose clamp bracket.
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b. Connect the No. 5 water by-pass hose to the No. 1 injector holder and water outlet sub-assembly, and slide
the 2 clamps to secure the hose.
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35.INSTALL ENGINE COOLANT TEMPERATURE SENSOR 89422C
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ENGINE COOLANT TEMPERATURE

SENSOR>INSTALLATION
36.INSTALL IDLER PULLEY ASSEMBLY (w/o Air Conditioning System) 16630D

NOTICE:
Install the idler pulley assembly exactly as described in the procedures below to properly secure and prevent
damage to the fan and generator V belt.
a.
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Temporarily install the idler pulley assembly with the 2 bolts to the cylinder block sub-assembly.
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HINT:
Temporarily install the idler pulley assembly with the 2 bolts so that the idler pulley assembly can be
moved by hand.
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b.
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*a No Clearance
*b Push
*c Front
Push the idler pulley assembly toward the cylinder block sub-assembly as shown in the illustration and
tighten bolt A.
Torque:
39 N*m (398 kgf*cm, 29 ft.*lbf)
HINT:

Make sure there is no clearance between the cylinder block sub-assembly and idler pulley assembly as
c.
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Uniformly tighten the 2 bolts in the order shown in the illustration.
Torque:
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39 N*m (398 kgf*cm, 29 ft.*lbf)
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37.INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning 88431
System)
NOTICE:
Install the No. 1 compressor mounting bracket exactly as described in the procedures below to properly secure
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and prevent damage to the fan and generator V belt.
a.
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Temporarily install the No. 1 compressor mounting bracket with the 2 bolts to the cylinder block sub-
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assembly.
HINT:
Temporarily install the No. 1 compressor mounting bracket with the 2 bolts so that the No. 1 compressor
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mounting bracket can be moved by hand.

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b.
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*a No Clearance
*b Push
*c Front
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Push the No. 1 compressor mounting bracket toward the cylinder block sub-assembly as shown in the
illustration and tighten bolt A.
Torque:
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39 N*m (398 kgf*cm, 29 ft.*lbf)
HINT:
Make sure there is no clearance between the cylinder block sub-assembly and No. 1 compressor
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mounting bracket as shown in the illustration.

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c.
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Uniformly tighten the 3 bolts in the order shown in the illustration.

Torque:
39 N*m (398 kgf*cm, 29 ft.*lbf)

a. Install a new gasket and the No. 5 water by-pass pipe sub-assembly with the 3 bolts to the cylinder block
sub-assembly.
Torque:
25 N*m (255 kgf*cm, 18 ft.*lbf)
HINT:
Make sure that the claw of the gasket faces the No. 5 water by-pass pipe sub-assembly.
39.INSTALL NO. 3 NOZZLE LEAKAGE PIPE (w/o DPF) 23780
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a. Install the No. 3 nozzle leakage pipe with the 2 nuts to the cylinder block sub-assembly.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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40.INSTALL FUEL FILTER ASSEMBLY (w/ DPF) 23300
a. Install the fuel filter assembly with the 2 nuts to the cylinder block sub-assembly.
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Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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41.INSTALL HOSE BRACKET 44781
a. Install the hose bracket with the 2 bolts to the cylinder head sub-assembly.
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Torque:
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42.INSTALL GLOW PLUG ASSEMBLY 19850

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Click hereEngine / Hybrid System>1GD-FTV STARTING>GLOW PLUG>INSTALLATION
43.INSTALL NO. 1 GLOW PLUG CONNECTOR 19871

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44.INSTALL COMMON RAIL ASSEMBLY 23810A
Click hereEngine / Hybrid System>1GD-FTV FUEL>COMMON RAIL>INSTALLATION

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45.TEMPORARILY INSTALL NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY 23701

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47.TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY 23701

a.
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Install the 2 wiring harness clamp brackets with the 2 bolts to the cylinder head cover sub-assembly.
Torque:
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for bolt B : 8.4 N*m (86 kgf*cm, 74 in.*lbf)
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59.INSTALL FUEL PUMP MOTOR WIRE 23243B
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a. Install the No. 2 fuel pipe with the bolt to the manifold stay.
Torque:
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b. Connect the No. 1 fuel hose to the No. 2 fuel pipe, and slide the clamp to secure the hose.
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65.INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC 25800
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a. Install the No. 4 water by-pass pipe sub-assembly with the 2 bolts to the intake manifold.
Torque:
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b. for Cold Area Specification Vehicles:

Attach the clamp and connect the No. 11 water by-pass hose to the No. 2 fuel pipe.
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c. Connect the water hose to the No. 2 EGR valve assembly, and slide the clamp to secure the hose.
d. Connect the No. 7 water by-pass hose to the No. 4 water by-pass pipe sub-assembly, and slide the clamp
to secure the hose.
e. Connect the No. 6 water by-pass hose to the No. 4 water by-pass pipe sub-assembly, and slide the clamp
to secure the hose.

a. Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.
Torque:
b. Install 2 new gaskets and the No. 1 EGR pipe with the bolt and 4 new nut to the exhaust manifold, electric
EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly.
Torque:
for bolt : 10 N*m (102 kgf*cm, 7 ft.*lbf)
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for nut : 29 N*m (296 kgf*cm, 21 ft.*lbf)
69.INSTALL CONNECTING WIRE 27148A
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a. Attach the 2 clamps and install the connecting wire to the hose bracket.
b. Connect the connector to the common rail assembly.
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73.INSTALL DIESEL TURBO PRESSURE SENSOR 89421C

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SENSOR>INSTALLATION
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a. Install the engine cover bracket with the 2 bolts to the cylinder head cover sub-assembly and hose bracket.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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76.INSTALL PIPE CLAMP (w/ DPF) 17578B

DPF)>INSTALLATION
77.TEMPORARILY INSTALL NO. 2 VACUUM PIPE (w/ DPF) 25734

DPF)>INSTALLATION
78.TEMPORARILY INSTALL NO. 1 VACUUM PIPE (w/ DPF) 25733A

DPF)>INSTALLATION
79.TIGHTEN NO. 2 VACUUM PIPE (w/ DPF) 25734

DPF)>INSTALLATION
80.TIGHTEN NO. 1 VACUUM PIPE (w/ DPF) 25733A
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DPF)>INSTALLATION
81.INSTALL EXHAUST GAS TEMPERATURE SENSOR (w/ DPF) 89425
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SENSOR>INSTALLATION
82.INSTALL DIFFERENTIAL PRESSURE SENSOR (w/ DPF) 89481B
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SENSOR>INSTALLATION

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86.INSTALL ENGINE WIRE 82121

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a. Install the No. 2 hose to hose tube to the cylinder head cover sub-assembly and hose bracket with the 2
bolts.
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Torque:
b. Connect the union to check valve hose to the vacuum pump assembly, and slide the clamp to secure the
hose.

Print Exit
1GD-FTV ENGINE MECHANICAL ENGINE UNIT PRECAUTION
HINT:
· Any digits beyond the 0.01 mm (1/1000 in.) place for standard, minimum and maximum values should
be used as a reference only.
· When both standard and maximum or minimum values are listed for an inspection, use the standard
value as a reference only and base any judgments on the maximum and minimum values.
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https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000LWPB.html?PUB_TYPE=RM&MODE=1 Page 1 of 1

Print Exit
1GD-FTV ENGINE MECHANICAL ENGINE UNIT REASSEMBLY
PROCEDURE
1.INSTALL STRAIGHT PIN
NOTICE:
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a. for Timing Chain Cover Sub-assembly Side:
i.
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Using a plastic-faced hammer, tap in 2 new straight pins to the timing chain cover sub-assembly.
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5.0 to 7.0 mm (0.197 to 0.276 in.)

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b. for Timing Chain Case Assembly Side:

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i.
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Using a plastic-faced hammer, tap in a new straight pin to the timing chain case assembly.
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18 to 20 mm (0.709 to 0.787 in.)
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2.INSTALL STUD BOLT
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NOTICE:
a. for Timing Chain Cover Sub-assembly Side:

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i.
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*a 16 mm (0.630 in.)
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*b 9.0 mm (0.354 in.)
*c 27 mm (1.06 in.)
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Using an E6 "TORX" socket wrench, install the stud bolts to the timing chain cover sub-assembly.
Torque:
6.0 N*m (61 kgf*cm, 53 in.*lbf)
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b. for Timing Chain Case Assembly Side:

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*a 19 mm (0.748 in.)
*b 16 mm (0.630 in.)
*c 44 mm (1.73 in.)

Using an E8 "TORX" socket wrench, install the stud bolts to the timing chain case assembly.
Torque:
ii.
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*a
*b
9.0 mm (0.354 in.)
19 mm (0.748 in.)
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Using an E6 "TORX" socket wrench, install the stud bolt to the timing chain case assembly.
Torque:
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6.0 N*m (61 kgf*cm, 53 in.*lbf)
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3.INSTALL LOCK PLATE 13577D

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a.
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*a Cylinder Block Sub-assembly Side

*b Oil Jet
Install the lock plate with the bolt to the cylinder block sub-assembly.
Torque:
HINT:
· Make sure the lock plate is facing the direction shown in the illustration.

· Make sure the end of the lock plate is holding the oil jet as shown in the illustration.
4.INSTALL CYLINDER HEAD GASKET 11115
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>CYLINDER HEAD GASKET>INSTALLATION
5.INSTALL CYLINDER HEAD SUB-ASSEMBLY 11101
Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>CYLINDER HEAD GASKET>INSTALLATION
6.INSTALL VALVE LASH ADJUSTER ASSEMBLY 13750
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a. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.
7.INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 13801
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a.
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*1 No. 1 Valve Rocker Arm Sub-assembly

*2 Valve Stem Cap
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Check that the No. 1 valve rocker arm sub-assembly is firmly set to the valve lash adjuster assembly.
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c. Install the 16 No. 1 valve rocker arm sub-assembly to the 16 valve lash adjuster assemblies.
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8.INSTALL NO. 2 CAMSHAFT 13512

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HINT:
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*a Glove
Engine Front Side
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a. Clean the No. 2 camshaft journals.
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b. Apply a light coat of engine oil to the No. 2 camshaft journals of the cylinder head sub-assembly and the
thrust portion of the No. 2 camshaft.
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9.INSTALL CAMSHAFT 13511
a. Clean the camshaft journals.

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*a Knock Pin
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Make sure the knock pins of the camshaft and No. 2 camshaft are facing the direction shown in the
illustration.
10.INSTALL NO. 1 AND NO. 2 CAMSHAFT BEARING CAP

a.
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b. Temporarily install the 20 camshaft bearing cap bolts.
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c.
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Camshaft Bearing Cap Bolt A

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Camshaft Bearing Cap Bolt B

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Uniformly tighten the 20 camshaft bearing cap bolts in several steps in the order shown in the illustration.
Torque:
for camshaft bearing cap bolt A (No. 1 camshaft bearing) : 21 N*m (214 kgf*cm, 15 ft.*lbf)
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for camshaft bearing cap bolt B (No. 2 camshaft bearing) : 10 N*m (102 kgf*cm, 7 ft.*lbf)
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a. Clean and degrease the contact surfaces of the No. 3 camshaft bearing cap and cylinder head sub-
assembly.

b.
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Seal Packing Application Area
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Apply seal packing to the No. 3 camshaft bearing cap in the areas indicated in the illustration.
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Seal packing:
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3.0 mm (0.118 in.)
NOTICE:
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· Install the No. 3 camshaft bearing cap within 3 minutes and tighten the camshaft bearing cap
bolts within 15 minutes after applying seal packing.
· Do not add engine oil within 2 hours of installation.
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· Do not start the engine for at least 2 hours after the installation.
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c. Install the No. 3 camshaft bearing cap with the 2 camshaft bearing cap bolts to the cylinder head sub-
assembly.
Torque:
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21 N*m (214 kgf*cm, 15 ft.*lbf)

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12.INSTALL TIMING CHAIN CASE ASSEMBLY AND ENGINE WATER PUMP 11310
ASSEMBLY
13.INSTALL INJECTION PUMP INSULATOR 22815A
a. Install the injection pump insulator to the cylinder block sub-assembly.

NOTICE:
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*A w/ DPF
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*B w/o DPF
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a. Install a new O-ring to the supply pump assembly.

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b. Install the supply pump assembly with the 3 nuts to the timing chain case assembly.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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c. w/ DPF:
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Install the No. 1 fuel pump bracket with the 2 bolts to the cylinder block sub-assembly and supply pump
assembly.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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a. Install the No. 1 chain tensioner slipper to the straight pin.
16.TEMPORARILY INSTALL NO. 1 CHAIN VIBRATION DAMPER 13561
a. Temporarily install the No. 1 chain vibration damper with the bolt to the cylinder block sub-assembly.

17.INSTALL CRANKSHAFT TIMING SPROCKET, INJECTION PUMP DRIVE GEAR 13506

a.
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*1 Crankshaft Pulley Set Key
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*a Timing Mark
*b Upper Side
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Install the crankshaft timing sprocket to the crankshaft.
b. Align the crankshaft pulley set key as shown in the illustration.

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c.
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*a Supply Pump Shaft Key
*b Upper Side
Align the supply pump shaft key as shown in the illustration.

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d. Remove the crankshaft timing sprocket from the crankshaft.

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*1 Crankshaft Timing Sprocket

*2 Injection Pump Drive Gear
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*a Mark Plate (Pink)

*b Mark Plate (Yellow)
*c Timing Mark
Align the 2 mark plates (pink) of the No. 1 chain sub-assembly with the 2 timing marks of the crankshaft
timing sprocket and install the No. 1 chain sub-assembly to the crankshaft timing sprocket as shown in the
illustration.
f. Align the mark plate (yellow) of the No. 1 chain sub-assembly with the timing mark of the injection pump
drive gear and install the No. 1 chain sub-assembly to the injection pump drive gear as shown in the
illustration.

g. Install the crankshaft timing sprocket, injection pump drive gear and No. 1 chain sub-assembly to the
crankshaft and supply pump shaft together.
18.TIGHTEN NO. 1 CHAIN VIBRATION DAMPER 13561
a. Tighten the No. 1 chain vibration damper with the bolt to the cylinder block sub-assembly.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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NOTICE:
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*b Spring
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*c Plunger
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a. Install a new gasket and No. 1 chain tensioner assembly with the 2 bolts to the cylinder block sub-
assembly.
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Torque:
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HINT:
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*a Claw (Lower Side)
*b Groove
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Align the claw (lower side) of the gasket with the groove of the No. 1 chain tensioner assembly body to
install the No. 1 chain tensioner assembly as shown in the illustration.
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20.INSTALL SUPPLY PUMP SHAFT NUT
a. Temporarily install the crankshaft pulley and crankshaft pulley set bolt to the crankshaft.
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b.
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*a Hold

Turn
Using SST, hold the crankshaft pulley and install the supply pump shaft nut to the supply pump shaft.
SST
09213-58014 (91551-80840)
09330-00021
Torque:
137 N*m (1397 kgf*cm, 101 ft.*lbf)
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NOTICE:
If the supply pump shaft nut is tightened with torque higher than the specified torque, the No. 1 chain
sub-assembly may break.
c. Remove the crankshaft pulley set bolt and crankshaft pulley from the crankshaft.
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d.
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*1 Crankshaft Timing Sprocket

*2 Injection Pump Drive Gear
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*a Mark Plate (Pink)

*b Mark Plate (Yellow)
*c Timing Mark
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Make sure that the timing marks of the crankshaft timing sprocket and injection pump drive gear are
aligned with the mark plates of the No. 1 chain sub-assembly as shown in the illustration.
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e. Remove the pin from the No. 1 chain tensioner assembly.

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21.INSTALL CAMSHAFT TIMING SPROCKET 13523

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a.
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*b Timing Mark
*c Knock Pin
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*d Cutout
Temporarily install the 2 camshaft timing sprockets with the 2 camshaft timing sprocket bolts to the
camshaft and No. 2 camshaft.
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NOTICE:
Make sure that the timing mark of the camshaft timing sprocket faces the front side of the engine.
HINT:
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Align the knock pins of the camshaft and No. 2 camshaft with the cutout of the camshaft timing sprocket
to install the camshaft timing sprocket.
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b. for Intake Side:

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*a Hold
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Turn
Use a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing sprocket bolt to
the camshaft.
Torque:
81 N*m (826 kgf*cm, 60 ft.*lbf)

NOTICE:
Be careful not to damage the camshaft or cylinder head sub-assembly with the wrench.
c. for Exhaust Side:

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*a Hold
Turn
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Use a wrench to hold the hexagonal portion of the No. 2 camshaft, install the camshaft timing sprocket
bolt to the No. 2 camshaft.
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Torque:
81 N*m (826 kgf*cm, 60 ft.*lbf)
NOTICE:
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Be careful not to damage the No. 2 camshaft or cylinder head sub-assembly with the wrench.
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22.INSTALL NO. 2 CHAIN VIBRATION DAMPER 13562

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a. Install the No. 2 chain vibration damper with the 2 bolts to the timing chain case assembly.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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23.INSTALL NO. 2 CHAIN SUB-ASSEMBLY 13507

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a.
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*a Mark Plate (Orange)

*b Timing Mark

Align the mark plate (orange) of the No. 2 chain sub-assembly with the timing mark of the camshaft timing
sprocket (intake side) and install the No. 2 chain sub-assembly to the camshaft timing sprocket (intake
side) as shown in the illustration.
b.
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*a Mark Plate (Yellow)
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*b Timing Mark
Align the mark plate (yellow) of the No. 2 chain sub-assembly with the timing mark of the injection pump
drive gear and install the No. 2 chain sub-assembly to the injection pump drive gear as shown in the
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illustration.
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*a Mark Plate (Orange)

*b Timing Mark
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Turn
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Using a wrench, turn the hexagonal portion of the No. 2 camshaft clockwise and align the mark plate
(orange) of the No. 2 chain sub-assembly with the timing mark of the camshaft timing sprocket (exhaust
side) to install the No. 2 chain sub-assembly to the camshaft timing sprocket (exhaust side).
24.INSTALL NO. 2 CHAIN TENSIONER SLIPPER

a. Install the No. 2 chain tensioner slipper with the bolt to the timing chain case assembly.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
a. Install the No. 2 chain tensioner assembly with the 2 bolts to the timing chain case assembly.
Torque:
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b. Remove the pin from the No. 2 chain tensioner assembly.
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27.CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
a. Make sure that the timing marks of the camshaft timing sprocket (exhaust side), camshaft timing sprocket
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(intake side), injection pump drive gear and crankshaft timing sprocket are at the positions shown in the
illustration.
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*a Camshaft Timing Sprocket (Exhaust Side) *b Camshaft Timing Sprocket (Intake Side)
*c Injection Pump Drive Gear *d Crankshaft Timing Sprocket
*e Mark Plate (Orange) *f Mark Plate (Yellow)
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*g Mark Plate (Pink) *h Timing Mark

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28.INSTALL OIL PUMP DRIVE GEAR 13519
29.INSTALL OIL PUMP RELIEF VALVE PLUG 15133B
a. Install a new gasket and oil pump relief valve plug to the timing chain cover sub-assembly.
Torque:

46 N*m (469 kgf*cm, 34 ft.*lbf)
31.INSTALL TIMING CHAIN COVER SUB-ASSEMBLY 11302
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SEAL>INSTALLATION
33.INSTALL REAR ENGINE OIL SEAL RETAINER 11381
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a. Clean and degrease the contact surfaces of the rear engine oil seal retainer and cylinder block sub-
assembly.
b.
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*a Seal Packing
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Apply seal packing to the rear engine oil seal retainer in the areas indicated in the illustration.
Seal packing:
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3.0 to 4.0 mm (0.118 to 0.157 in.)
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NOTICE:
· Remove any engine oil from the contact surface.
· Install the rear engine oil seal retainer within 3 minutes and tighten the bolts within 10 minutes
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after applying seal packing.

· Do not add engine oil within 2 hours of installation.
· Do not start the engine for at least 2 hours after the installation.
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c. Install the rear engine oil seal retainer to the cylinder block sub-assembly, and then install the 5 bolts.
Torque:
34.INSTALL REAR ENGINE OIL SEAL 11381A

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>REAR CRANKSHAFT OIL SEAL>INSTALLATION
35.INSTALL OIL STRAINER SUB-ASSEMBLY 15104
a.
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Install a new gasket and oil strainer sub-assembly with the 4 bolts to the cylinder block sub-assembly in
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several steps in the sequence shown in the illustration.
Torque:
HINT:
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Make sure that the claw of the gasket faces the oil strainer sub-assembly.
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36.INSTALL OIL PAN SUB-ASSEMBLY 12101

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Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL LEVEL SENSOR>INSTALLATION

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38.INSTALL OIL PAN COVER SILENCER 12144

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39.INSTALL CRANKSHAFT POSITION SENSOR 11401G

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Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>CRANKSHAFT POSITION SENSOR>INSTALLATION
40.INSTALL CRANKSHAFT POSITION SENSOR HARNESS BRACKET

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a. Install the crankshaft position sensor harness bracket with the bolt to the cylinder block sub-assembly.
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Torque:
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b. Connect the crankshaft position sensor connector.
41.INSTALL NO. 1 CYLINDER BLOCK INSULATOR 12581A
a. Install the No. 1 cylinder block insulator to the cylinder block sub-assembly.
42.INSTALL NO. 5 CYLINDER BLOCK INSULATOR 12585

44.INSTALL OIL FILLER CAP GASKET 12108A
a. Install the oil filler cap gasket to the oil filler cap sub-assembly.
45.INSTALL OIL FILLER CAP SUB-ASSEMBLY 12108
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a. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
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48.INSTALL OIL FILTER BRACKET 15677

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a. Install 2 new O-rings to the cylinder block sub-assembly.
b. Install the oil filter bracket with the 2 nuts and bolt to the cylinder block sub-assembly.
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Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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49.INSTALL OIL FILTER UNION 15600A

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a. Using a 27 mm deep socket wrench, install the oil filter union to the oil filter bracket.
Torque:
29.4 N*m (300 kgf*cm, 22 ft.*lbf)
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51.INSTALL OIL COOLER ASSEMBLY 15710

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Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>ENGINE OIL COOLER>INSTALLATION
52.INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH 12311
a. Install the front No. 1 engine mounting bracket RH with the 4 bolts to the cylinder block sub-assembly.
Torque:
68 N*m (693 kgf*cm, 50 ft.*lbf)

53.INSTALL GENERATOR BRACKET SUB-ASSEMBLY 12501
a. Install the generator bracket sub-assembly with the 4 bolts to the cylinder head sub-assembly and timing
chain case assembly.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
54.INSTALL NO. 3 CYLINDER BLOCK INSULATOR 12583A
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55.INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH 12315
a. Install the front No. 1 engine mounting bracket LH with the 4 bolts to the cylinder block sub-assembly.
Torque:
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68 N*m (693 kgf*cm, 50 ft.*lbf)
56.INSTALL NO. 2 CYLINDER BLOCK INSULATOR 12582
a.
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Install the No. 2 cylinder block insulator to the front No. 1 engine mounting bracket LH.
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57.INSTALL NO. 1 ENGINE HANGER 12281A
a. Install the No. 1 engine hanger with the 2 bolts to the cylinder head sub-assembly.
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Torque:
26 N*m (265 kgf*cm, 19 ft.*lbf)
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Print Exit
1GD-FTV ENGINE MECHANICAL ENGINE UNIT REMOVAL
NOTICE:
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dropped.
or dropped.
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or dropped.
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PROCEDURE
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a.
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Slide the clamp and disconnect the union to check valve hose from the vacuum pump assembly.
b. Remove the 2 bolts and No. 2 hose to hose tube from the cylinder head cover sub-assembly and hose
bracket.
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000LWPA.html?PUB_TYPE=RM&MODE=1 Page 1 of 16

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7.REMOVE DIFFERENTIAL PRESSURE SENSOR (w/ DPF) 89481B
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8.REMOVE EXHAUST GAS TEMPERATURE SENSOR (w/ DPF) 89425

SENSOR>REMOVAL
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9.REMOVE NO. 1 VACUUM PIPE (w/ DPF) 25733A

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10.REMOVE NO. 2 VACUUM PIPE (w/ DPF) 25734

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11.REMOVE PIPE CLAMP (w/ DPF) 17578B

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a.
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Remove the 2 bolts and engine cover bracket from the cylinder head sub-assembly.

14.REMOVE DIESEL TURBO PRESSURE SENSOR 89421C

SENSOR>REMOVAL
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18.REMOVE CONNECTING WIRE 27148A
a.
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Disconnect the connector from the common rail assembly.

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b. Detach the 2 clamps and remove the connecting wire from the hose bracket.
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a.
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Remove the 4 nuts, bolt and No. 1 EGR pipe sub-assembly from the exhaust manifold, electric EGR control
valve assembly and No. 1 vacuum transmitting pipe sub-assembly.
b. Remove the 2 gaskets from the exhaust manifold and electric EGR control valve assembly.

c.
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Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.
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*A for Cold Area Specification Vehicles

*B except Cold Area Specification Vehicles
*3 Water Hose
assembly.

b. Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 4 water by-pass pipe sub-
assembly.
c. Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.
d. for Cold Area Specification Vehicles:

Detach the clamp and disconnect the No. 11 water by-pass hose from the No. 2 fuel pipe.
e. Remove the 2 bolts and No. 4 water by-pass pipe sub-assembly from the intake manifold.
22.REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC 25800
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24.REMOVE NO. 2 FUEL PIPE 23812D
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Slide the clamp and disconnect the No. 1 fuel hose from the No. 2 fuel pipe.
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b. Remove the bolt and No. 2 fuel pipe from the manifold stay.
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28.REMOVE FUEL PUMP MOTOR WIRE 23243B

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INJECTOR>REMOVAL
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Remove the 2 bolts and 2 wiring harness clamp brackets from the cylinder head cover sub-assembly.
40.REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY 23701

41.REMOVE COMMON RAIL ASSEMBLY 23810A
Click hereEngine / Hybrid System>1GD-FTV FUEL>COMMON RAIL>REMOVAL
42.REMOVE NO. 1 GLOW PLUG CONNECTOR 19871
Click hereEngine / Hybrid System>1GD-FTV STARTING>GLOW PLUG>REMOVAL
43.REMOVE GLOW PLUG ASSEMBLY 19850
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44.REMOVE HOSE BRACKET 44781
a.
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Remove the 2 bolts and hose bracket from the cylinder head sub-assembly.
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45.REMOVE FUEL FILTER ASSEMBLY (w/ DPF) 23300

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Remove the 2 nuts and fuel filter assembly from the cylinder block sub-assembly.
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46.REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/o DPF) 23780

a.
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Remove the 2 nuts and No. 3 nozzle leakage pipe from the cylinder block sub-assembly.
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Remove the 3 bolts, No. 5 water by-pass pipe sub-assembly and gasket from the cylinder block sub-
assembly.
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48.REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning 88431

System)
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a.
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Remove the 4 bolts and No. 1 compressor mounting bracket from the cylinder block sub-assembly, timing
chain case assembly and timing chain cover sub-assembly.
49.REMOVE IDLER PULLEY ASSEMBLY (w/o Air Conditioning System) 16630D

a.
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Remove the 3 bolts and idler pulley assembly from the cylinder block sub-assembly, timing chain case
assembly and timing chain cover sub-assembly.
50.REMOVE ENGINE COOLANT TEMPERATURE SENSOR 89422C
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Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ENGINE COOLANT TEMPERATURE
SENSOR>REMOVAL
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52.REMOVE NO. 5 WATER BY-PASS HOSE (w/ DPF) 16282
a.
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Slide the 2 clamps and disconnect the No. 5 water by-pass hose from the No. 1 injector holder and water
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outlet sub-assembly.
b. Detach the clamp and remove the No. 5 water by-pass hose from the No. 1 water hose clamp bracket.
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53.DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ DPF) 16281

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a.
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Slide the clamp and disconnect the No. 4 water by-pass hose from the No. 1 injector holder.
54.REMOVE NO. 1 INJECTOR HOLDER (w/ DPF) 23295D
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INJECTOR>REMOVAL
55.REMOVE AIR FUEL RATIO SENSOR (w/ DPF) 89467B
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· w/ DPF:
DPF)>REMOVAL
· w/o DPF:
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DPF)>REMOVAL
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· w/ DPF:
DPF)>REMOVAL
· w/o DPF:
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DPF)>REMOVAL
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58.REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY

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· w/ DPF:
DPF)>REMOVAL
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· w/o DPF:
DPF)>REMOVAL
59.REMOVE EXHAUST PIPE SUPPORT STAY
· w/ DPF:
DPF)>REMOVAL
· w/o DPF:
https://toyotamanuals.com.au/docs/hilux-service-repair-manual…anual/repair/contents/RM100000000LWPA.html?PUB_TYPE=RM&MODE=1 Page 10 of 16


DPF)>REMOVAL
· w/ DPF:
DPF)>REMOVAL
· w/o DPF:
DPF)>REMOVAL
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*A for Cold Area Specification Vehicles

*B except Cold Area Specification Vehicles
Remove the 3 bolts, No. 1 water by-pass pipe and gasket from the timing chain cover sub-assembly.
64.DISCONNECT NO. 1 AND NO. 2 TURBO WATER HOSE 16284


65.REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous 87101

Heater)
a.
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Remove the 4 bolts and No. 1 viscous heater bracket sub-assembly from the cylinder block sub-assembly
and timing chain cover sub-assembly.
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67.REMOVE TURBO OIL OUTLET PIPE 15474

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70.REMOVE EXHAUST MANIFOLD 17141

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71.REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 83530

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Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL PRESSURE SWITCH>REMOVAL

a.
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Slide the clamp and disconnect the No. 3 water by-pass hose from the water outlet sub-assembly.
b. Remove the 2 bolts and No. 2 water by-pass pipe sub-assembly from the engine water pump assembly and
water inlet.
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73.REMOVE WATER OUTLET SUB-ASSEMBLY 16304
a.
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*A w/ DPF
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*B w/o DPF
Remove the 4 bolts, 2 nuts and water outlet sub-assembly from the timing chain cover sub-assembly.
b. Remove the gasket from the timing chain cover sub-assembly.

a.
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Remove the 3 bolts and water inlet from the timing chain cover sub-assembly.
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76.REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY 16603
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78.REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY 25706
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a.
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Disconnect the No. 1 vacuum transmitting hose from the vacuum pump assembly.
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b. Remove the 3 bolts and No. 1 vacuum transmitting pipe sub-assembly from the cylinder head sub-
assembly.
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a.
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Remove the 3 bolts and vacuum pump assembly from the cylinder head sub-assembly.
b. Remove the 2 O-rings from the vacuum pump assembly.
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a.
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Remove the camshaft oil seal retainer from the No. 3 camshaft bearing cap and cylinder head sub-
assembly.
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82.REMOVE CRANKSHAFT PULLEY COVER 13496

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84.REMOVE NO. 1 WATER HOSE CLAMP BRACKET (w/ DPF) 16575C

a.
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Remove the bolt and No. 1 water hose clamp bracket from the timing chain case assembly.
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Print Exit
1GD-FTV ENGINE MECHANICAL FRONT CRANKSHAFT OIL SEAL COMPONENTS
ILLUSTRATION
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*A w/ Viscous Heater *B w/o Viscous Heater

*1 CRANKSHAFT PULLEY *2 CRANKSHAFT PULLEY COVER
*3 FRONT CRANKSHAFT OIL SEAL *4 VISCOUS HEATER CRANKSHAFT PULLEY
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MP grease - -
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https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000LWOW.html?PUB_TYPE=RM&MODE=1 Page 1 of 1

Print Exit
1GD-FTV ENGINE MECHANICAL FRONT CRANKSHAFT OIL SEAL INSTALLATION
PROCEDURE
a. Apply MP grease to the lip of a new front crankshaft oil seal.

NOTICE:
· Keep the lip free of foreign matter.
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· Do not allow MP grease to contact the dust seal.
b.
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*1 Front Crankshaft Oil Seal

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*2 Timing Chain Cover Assembly

*a 0 to 1.0 mm (0 to 0.0394 in.)
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Using SST and a hammer, tap in the front crankshaft oil seal.
SST
09214-76011
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NOTICE:
· The acceptable depth from the top of the timing chain cover assembly is 0 to 1.0 mm (0 to
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0.0394 in.)
· Do not tap the front crankshaft oil seal at an angle.
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· Make sure that the front crankshaft oil seal is properly installed.
a. Align the keyway of the crankshaft pulley with the key located on the crankshaft, and then slide the
crankshaft pulley into place to install it.
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b.
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Using SST, install a new pulley bolt.
SST
09213-58014 (91551-80840)
09330-00021
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Torque:
365 N*m (3722 kgf*cm, 269 ft.*lbf)
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a. w/o Viscous Heater:

Install the crankshaft pulley cover to the crankshaft pulley with the 4 bolts.
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Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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b. w/ Viscous Heater:
Install the crankshaft pulley cover to the crankshaft pulley.
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a. Install the viscous heater crankshaft pulley to the crankshaft pulley with the 4 bolts.
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Torque:
24.5 N*m (250 kgf*cm, 18 ft.*lbf)
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1GD-FTV ENGINE MECHANICAL FRONT CRANKSHAFT OIL SEAL REMOVAL
PROCEDURE
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a.
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Remove the 4 bolts and viscous heater crankshaft pulley from the crankshaft pulley.
13496
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3.REMOVE CRANKSHAFT PULLEY COVER
a.
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w/ Viscous Heater:
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Remove the crankshaft pulley cover from the crankshaft pulley.

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b.
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w/o Viscous Heater:
Remove the 4 bolts and crankshaft pulley cover from the crankshaft pulley.
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Using SST, hold the crankshaft pulley and loosen the pulley bolt.
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SST
09213-58014 (91551-80840)
09330-00021
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HINT:
Make sure to leave the pulley bolt screwed into the crankshaft by 2 or 3 threads.
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b.
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Using SST, remove the pulley bolt and crankshaft pulley from the crankshaft.
SST
09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

a.
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Using SST, remove the front crankshaft oil seal from the timing chain cover assembly.
SST
09308-10010
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09950-40011 (09957-04010)
09950-60010 (09951-00350)
HINT:
After removal, check the crankshaft for damage. If damaged, smooth the surface with #400 sandpaper.

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1GD-FTV ENGINE MECHANICAL REAR CRANKSHAFT OIL SEAL COMPONENTS
ILLUSTRATION
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*A for Manual Transmission *B for Automatic Transmission

*1 CLUTCH COVER ASSEMBLY *2 CLUTCH DISC ASSEMBLY
*3 FLYWHEEL SUB-ASSEMBLY *4 REAR END PLATE
*5 REAR ENGINE OIL SEAL *6 PUMP IMPELLER DRIVE PLATE
*7 REAR DRIVE PLATE SPACER - -
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000LWOZ.html?PUB_TYPE=RM&MODE=1 Page 1 of 2

MP grease - -
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1GD-FTV ENGINE MECHANICAL REAR CRANKSHAFT OIL SEAL INSTALLATION
PROCEDURE
1.INSTALL REAR ENGINE OIL SEAL 11381A
a. Apply MP grease to the lip of a new rear engine oil seal.

NOTICE:
· Keep the lip free of foreign matter.
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· Do not allow MP grease to contact the dust seal.
b.
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*1 Rear Oil Seal Retainer

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*2 Rear Engine Oil Seal

*a 0 to 1.0 mm (0 to 0.0394 in.)
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Using SST and a hammer, tap in the rear engine oil seal to the rear engine oil seal retainer edge.
SST
09351-40010 (09351-04010, 09351-04020)
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NOTICE:
· The acceptable depth from the top of the rear engine oil seal retainer is 0 to 1.0 mm (0 to 0.0394
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in.)
· Do not tap the rear engine oil seal at an angle.
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· Make sure that the rear engine oil seal is properly installed.
2.INSTALL REAR END PLATE 11355
3.INSTALL FLYWHEEL SUB-ASSEMBLY 13405
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4.INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission) 31250
· for R151:
· for RC61:
5.INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission) 31210
· for R151:
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· for RC61:
6.INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transmission) 31210
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· for R151:
· for RC61:
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7.INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission) 35000
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· for AC60E:
· for AC60F:
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8.INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission) 33030

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· for R151:
· for RC61:
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· for RC61F:
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1GD-FTV ENGINE MECHANICAL REAR CRANKSHAFT OIL SEAL REMOVAL
parts are removed, installed, or replaced during the rear crankshaft oil seal removal/installation are shown below.
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w/o DPF
· Learning values save ( )
· Learning values write Engine starting w/ DPF
( )
for RC61:
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Replacement of ECM
installation · DTCs are output ( )
information reset
See the Service
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method.
· Injector
w/o DPF
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compensation code
registration ( )
Engine starting
· Pilot quantity w/ DPF
Replacement of engine learning ( )
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assembly
w/o DPF
Clear Crank Time ( )
Engine starting
Compensation Data w/ DPF
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( )
for AC60E:
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Replacement of
transmission
assembly
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( )
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for AC60F:
Replacement of
automatic Reset memory
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· Engine overruns
transmission
assembly
( )
Beam Level Control

System:
The vehicle height
changes due to
replacement of Headlight leveling ECU
Headlight leveling function ( )
suspension assembly initialization
components or after
performing such
operations as
removal and
reinstallation

for 4WD:
calibration data
Front wheel
alignment ( )
acceleration sensor
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adjustment
PROCEDURE
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1.REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission) 33030
· for R151:
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ASSEMBLY>REMOVAL
· for RC61:
ASSEMBLY>REMOVAL
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· for RC61F:
ASSEMBLY>REMOVAL
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2.REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission) 35000

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· for AC60E:
· for AC60F:
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3.REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission) 31210

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· for R151:
· for RC61:
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4.REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission) 31250
· for R151:
· for RC61:
5.REMOVE FLYWHEEL SUB-ASSEMBLY 13405

6.REMOVE REAR END PLATE 11355
7.REMOVE REAR ENGINE OIL SEAL 11381A
a.
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*a Protective Tape
*b Cloth
*c Cut
b.
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Using a knife, cut off the lip of the rear engine oil seal.
Using a cloth and screwdriver, pry out the rear engine oil seal from the rear engine oil seal retainer.
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NOTICE:
Be careful not to damage the crankshaft and rear engine oil seal retainer.
HINT:
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· After removal, check the crankshaft for damage. If damaged, smooth the surface with #400
sandpaper.
· Tape the screwdriver tip before use.
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1GD-FTV FUEL COMMON RAIL COMPONENTS
ILLUSTRATION
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*A w/ DPF - -
*1 COMMON RAIL ASSEMBLY *2 FUEL INLET PIPE SUB-ASSEMBLY
*5 NO. 4 FUEL HOSE *6 NO. 4 FUEL PIPE SUB-ASSEMBLY
*7 WIRING HARNESS CLAMP BRACKET *8 WIRE HARNESS
*9 NO. 1 INJECTION PIPE CLAMP *10 NO. 2 INJECTION PIPE CLAMP
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000MGQ1.html?PUB_TYPE=RM&MODE=1 Page 1 of 2


ft.*lbf)
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1GD-FTV FUEL COMMON RAIL INSPECTION
PROCEDURE
1.INSPECT COMMON RAIL ASSEMBLY 23810A
a.
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*a
(Fuel Pressure Sensor)
Inspect the fuel pressure sensor.

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i. Measure the resistance according to the value(s) in the table below.
Tester Specified
Condition
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16.4 kΩ or
5 (PR) - 4 (E2)
less
2 (PR2) - 3 16.4 kΩ or
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(E2S) less
25°C (77°F)
6 (VC) - 5
3 kΩ or less
(PR)
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1 (VCS) - 2
3 kΩ or less
(PR2)
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If the result is not as specified, replace the common rail assembly.

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b. Inspect the pressure discharge valve.

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Tester Specified
Condition
1-2 20°C (68°F) 0.42 to 0.52 Ω
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HINT:
The temperature indicated in "Condition" is the temperature of the pressure discharge valve.
If the result is not as specified, replace the common rail assembly.
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1GD-FTV FUEL COMMON RAIL INSTALLATION
NOTICE:
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cylinders)
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·
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The common rail assembly is a precision instrument. Do not use the common rail assembly if it is struck
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or dropped.
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PROCEDURE
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a. Install the common rail assembly with the 2 nuts.

Torque:
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21 N*m (214 kgf*cm, 15 ft.*lbf)

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b. Connect the fuel pressure sensor connector to the common rail assembly.
c. Attach the wire harness clamp.

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2.INSTALL NO. 4 FUEL HOSE 23282D

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a. Connect the No. 4 fuel hose to the common rail assembly, and slide the clamp to secure it.
3.TEMPORARILY INSTALL NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY
4.TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

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8.INSTALL EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE ASSEMBLY WITH 25800
ELECTRIC EGR CONTROL VALVE ASSEMBLY
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NOTICE:
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1GD-FTV FUEL COMMON RAIL REMOVAL
NOTICE:
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cylinders)
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·
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The common rail assembly is a precision instrument. Do not use the common rail assembly if it is struck
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or dropped.
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PROCEDURE
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1. PRECAUTION
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NOTICE:
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NOTICE:
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3.REMOVE EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE ASSEMBLY WITH 25800

5.REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY
8.REMOVE NO. 4 FUEL HOSE 23282D
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a.
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Slide the clamp and disconnect the No. 4 fuel hose from the common rail assembly.
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a.
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Detach the wire harness clamp.
b. Disconnect the fuel pressure sensor connector from the common rail assembly.
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c.
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Remove the 2 nuts and common rail assembly.
NOTICE:
Do not remove the pressure discharge valve or fuel pressure sensor.
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1GD-FTV FUEL FUEL FILTER COMPONENTS
ILLUSTRATION
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*1 FUEL FILTER ELEMENT ASSEMBLY *2 FUEL FILTER CAP

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*3 CLOGGING SWITCH CONNECTOR *4 O-RING

*5 FUEL FILTER CASE *6 LEAD WIRE
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1GD-FTV FUEL FUEL FILTER INSPECTION
PROCEDURE
1.INSPECT FUEL FILTER ASSEMBLY 23300
a.
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*a
(Level Warning Switch)
*b Level Warning Switch Connector
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Inspect the level warning switch.

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Tester Specified
Condition
Float at upper
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Below 1 Ω
end position
3-4
Float at lower 10 kΩ or
end position higher
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If the result is not as specified, replace the fuel filter assembly.
b. Inspect the clogging switch.

Tester Specified
Condition
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1-2 20°C (68°F) Below 1 Ω
If the result is not as specified, replace the fuel filter assembly.
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1GD-FTV FUEL FUEL FILTER REPLACEMENT
HINT:
· When replacing the fuel filter element assembly, use TOYOTA genuine parts.
· When replacing the fuel filter element assembly, clean the fuel filter case and remove dirt completely.
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PROCEDURE
1.REMOVE FUEL FILTER ELEMENT ASSEMBLY 23390
HINT:
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Replacement of the fuel filter element assembly can be performed with the fuel filter installed to the fuel filter
bracket.
a.
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Detach the clamp and disconnect the No. 1 fuel hose from the No. 2 fuel pipe clamp.
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b.
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c.
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Disconnect the level warning switch connector.
d.
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Slide the fuel filter assembly and lift it up.
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Connect a hose to the drain cock. Place the other end of the hose into a container under the drain cock.
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f. Loosen the drain cock to drain fuel.
g. Tighten the drain cock by hand.

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h. Disconnect a hose from the drain cock.
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000M7RS.html?PUB_TYPE=RM&MODE=1 Page 2 of 8

i.
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Disconnect the clogging switch connector.
j.
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Using a screwdriver as a lever, loosen the fastener nut until it can be loosened by hand.
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Fully loosen the fastener nut by hand.

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*1 O-ring

To remove the fuel filter cap, pull up one side of the fuel filter cap, and then lift it off.
m. Remove the fuel filter element assembly from the fuel filter case.
n. Remove the O-ring from the fuel filter case.
2.INSTALL FUEL FILTER ELEMENT ASSEMBLY 23390
a. Clean the fuel filter case and remove dirt completely.
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b.
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*1
*2
O-ring
Fuel Filter Element Assembly
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Install a new O-ring to the fuel filter case.
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c. Install the fuel filter element assembly to the fuel filter case.
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Align the mark on the fuel filter cap and the mark on the fuel filter case.
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Push the fuel filter cap onto the fuel filter case by hand.
Standard clearance (A):
1.5 mm (0.0590 in.) or less
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HINT:
The clearance between the fuel filter cap and fuel filter case should be even around the entire
circumference of the fuel filter cap and fuel filter case.
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Turn the fastener nut until a "click" sound is heard.
HINT:
Just before the marks of the fuel filter case and nut align, the fastener nut will become more difficult to
turn. Use a screwdriver as a lever to turn the fastener nut.
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g. Measure the distance between the marks on the fuel filter cap and fuel filter case, and the clearance
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between the fuel filter cap and fuel filter case.

Standard distance (A):
1.0 mm (0.0393 in.) or more
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Standard clearance (B):

1.0 mm (0.0393 in.) or less
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h. Connect the clogging switch connector.

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i.
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Slide the fuel filter assembly to install it.

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*1 No. 1 Fuel Hose
*2 No. 2 Fuel Pipe Clamp
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*a Paint Mark
Attach the clamp and connect the No. 1 fuel hose to the No. 2 fuel pipe clamp.
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HINT:
Make sure that the paint mark of the No. 1 fuel hose is positioned as shown in the illustration.
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3.RESET FUEL SYSTEM WARNING LIGHT

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a. Turn the ignition switch to ON.

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b.
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After turning the ignition switch to ON, connect the level warning switch connector no sooner than 3
seconds have passed but no later than 60 seconds have passed.
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c. Check that the combination meter's fuel system warning light turns off.

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1GD-FTV FUEL FUEL FILTER(for Cylinder Block Side) COMPONENTS
ILLUSTRATION
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*1 FUEL FILTER CAP WITH ELEMENT *2 ENGINE WIRE

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*3 NO. 4 FUEL PIPE SUB-ASSEMBLY *4 UNION BOLT

*5 GASKET *6 FUEL PIPE CLAMP
*7 NO. 3 FUEL PIPE *8 O-RING
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1GD-FTV FUEL FUEL FILTER(for Cylinder Block Side) REPLACEMENT
HINT:
When replacing the fuel filter element with cap, clean the fuel filter assembly and remove dirt completely.
PROCEDURE
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1.REMOVE STARTER ASSEMBLY 28100
· for 2.0 kW Type:

Click hereEngine / Hybrid System>1GD-FTV STARTING>STARTER(for 2.0 kW Type)>REMOVAL
· for 2.2 kW Type:
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Click hereEngine / Hybrid System>1GD-FTV STARTING>STARTER(for 2.2 kW Type)>REMOVAL
2.REMOVE FUEL FILTER CAP WITH ELEMENT
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Disconnect the crankshaft position sensor connector and remove the 2 bolts.
b. Detach the 3 clamps and disconnect the engine wire.

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c.
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Remove the union bolt and gasket, disconnect the No. 4 fuel pipe sub-assembly from the fuel filter
assembly.
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d.
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Remove the 2 fuel pipe clamps from the No. 3 fuel pipe and fuel filter assembly.
e.
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Remove the union bolt and gasket, disconnect the No. 3 fuel pipe from the fuel filter assembly.
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Loosen the 4 screws.

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Remove the 2 nuts and disconnect the fuel filter assembly from the cylinder block sub-assembly.
h.
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Remove the 4 screws and fuel filter element from the fuel filter assembly.
HINT:
Use a container to catch the draining fuel.
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Remove the O-ring from the fuel filter assembly.

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3.INSTALL FUEL FILTER CAP WITH ELEMENT

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a. Clean the fuel filter assembly and remove dirt completely.

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b. Apply a light coat of diesel fuel to a new O-ring.
c. Install the O-ring to the fuel filter assembly.

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d. Install a new fuel filter element with cap to the fuel filter assembly with the 4 screws.
Torque:
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e. Connect the fuel filter assembly to the cylinder block sub-assembly with the 2 nuts.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
f. Install the No. 3 fuel pipe and a new gasket to the fuel filter assembly with the union bolt.
Torque:
42 N*m (428 kgf*cm, 31 ft.*lbf)

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*a Paint Mark
*b 0 to 2 mm (0 to 0.0787 in.)
Install the 2 fuel pipe clamps to the fuel filter assembly and No. 3 fuel pipe.
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NOTICE:
Be careful that the fuel pipe clamp and No. 4 fuel pipe sub-assembly do not interfere with each other.
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HINT:
Make sure the fuel pipe clamp is oriented as shown in the illustration.
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h. Install the No. 4 fuel pipe sub-assembly and a new gasket with the union bolt to the fuel filter assembly.
Torque:
42 N*m (428 kgf*cm, 31 ft.*lbf)
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Connect the crankshaft position sensor connector.
j. Attach the 3 clamps and connect the engine wire with the 2 bolts.
Torque:

for bolt A : 12.5 N*m (127 kgf*cm, 9 ft.*lbf)

for bolt B : 18.5 N*m (189 kgf*cm, 14 ft.*lbf)
4.INSTALL STARTER ASSEMBLY 28100
· for 2.0 kW Type:

Click hereEngine / Hybrid System>1GD-FTV STARTING>STARTER(for 2.0 kW Type)>INSTALLATION
· for 2.2 kW Type:
Click hereEngine / Hybrid System>1GD-FTV STARTING>STARTER(for 2.2 kW Type)>INSTALLATION
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1GD-FTV FUEL FUEL INJECTOR COMPONENTS
ILLUSTRATION
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*A w/ DPF - -
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MGPS.html?PUB_TYPE=RM&MODE=1 Page 1 of 2

*5 NO. 1 FUEL PIPE *6 NOZZLE HOLDER GASKET

*7 NOZZLE LEAKAGE PIPE ASSEMBLY *8 WIRING HARNESS CLAMP BRACKET
*9 NO. 5 FUEL HOSE *10 INJECTION NOZZLE SEAT
*11 NOZZLE HOLDER CLAMP *12 WASHER
*13 NOZZLE HOLDER CLAMP BOLT *14 UNION BOLT

ft.*lbf)
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1GD-FTV FUEL FUEL INJECTOR INSPECTION
PROCEDURE
1.INSPECT INJECTOR ASSEMBLY 23670
a. Inspect the injector assembly.

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Tester Specified
Condition
1-2 20°C (68°F) 0.52 to 0.66 Ω
HINT:
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The temperature indicated in "Condition" is the temperature of the injector assembly.
If the result is not as specified, replace the injector assembly.
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1GD-FTV FUEL FUEL INJECTOR INSTALLATION
NOTICE:
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cylinders)
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The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or
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PROCEDURE
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a. Install 4 new nozzle holder gaskets to the cylinder head cover sub-assembly.
23670
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2.TEMPORARILY INSTALL INJECTOR ASSEMBLY
NOTICE:
Before installing the injector assembly, check for carbon, foreign matter, etc. on the seal surfaces of the cylinder
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head sub-assembly and injector assembly. If there is foreign matter, remove it before installing the injector
assembly.
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a. Install 4 new injection nozzle seats to the cylinder head sub-assembly.
b. Apply a light coat of engine oil to the O-ring on each injector assembly.
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c.
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*1 O-Ring
Install a new O-ring to each injector assembly.
d. Install the 4 injector assemblies to the cylinder head sub-assembly.
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NOTICE:
Fit the injector assembly to the injection nozzle seats.
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*1 Washer
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Install the nozzle holder clamps and washers as shown in the illustration.
NOTICE:
Pay attention to the mounting orientation (beveled edge) of the washer.
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f. Temporarily install the nozzle holder clamp bolts.

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NOTICE:
When temporarily installing the nozzle holder clamp bolt to the No. 1 nozzle holder clamp, make sure that
the bolt and clamp are not at an angle.
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HINT:
Apply a light coat of engine oil to the threads of the nozzle holder clamp bolts.
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3.TEMPORARILY INSTALL NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY
a. Temporarily install the 2 No. 2 injection pipe sub-assemblies 4 union nuts.
b. Temporarily install the 2 No. 1 injection pipe sub-assemblies 4 union nuts.

a. Tighten the 4 nozzle holder clamp bolts.

Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
5.TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY
a.
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Using SST, tighten the No. 1 and No. 2 injection pipe sub-assemblies 8 union nuts.
SST
09245-11010
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Torque:
HINT:
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· When using SST (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 180
mm (7.09 in.)): 31 N*m (316 kgf*cm, 23 ft.*lbf)
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Temporarily install the nozzle leakage pipe assembly and 4 new gaskets with the 4 union bolts and bolt.
b. Tighten the 4 union bolts and bolt in the order shown in the illustration.
Torque:

c. Connect the No. 5 fuel hose to the nozzle leakage pipe assembly.
a. Install the harness bracket with the bolt.

Torque:
8.4 N*m (86 kgf*cm, 74 in.*lbf)
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a. Install the wiring harness clamp bracket with bolt to the cylinder head cover sub-assembly.
Torque:
b. Connect the pressure discharge valve connector to the common rail assembly.
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NOTICE:
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12.PERFORM REGISTRATION
a. Perform registration of injector compensation codes.

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Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>REGISTRATION
b. Perform registration of pilot quantity learning.

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1GD-FTV FUEL FUEL INJECTOR ON-VEHICLE INSPECTION
PROCEDURE
1.CHECK INJECTOR ASSEMBLY 23670
a. Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher.
b. Allow the engine to idle for 1 minute or more.
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c. Connect the GTS to the DLC3.
d. Turn the GTS on.
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e. Enter the following menus: Powertrain / Engine / Data List / Injection Volume and Injector Feedback Val.
#1 to #4.
Powertrain > Engine > Data List
Tester Display
Injection Feedback Val #1
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f. Read the values when the engine is idling.
g. Check that the "Injector Feedback Val. #1 to #4" values are within the specification.
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Standard:
Tester Display Engine Condition Specified Condition
Injection Volume Idling 3 to 10 mm3/st
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Injector Feedback Val. #1

Idling -3.0 to 3.0 mm3/st
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If the result is not as specified, replace the fuel injector assembly.

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2.CHECK INJECTOR COMPENSATION CODE

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HINT:
If the injector compensation code is not correctly registered, it may cause malfunctions.
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a. Read the injector compensation code.

b. Check that the compensation code of the installed injector assembly is the same as the code registered in
the ECM. If the code is not the same, register the injector compensation code on the injector assembly.
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1GD-FTV FUEL FUEL INJECTOR REMOVAL
parts are removed, installed, or replaced during the injector assembly removal/installation are shown below.
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· Injector
compensation code
Replacement of injector registration Engine starting ( )
assembly · Pilot quantity
learning
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NOTICE:
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cylinders)
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dropped.
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PROCEDURE
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1. PRECAUTION
NOTICE:
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NOTICE:
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4.CHECK INJECTOR COMPENSATION CODE
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>ON-VEHICLE INSPECTION
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INJECTOR>REMOVAL
a.
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Disconnect the pressure discharge valve connector from the common rail assembly.
b. Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.
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Remove the bolt and harness bracket.
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a.
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Slide the clamp and disconnect the No. 5 fuel hose from the nozzle leakage pipe assembly.
b. Remove the 4 union bolts and 4 gaskets.
c. Remove the bolt and nozzle leakage pipe assembly.
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9.REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY
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NOTICE:
After removing the No. 1 and No. 2 injection pipe sub-assemblies, cover the common rail assembly with
electrical tape to prevent dirt or foreign objects from entering the pipe inlet. Also, protect the injector inlets with
electrical tape or plastic bags.
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a.
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Using SST, loosen the No. 1 and No. 2 injection pipe sub-assemblies and 8 union nuts of the fuel injector
assembly side and common rail assembly side.
SST
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09245-11010
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b.
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Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.
NOTICE:
When removing the No. 1 injection pipe sub-assembly and No. 2 injection pipe sub-assembly, store the
injector assemblies in the correct order so that they can be returned to their original locations when
reassembling.
a.
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Remove the 4 nozzle holder clamp bolts, 4 washers and 4 nozzle holder clamps.
b. Remove the 4 fuel injector assemblies and 4 injection nozzle seats from the cylinder head sub-assembly.
NOTICE:
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When removing the injector assembly, store the injector assemblies in the correct order so that they can
be returned to their original locations when reassembling.
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c. Remove the O-ring from each injector assembly.

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Remove the 4 nozzle holder gaskets from the cylinder head cover sub-assembly.

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1GD-FTV FUEL FUEL SENDER GAUGE ASSEMBLY COMPONENTS
ILLUSTRATION
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*1 FUEL SENDER GAUGE ASSEMBLY *2 FUEL TANK VENT TUBE ASSEMBLY

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1GD-FTV FUEL FUEL SENDER GAUGE ASSEMBLY INSPECTION
PROCEDURE
1.INSPECT FUEL SENDER GAUGE ASSEMBLY 83320
a. Check the fuel sender gauge assembly output voltage.

i.
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*a
(Fuel Sender Gauge Assembly)
*b Voltage applied between terminals
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Apply 5 V between terminals 1 (FV) and 2 (FE).
NOTICE:
· Be careful when connecting the leads, as the fuel sender gauge assembly may be damaged if
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the leads are connected to the wrong terminals.
· Do not apply more than 6 V to terminals 1 (FV) and 2 (FE).
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HINT:
If a stable power supply is not available, use 4 1.2 V nickel-metal hydride batteries or equivalent.
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ii.
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*a
(Fuel Sender Gauge Assembly)
Measure the voltage according to the value(s) in the table below.

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Standard Voltage:
Tester Specified
Condition
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Float position 4.25 to 4.61

is F (upper) V*
2 (FE) - 3 (FR)
Float position 0.34 to 0.70
is E (lower) V*
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*: The output voltage changes depending on the voltage applied to the terminals.
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HINT:
· Output voltage (F) = (0.850 x Voltage applied to terminals) to (0.922 x Voltage applied to
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terminals)
· Output voltage (E) = (0.068 x Voltage applied to terminals) to (0.140 x Voltage applied to
terminals)
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If the result is not as specified, replace the fuel sender gauge assembly.
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1GD-FTV FUEL FUEL SENDER GAUGE ASSEMBLY INSTALLATION
PROCEDURE
1.INSTALL FUEL SENDER GAUGE ASSEMBLY 83320
a.
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Slide
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Set the fuel sender gauge assembly on the fuel tank vent tube assembly. Then slide the fuel sender gauge
downward to install it.
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b. Connect the fuel sender gauge assembly connector.
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2.INSTALL FUEL TANK VENT TUBE ASSEMBLY 77010
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL TANK>INSTALLATION

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1GD-FTV FUEL FUEL SENDER GAUGE ASSEMBLY REMOVAL
PROCEDURE
1.REMOVE FUEL TANK VENT TUBE ASSEMBLY 77010
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL TANK>REMOVAL
2.REMOVE FUEL SENDER GAUGE ASSEMBLY 83320
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a.
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Disconnect the fuel sender gauge connector.
b.
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Slide
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Detach the claw and slide the fuel sender gauge assembly upward to remove it.
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1GD-FTV FUEL FUEL SUPPLY PUMP COMPONENTS
ILLUSTRATION
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*1 FAN SHROUD *2 NO. 1 ENGINE UNDER COVER
*3 NO. 1 OIL RESERVOIR BRACKET *4 NO. 1 RADIATOR HOSE
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*9 FAN AND GENERATOR V BELT *10 FAN PULLEY
*11 FLUID COUPLING ASSEMBLY *12 NO. 1 WATER BY-PASS HOSE
*13 VACUUM HOSE - -
ILLUSTRATION
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*A w/ DPF - -
*3 NO. 1 FUEL HOSE *4 NO. 2 FUEL HOSE
*5 SUPPLY PUMP ASSEMBLY *6 TIMING CHAIN COVER PLATE
*7 V-RIBBED BELT TENSIONER ASSEMBLY *8 SUPPLY PUMP SHAFT NUT
*11 NO. 1 FUEL PUMP BRACKET *12 NO. 3 FUEL PIPE
*13 NO. 4 FUEL PIPE SUB-ASSEMBLY *14 UNION BOLT
*15 SUPPLY PUMP HOLLOW SCREW - -


ft.*lbf)
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1GD-FTV FUEL FUEL SUPPLY PUMP INSPECTION
PROCEDURE
1.INSPECT SUPPLY PUMP ASSEMBLY 22100
a. Inspect the pre-stroke control valve assembly.

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Tester Specified
Condition
1-2 20°C (68°F) 0.42 to 0.52 Ω
HINT:
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The temperature indicated in "Condition" is the temperature of the pre-stroke control valve.
If the result is not as specified, replace the supply pump assembly.
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1GD-FTV FUEL FUEL SUPPLY PUMP INSTALLATION
NOTICE:
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cylinders)
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The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck
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or dropped.
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PROCEDURE
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NOTICE:
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*A w/ DPF
*B w/o DPF
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· With SST set, do not turn the crankshaft more than a half rotation.
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a. Apply a light coat of engine oil to a new O-ring.
b. Install the O-ring to the supply pump assembly.

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c.
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*a Groove
To insert the supply pump assembly shaft in the supply pump shaft sprocket, it may be necessary to turn
the supply pump assembly several degrees and the groove in the supply pump assembly shaft are aligned.
HINT:

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*a Supply Pump Shaft Key
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*b Upper Side
When installing a new supply pump assembly, adjust the supply pump assembly injection pump drive
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shaft key assignment by turning the supply pump assembly shown in the illustration.
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*a Hold
Turn
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Using SST, tighten clockwise direction the supply pump assembly, and then temporarily install the 3 fuel
supply pump fixing nuts.
SST
09213-58014 (91551-80840)
09330-00021
09241-11010

e.
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Using SST, tighten and insert the supply pump assembly up to the position shown in the illustration and
tighten the 3 fuel supply pump fixing nuts.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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HINT:
After tightening the part with SST, a gap of 2 to 3 mm in area A shown in the illustration is normal.
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f. w/ DPF:
Install the No. 1 fuel pump bracket with the 2 bolts to the supply pump assembly and cylinder block sub-
assembly.
Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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Remove SST and the 3 set bolts.

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h.
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*a Hold

Turn
Using SST, hold the crankshaft pulley sub-assembly and tighten the set nut.
Torque:
137 N*m (1397 kgf*cm, 101 ft.*lbf)
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a. Install the timing chain cover plate and new gasket with the 3 bolts.
Torque:
NOTICE:
Do not install the timing chain cover plate with the bolts included with SST.
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3.INSTALL FUEL PUMP MOTOR WIRE
a.
b.
Attach the clamp and install the fuel pump motor wire.
Connect the fuel pump motor wire connector.

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a. Install the fuel injection pump cover sub-assembly to the supply pump assembly.
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a. Install the No. 2 fuel hose to the supply pump assembly and No. 3 nozzle leakage pipe assembly, and slide
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the 2 clamps to secure it.

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a. Install the No. 1 fuel hose to the supply pump assembly and No. 2 fuel pipe, and slide the 2 clamps to
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secure it.
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NOTICE:
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19.INSTALL NO. 1 ENGINE UNDER COVER 51441

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1GD-FTV FUEL FUEL SUPPLY PUMP REMOVAL
NOTICE:
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cylinders)
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The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck
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or dropped.
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PROCEDURE
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1. PRECAUTION
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NOTICE:
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NOTICE:
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4.REMOVE NO. 1 ENGINE UNDER COVER 51441
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a.
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Slide the 2 clips and remove the No. 2 fuel hose from the supply pump assembly and No. 3 nozzle leakage
pipe assembly.
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a.
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Slide the 2 clips and remove the No. 1 fuel hose from the supply pump assembly and No. 2 fuel pipe.
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a. Remove the fuel injection pump cover sub-assembly from the supply pump assembly.
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16.REMOVE FUEL PUMP MOTOR WIRE

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a.
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Disconnect the fuel pump motor wire connector.
b. Detach the clamp and remove the fuel pump motor wire.

a.
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Remove the 3 bolts and timing chain cover plate.
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NOTICE:
·
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*A w/ DPF
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*B w/o DPF
· With SST set, do not turn the crankshaft more than a half rotation.

a.
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*a Timing Mark
Align the timing mark of the crankshaft pulley sub-assembly and timing chain cover by rotating the
crankshaft clockwise.
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b.
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*a Hold
Turn
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Using SST, hold the crankshaft pulley assembly and loosen the fuel supply pump shaft nut.
SST
09213-58014 (91551-80840)
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09330-00021
NOTICE:
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Do not excessively loosen the supply pump shaft nut, otherwise SST cannot be installed.
HINT:
Rotate the supply pump shaft nut once to loosen it.
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*A w/ DPF
*B w/o DPF
Loosen the 3 nuts from the supply pump assembly.

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NOTICE:
Do not completely remove the nuts. Otherwise, the supply pump assembly may fall off.
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d.
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Install SST with 3 bolts.

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SST
09241-11010
Torque:
NOTICE:
Install SST with the bolts included with SST.
HINT:

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*b Engine Rear Side
*c SST Hexagonal Portion
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· Make sure that the installation direction of SST is as shown in the illustration.
· Align the hexagonal portion of SST with the supply pump shaft nut to install SST.
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w/ DPF:
Remove the 2 bolts and No. 1 fuel pump bracket from the supply pump assembly and cylinder block sub-
assembly.

f.
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*a Hold
Turn
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Install the handle to SST. While holding the crankshaft pulley assembly in place with the crankshaft holding
tool, turn the handle in the counterclockwise direction to disconnect the supply pump assembly.
SST
09213-58014 (91551-80840)
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09330-00021
09241-11010
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g. Remove the 3 nuts and supply pump assembly from the timing chain case assembly.
h.
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Remove the O-ring from the supply pump assembly.

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1GD-FTV FUEL FUEL SYSTEM ON-VEHICLE INSPECTION
PROCEDURE
CAUTION:
· During Active Test mode, the engine speed becomes high and the combustion noise becomes loud, so
pay attention.
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· During Active Test mode, the fuel pressure becomes high. Be extremely careful not to expose your eyes,
hands, or body to escaping fuel.
HINT:
Using the GTS to perform Active Tests allow relays, VSVs, actuators and other items to be operated without
removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation
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may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one
way to save diagnostic time. Data List information can be displayed while performing Active Tests.
a. Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel
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leakage, repair or replace parts as necessary.
b. Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel
leakage, repair or replace parts as necessary.
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c. Disconnect the return hose from the common rail assembly.
d. Start the engine and check for fuel leaks from the return pipe.
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If there is fuel leakage, replace the common rail assembly.
e. Connect the GTS to the DLC3.

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f. Start the engine and turn the GTS on.
g. Enter the following menus: Powertrain / Engine / Active Test / Test the Fuel Leak.
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Tester Display
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Test the Fuel Leak
Execute
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h. If the GTS is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the
maximum and maintain that speed for 2 seconds. Repeat this operation several times.
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i. Check that there are no leaks from any part of the fuel system.
NOTICE:
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A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.
If there is fuel leakage, repair or replace parts as necessary.
j. Reconnect the return hose to the common rail assembly.
2.CHECK PRESSURE DISCHARGE VALVE
HINT:
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· This is the procedure for troubleshooting fuel pressure control malfunctions and combustion problems.
· Malfunctions can be determined by checking the fuel pressure when performing a fuel cut and operating
the pressure discharge valve with the GTS.
· During "Pressure Discharge Valve Check", the GTS measures the fuel pressure while the engine is
running, after the engine is stopped, and after the pressure discharge valve operates.
b. Turn the ignition switch to ON.
c. Turn the GTS on.

NOTICE:
The following conditions must be met:
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· Engine is idling.
· Vehicle is stopped.
· Fuel pressure is not extremely high (below 100000 kPa).
· Fuel pressure is not extremely low (higher than 26000 kPa).
· Fuel pressure sensor is normal.
· Battery voltage is higher than 8 V.
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HINT:
When the common rail pressure is unstable, the fuel pressure may decrease to a level where the test
cannot be performed. In this situation, wait until the common rail pressure meets the test condition, and
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then perform the test.
d. Enter the following menus: Powertrain / Engine / Utility / Pressure Discharge Valve Check.
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Powertrain > Engine > Utility
Tester Display
Pressure Discharge Valve Check
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Execute
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e. Press "Next".
f. Press "Next" again to proceed.

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g. Select the check type for "Valve Check for Graph".

1. Press "Next" again to proceed.
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2. Press "Start" again to proceed.

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*a Engine Speed *b Fuel Pressure
When "Start" is pressed, the pressure
*c Pressure Discharge Valve *d
discharge valve check begins.
If "Save" is pressed after the pressure
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*e discharge valve check, the data recorded - -
during the valve check can be saved.
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h. Select the check type "Close to Open Check" or "Always Closed Check".
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HINT:
· "Close to Open Check" opens the pressure discharge valve after the engine stops.
· "Always Closed Check" holds the pressure discharge valve closed during the check.
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i. Press "Next".
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j. Perform troubleshooting based on the measurement results.

OK:
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0.5 MPa or less
HINT:
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· During "Close to Open Check", if there is no large change in fuel pressure when the pressure
discharge valve is closed while the engine is running and after the engine is stopped, and if the
value is 0 MPa when the pressure discharge valve is open, the system is normal.
· Perform "Always Closed Check" if the value is not 0 MPa when the pressure discharge valve is
open during "Close to Open Check". If the results are the same as during "Close to Open Check",
there is a pressure discharge valve operation malfunction.
· If a large amount of fuel is leaking, the fuel pressure decreases when the engine is stopped.
However, the condition of the pressure discharge valve can still be determined by comparing the
measurement results of "Close to Open Check" and "Always Closed Check".

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Fuel Press Fuel Press

*a *b
(Always Closed Check) (Close to Open Check)
*c Engine Speed *d Fuel Cut Operation Signal
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*e Pressure Discharge Valve Operation *f Pressure Discharge Valve Operation

(Prohibition) (Always Closed Check)
Pressure Discharge Valve Operation
*g *h 0 MPa
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(Close to Open Check)

*i 0 rpm *j On
*k Off *l Closed (on)
*m Open (on) *n Fuel Press Recorded
*o Pressure Discharge Valve Operation Start - -

a.
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Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping
until the pump resistance increases.
NOTICE:
· Hand pump pumping speed: Max. 2 strokes/ sec.
· The hand pump must be pushed with a full stroke during pumping.
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· When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand
pump resistance increases.
· If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the
fuel tank assembly. Continue pumping until the hand pump resistance increases.
· If the hand pump resistance does not increase despite consecutively pumping 200 times or more,
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there may be a fuel leak between the fuel tank assembly and fuel filter assembly, the hand pump
may be malfunctioning, or the vehicle may have run out of fuel.
· If air bleeding using the hand pump is incomplete, the common rail assembly pressure does not
rise to the pressure range necessary for normal use, and the engine cannot be started.
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b. Check if the engine starts.
NOTICE:
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· Even if air bleeding using the hand pump has been completed, the starter assembly may need to
be cranked for 10 seconds or more to start the engine.
· Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
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· Use a fully-charged battery.
i. When the engine can be started, proceed to the next step.

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ii. If the engine cannot be started, bleed the air again using the hand pump until the hand pump
resistance increases (refer to the procedures above). Then start the engine.
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c. Turn the ignition switch off.

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d. Connect the GTS to the DLC3.
e. Turn the ignition switch to ON and turn the GTS on.

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f. Clear the DTCs.

Powertrain > Engine > Clear DTCs
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Execute
g. Start the engine.*1
h. Enter the following menus: Powertrain / Engine / Active Test / Test the Fuel Leak.*2
Tester Display
Test the Fuel Leak

Execute
i. Perform the following test 5th times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3
j. Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.
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*a Active Test Operation *b ON
*c OFF *d 1st time
*e 2nd time *f 5th time
*g 10 seconds *h 3 minutes
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*i Time - -
HINT:
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When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel
pressure inside the common rail assembly drops below the target fuel pressure when the Active Test is
off, but this is normal and does not indicate a pump malfunction.
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k. Enter the following menus: Powertrain / Engine / Trouble Codes.

Powertrain > Engine > Trouble Codes
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Execute
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l. Read Current DTCs.

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m. Clear the DTCs.

Powertrain > Engine > Clear DTCs
Execute
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HINT:
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It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel
system after replacing or repairing fuel system parts.
n. Repeat steps *1 to *3.
o. Enter the following menus: Powertrain / Engine / Trouble Codes.

Powertrain > Engine > Trouble Codes
Execute

p. Read Current DTCs.

OK:
No DTCs are output.
4.CHECK FUEL SYSTEM WARNING LIGHT AND DRAIN WATER
a. w/ Multi-information Display:
Check the fuel system warning is displayed on the multi-information display, replace the fuel filter element
assembly (Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL FILTER>REPLACEMENT) or drain the
water in the fuel filter assembly.
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b. w/o Multi-information Display:
Check the fuel system warning light in the combination meter assembly and either replace the fuel filter
element assembly (Click here Engine / Hybrid System>1GD-FTV FUEL>FUEL FILTER>REPLACEMENT) or
drain the water in the fuel filter assembly based on the instructions shown in the illustration.
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*a Fuel System Warning Light *b Fuel Filter Condition

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*c Necessary Procedure *d On
*e Off *f Illuminate
*g Blinking *h Clogged
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*i Water Level Warning *j Replace the Fuel Filter Element Assembly

*k Drain the Water - -
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c. Drain water.
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Detach the clamp and disconnect the No. 1 fuel hose from the No. 2 fuel pipe clamp.

ii.
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Disconnect the level warning switch connector.
iv.
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Slide the fuel filter assembly and lift it up.

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v.
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Connect a hose to the drain cock. Place the other end of the hose into a container under the drain cock.
vi. Loosen the drain cock to drain water.
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vii. Operate the hand pump until fuel begins to run out.
viii. Tighten the drain cock by hand.

NOTICE:
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Do not use any tools in this procedure.
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Slide the fuel filter assembly to install it.
x. Connect the level warning switch connector.

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xi.
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*1 No. 1 Fuel Hose
*2 No. 2 Fuel Pipe Clamp
*a Paint Mark
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Attach the clamp and connect the No. 1 fuel hose to the No. 2 fuel pipe clamp.
HINT:
Make sure that the paint mark of the No. 1 fuel hose is positioned as shown in the illustration.
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1GD-FTV FUEL FUEL SYSTEM PARTS LOCATION
ILLUSTRATION
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*1 COMMON RAIL *2 FUEL FILTER

*3 FUEL INJECTOR *4 FUEL SENDER GAUGE ASSEMBLY
*5 FUEL SUPPLY PUMP *6 FUEL TANK CAP
*7 RELAY *8 FUEL FILTER (w/ Secondary Fuel Filter)
*9 FUEL TANK ASSEMBLY *10 VENT TUBE ASSEMBLY
*11 ECM (for LHD) *12 ECM (for RHD)
ENGINE ROOM RELAY BLOCK AND JUNCTION INSTRUMENT PANEL JUNCTION BLOCK
*13 BLOCK ASSEMBLY *14
- EFI MAIN NO. 1 FUSE
- EDU FUSE
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*15 FUEL PRESSURE SENSOR *16 PRESSURE DISCHARGE VALVE

*17 EFI MAIN NO. 1 RELAY *18 PRE-STROKE CONTROL VALVE
*19 LEVEL WARNING SWITCH *20 CLOGGING SWITCH
ILLUSTRATION
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*A for LHD *B for RHD

*1 COMBINATION METER ASSEMBLY - -
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1GD-FTV FUEL FUEL SYSTEM PRECAUTION
CAUTION:
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The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel
tank assembly may fall off the engine lifter.
a.
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The type of ignition switch used on this model differs depending on the specifications of the vehicle. The
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Expression
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FUEL SYSTEM
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a. When disconnecting the fuel pressure fuel line, a large amount of diesel fuel will spill out. Follow these
procedures.
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i. Disconnect the fuel tube.
ii. Drain any fuel remaining inside the fuel tube.

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iii. To protect the disconnected fuel tube from damage and contamination, cover it with a plastic bag.
iv. Put a container under the connection.

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b. Perform the following procedure when disconnecting the fuel tube connector (quick type A).
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i.
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*a Fuel Tube Connector Cover
Pull
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Remove the fuel tube connector cover.
ii. Check whether there is any foreign matter on the fuel pipe around the fuel tube connector before
disconnecting it. Clean it if necessary.
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*a Retainer
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Pinch
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Pull Out
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Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.
NOTICE:
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Be sure to disconnect the fuel tube connector by hand.

iv.
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*a Retainer
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*b Nylon Tube
*c Fuel Pipe
*d O-ring
*e Fuel Tube Connector
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If the fuel tube connector and the fuel pipe are stuck, push in and pull on the fuel tube connector to
release it. Pull the fuel tube connector out of the fuel pipe carefully.
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NOTICE:
· Check for any dirt and foreign matter contamination in the fuel pipe and around the connector.
Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between
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the fuel pipe and fuel tube connector.

· Do not use any tools to separate the fuel pipe and fuel tube connector.
· Check for any dirt and foreign matter on the fuel pipe seal surface. Clean if necessary.
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· Do not forcibly bend, twist or turn the nylon tube.

· Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the
fuel tube.
· If the fuel pipe and fuel tube connector are stuck together, pinch the connector between your
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fingers and turn it carefully to free it. Then disconnect the fuel tube.
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v. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel pipes. Clean the
surfaces if necessary.
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vi. Cover the disconnected fuel pipe and fuel tube connector with a plastic bag to prevent damage and
contamination.
c. Perform the following procedure when connecting the fuel tube connector (quick type A).
i. Check if there is any damage or foreign matter on the connecting parts of the fuel pipe.

ii.
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Line up the 2 parts of the fuel lines to be connected, and push them together until the fuel tube
connector makes a "click" sound. If the fuel pipe is difficult to push into the fuel tube connector, apply a
small amount of clean engine oil to the tip of the fuel pipe and reinsert it.
iii.
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After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected
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by pulling on them.
iv. Inspect for fuel leaks.

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v. Install the fuel tube connector cover.

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1GD-FTV FUEL FUEL SYSTEM SYSTEM DIAGRAM
FUEL FLOW DIAGRAM
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*A w/ DPF - -
*1 Fuel Pressure Sensor *2 Common Rail Assembly
*3 Pressure Discharge Valve *4 Fuel Supply Pump Assembly
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*5 Pre-Stroke Control Valve *6 Injector Assembly

*7 Exhaust Fuel Addition Injector Assembly *8 ECM
Fuel Filter Assembly
*9 Fuel Filter Assembly *10
(for Cylinder Block Side)
*11 Fuel Tank Assembly - -
High Pressure Fuel Return Fuel
Suction Fuel Feed Pressure Fuel
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*A w/o DPF - -
*1 Fuel Pressure Sensor *2 Common Rail Assembly
*3 Pressure Discharge Valve *4 Fuel Supply Pump Assembly
*5 Pre-Stroke Control Valve *6 Injector Assembly
*7 ECM *8 Fuel Filter Assembly
*9 Fuel Tank Assembly - -
High Pressure Fuel Return Fuel

Suction Fuel - -
FUEL SYSTEM WIRING DIAGRAM
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1GD-FTV FUEL FUEL TANK COMPONENTS
ILLUSTRATION
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*A for Type A *B for Type B

*C for Smart Cab - -
*1 FUEL TANK ASSEMBLY *2 FUEL TANK BREATHER HOSE
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*3 FUEL TANK CUSHION *4 FUEL TANK MAIN TUBE SUB-ASSEMBLY

*5 FUEL TANK RETURN TUBE *6 FUEL TANK TO FILLER PIPE HOSE
*7 FUEL TANK VENT TUBE ASSEMBLY *8 NO. 1 FUEL TANK HEAT INSULATOR
*9 NO. 1 FUEL TANK PROTECTOR *10 NO. 3 FUEL TUBE CLAMP
*11 TUBE JOINT CLIP *12 FUEL PUMP GAUGE RETAINER
*13 FUEL TANK VENT TUBE GASKET *14 WIRE HARNESS
*15 FUEL TANK BAND *16 FUEL TANK PROTECTOR
*17 CLIP *18 FUEL TANK BOLT
*19 FUEL TANK BAND PIN *20 NO. 3 FUEL TUBE JOINT
*21 FUEL HOSE - -

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ft.*lbf)
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1GD-FTV FUEL FUEL TANK INSTALLATION
PROCEDURE
1.INSTALL FUEL TANK TO FILLER PIPE HOSE 77213B
a. for Type A:
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*a Protrusion
*b Paint Mark
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Install the fuel tank to filler pipe hose to the fuel tank assembly, and tighten the clamp to secure the
hose.
HINT:
Make sure the clamp is oriented as shown in the illustration.
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ii. Install the fuel hose to the fuel tank evaporation tube sub-assembly.
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b. for Type B:
i. Install the fuel tank to filler pipe hose to the fuel tank assembly, and tighten the clamp to secure the
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hose.
ii. Install the No. 3 fuel tube joint to the fuel tank cut off valve.
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2.INSTALL FUEL TANK VENT TUBE ASSEMBLY 77010
a. Apply a light coat of diesel fuel or grease to a new fuel tank vent tube gasket, and install it to the fuel tank
sub-assembly.
b. Install the fuel tank vent tube assembly to the fuel tank sub-assembly.
NOTICE:
Be careful not to bend the arm of the fuel sender gauge assembly.
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c.
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*a Protrusion
Hole
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Align the protrusions of the fuel tank vent tube assembly with the holes in the fuel tank sub-assembly.
d. While pressing down on the fuel tank vent tube assembly, temporarily install the fuel pump gauge retainer.
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e.
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*a SST (Plate)
*b SST (Claw)
*c Insertion Point
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Set the 2 claws and plate of SST on the fuel pump gauge retainer.
SST
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09808-14030 (09808-01010, 09808-01030, 09808-01040)
HINT:
Securely insert the ends of SST into the insertion points in the fuel pump gauge retainer.
f. While firmly pressing the claws of SST into the insertion points in the fuel pump gauge retainer, tighten the
bolts of the claws.
g. Attach the handle of SST.
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*a Alignment Mark ke
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*b Groove
Turn
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Front of Vehicle
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Using SST, rotate the fuel pump gauge retainer so that the protrusions of the fuel pump gauge retainer are
aligned with the grooves in the fuel tank sub-assembly to install the fuel tank vent tube assembly to the
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fuel tank sub-assembly.

NOTICE:
· Do not use any tools other than SST, such as a screwdriver, etc.
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· Do not use excessive force when pressing down on SST, as the fuel pump gauge retainer will place
excessive force on the fuel tank vent tube assembly and be difficult to remove, and parts may be
damaged.
· Be sure to keep the handle level when turning it, as SST may slip off the retainer if the handle is
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turned at an angle with excessive force.

· Do not use an impact wrench or turn the handle with excessive force, as parts may be damaged.
· If SST slips off the fuel pump gauge retainer, loosen the bolts and reattach SST to the fuel pump
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gauge retainer.
i. Insert the fuel tank main tube sub-assembly and fuel tank return tube into the plugs of the fuel tank vent
tube assembly and fix them in place with the 2 tube joint clips.
NOTICE:

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*a Fuel Tube Joint
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*b Tube Joint Clip
*c O-Ring
*d Fuel Tank Vent Tube Assembly
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*e Collar
*f CORRECT
*g INCORRECT
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· Check that there are no scratches or foreign objects on the connecting parts.
· Check that the fuel tube joints are inserted securely.
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· Check that the tube joint clips are on the collars of the fuel tube joints.
· After installing the tube joint clips, check that the fuel tube joints cannot be pulled off.
· Be careful not to damage any clips.
If a clip is damaged, replace it.
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3.INSTALL NO. 3 FUEL TUBE CLAMP 77289B

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a. Attach the claw to install the No. 3 fuel tube clamp.

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4.INSTALL FUEL TANK CUSHION 77652A
a. Install the 2 new fuel tank cushions to the fuel tank sub-assembly.
5.INSTALL NO. 1 FUEL TANK HEAT INSULATOR 77697
a. Install the No. 1 fuel tank heat insulator with the 4 fuel tank bolts and nut.
Torque:
6.0 N*m (61 kgf*cm, 53 in.*lbf)

6.INSTALL FUEL TANK ASSEMBLY
CAUTION:
a. Set the fuel tank sub-assembly on an engine lifter and raise the fuel tank sub-assembly.
NOTICE:
Do not allow the fuel tank sub-assembly to contact the vehicle, especially the differential.
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*1 Fuel Tank Cushion

*2 Wire Harness
*3 Fuel Tank Assembly
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Fold back approximately half of each fuel tank cushion so that the wire harness can be installed in the step
below.
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c. Attach the wire harness to the 6 clamps and connect the fuel sender gauge connector.
NOTICE:
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Be careful not to cut the wire harness.
d. for Smart Cab:

Install the fuel tank protector with attach the 3 claws.
e. Install the 2 fuel tank bands with the 2 fuel tank band pins and 2 clips.
f. Install the 2 fuel tank bands with the 2 bolts.

Torque:
45 N*m (459 kgf*cm, 33 ft.*lbf)

7.CONNECT FUEL TANK TO FILLER PIPE HOSE 77213B
a.
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*a
*b
Protrusion
Paint Mark (Yellow)
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*c 0 to 3 mm (0 to 0.118 in.)
*d 2 to 7 mm (0.0787 to 0.276 in.)
Connect the fuel tank to filler pipe hose to the fuel tank filler pipe sub-assembly, and tighten the clamp to
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secure the hose.
HINT:
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8.CONNECT FUEL TANK BREATHER HOSE

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a. for Type A:
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*a Paint Mark
*b Top of Vehicle
Connect the fuel tank breather hose to the fuel tank filler pipe sub-assembly, and slide the clamp to
secure the hose.
HINT:
ii. Connect the fuel hose to the fuel tank filler pipe sub-assembly.
iii. Attach the 2 clamps to connect the fuel tank breather hose and fuel hose.
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b. for Type B:
i. Connect the fuel tank breather hose to the fuel tank filler pipe sub-assembly, and slide the clamp to
secure the hose.
HINT:
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ii. Attach the clamp to connect the fuel tank breather hose.
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9.CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN 77209F
TUBE
a. Connect the 2 fuel hoses to the fuel tank main tube sub-assembly and fuel tank return tube, and slide the 2
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clamps to secure the hoses.
10.INSTALL NO. 1 FUEL TANK PROTECTOR 77641A

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a. Install the fuel tank protector to the fuel tank sub-assembly with the 5 nuts.
Torque:
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13 N*m (133 kgf*cm, 10 ft.*lbf)

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11.INSTALL FUEL TANK CAP ASSEMBLY 77310A

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NOTICE:
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1GD-FTV FUEL FUEL TANK REMOVAL
CAUTION:
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PROCEDURE
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1. PRECAUTION
NOTICE:
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NOTICE:
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3.REMOVE FUEL TANK CAP ASSEMBLY 77310A

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4.REMOVE NO. 1 FUEL TANK PROTECTOR 77641A

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Remove the 5 nuts and No. 1 fuel tank protector from fuel tank bands.
5.DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN 77209F
TUBE
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Slide the 2 clamps and disconnect the 2 fuel hoses from the fuel tank main tube sub-assembly and fuel
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tank return tube.
6.DISCONNECT FUEL TANK BREATHER HOSE

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a.
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for Type A:
i. Detach the 2 clamps.
ii. Slide the clamp and disconnect the fuel hose and fuel tank breater hose from the fuel tank filler pipe
sub-assembly.
b. for Type B:

i. Detach the clamp.
ii.
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Slide the clamp and disconnect the fuel tank breater hose from the fuel tank filler pipe sub-assembly.
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7.DISCONNECT FUEL TANK TO FILLER PIPE HOSE 77213B
a.
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Loosen the clamp and disconnect the fuel tank to filler pipe hose from the fuel tank filler pipe sub-
assembly.
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8.REMOVE FUEL TANK ASSEMBLY

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CAUTION:
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a. Using an engine lifter and attachments, support the fuel tank assembly.
b.
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Remove the 2 bolts and disconnect the 2 fuel tank bands.
c. Remove the 2 clips, 2 fuel tank band pins and 2 fuel tank bands.
HINT:
Move the fuel tank assembly just enough to remove the fuel tank band pins.
d. Slightly lower the engine lifter.

NOTICE:
Be careful not to cut the wire harness.
e.
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*2 Wire Harness
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*3 Fuel Tank Assembly
Fold back approximately half of each fuel tank cushion so that the wire harness can be removed in the step
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below.
f.
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for Smart Cab:

Detach the 3 claws and remove the fuel tank protector.
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*a Claw
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Detach the wire harness from the 6 clamps shown in the illustration.
h. Disconnect the fuel sender gauge connector from the fuel tank vent tube assembly.
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9.REMOVE NO. 1 FUEL TANK HEAT INSULATOR 77697

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a.
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Fuel Tank Bolt
Nut
Remove the nut.
b. Using needle-nose pliers, remove the 4 fuel tank bolts shown in the illustration, and then remove the No. 1
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fuel tank heat insulator.
10.REMOVE FUEL TANK CUSHION 77652A
a.
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Remove the 2 fuel tank cushions from the fuel tank sub-assembly.
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11.REMOVE NO. 3 FUEL TUBE CLAMP 77289B

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a.
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Detach the claw and remove the No. 3 fuel tube clamp.
12.REMOVE FUEL TANK VENT TUBE ASSEMBLY 77010

a.
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Remove the 2 tube joint clips and pull out the fuel tank main tube sub-assembly and fuel tank return tube
from the fuel tank vent tube assembly.
NOTICE:
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*a Fuel Tube Joint
*b Fuel Tube
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*c O-Ring
*d Tube Joint Clip
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· Remove any dirt and foreign matter on the fuel tube joint before performing this work.
· Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel
tube joint contains the O-rings that seal the plug.
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· Perform this work by hand. Do not use any tools.

· Do not forcibly bend or twist the nylon tube.
· Protect the disconnected parts by covering them with plastic bags and tape after disconnecting
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the fuel tank main tube sub-assembly and fuel tank return tube.
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b. Remove the fuel pump gauge retainer from the fuel tank assembly.
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*a SST (Plate)
*b SST (Claw)
*c Insertion point
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Set the 2 claws and plate of SST on the fuel pump gauge retainer.
SST
09808-14030 (09808-01010, 09808-01030, 09808-01040)
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HINT:
Securely insert the ends of SST into the insertion points in the fuel pump gauge retainer.
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ii. While firmly pressing the claws of SST into the insertion points in the fuel pump gauge retainer, tighten
the bolts of the claws.
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iii.
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Attach the handle of SST.
iv. While lightly pressing down on SST so it does not come off the fuel pump gauge retainer, slowly turn
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the handle and remove the fuel pump gauge retainer.

NOTICE:
· Do not use any tools other than SST, such as a screwdriver, etc.
· Do not use excessive force when pressing down on SST, as the fuel pump gauge retainer will
place excessive force on the fuel tank vent tube assembly and fuel pump gauge retainer and
be difficult to remove, and parts may be damaged.
· Be sure to keep the handle level when turning it, as SST may slip off the fuel pump gauge
retainer if the handle is turned at an angle with excessive force.
· Do not use an impact wrench or turn the handle with excessive force, as parts may be
damaged.
· If SST slips off the fuel pump gauge retainer, loosen the bolts and reattach SST to the fuel

pump gauge retainer.
c. Remove the fuel tank vent tube assembly from the fuel tank sub-assembly.
NOTICE:
Be careful not to bend the arm of the fuel sender gauge assembly.
d.
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Remove the fuel tank vent tube gasket from the fuel tank sub-assembly.
13.REMOVE FUEL TANK TO FILLER PIPE HOSE 77213B

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*A for Type A
*B for Type B
a. for Type A:
i. Loosen the clamp and remove the fuel tank to filler pipe hose from the fuel tank sub-assembly.

ii. Remove the fuel hose from the fuel tank evaporation tube sub-assembly.
b. for Type B:
i. Loosen the clamp and remove the fuel tank to filler pipe hose from the fuel tank sub-assembly.
ii. Remove the No. 3 fuel tube joint from the fuel tank cut off valve.
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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER COMPONENTS
ILLUSTRATION
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*A w/ Viscous Heater *B for 4WD and Pre-Runner
*1 AIR CLEANER CAP SUB-ASSEMBLY WITH AIR *2 AIR CLEANER CASE SUB-ASSEMBLY
CLEANER HOSE
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*3 AIR CLEANER FILTER ELEMENT SUB- *4 FAN SHROUD

ASSEMBLY
*5 NO. 1 AIR HOSE *6 NO. 1 ENGINE UNDER COVER ASSEMBLY
*7 NO. 1 OIL RESERVOIR BRACKET *8 NO. 1 RADIATOR HOSE
NO. 1 VISCOUS HEATER BRACKET SUB-
*9 *10 NO. 2 AIR TUBE
ASSEMBLY
*11 NO. 4 AIR HOSE *12 RADIATOR RESERVOIR
VISCOUS HEATER WITH MAGNET CLUTCH
*13 VANE PUMP OIL RESERVOIR ASSEMBLY *14
ASSEMBLY
*15 WATER HOSE SUB-ASSEMBLY *16 FAN AND GENERATOR V BELT
*17 FAN PULLEY *18 FLUID COUPLING ASSEMBLY
*19 NO. 1 WATER BY-PASS HOSE *20 VISCOUS V BELT
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ILLUSTRATION
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*A for Cold Specification Vehicles *B w/o DPF

*1 EXHAUST MANIFOLD *2 NO. 1 EGR PIPE SUB-ASSEMBLY
*3 NO. 1 WATER BY-PASS PIPE *4 NO. 3 WATER BY-PASS PIPE
*5 PCV PIPE *6 TURBO OIL OUTLET PIPE
*9 COLLAR *10 GASKET
*11 PLATE WASHER *12 TURBO OIL OUTLET HOSE
*13 WIRE HARNESS *14 NO. 20 WATER BY-PASS HOSE
*15 WATER HOSE *16 STUD BOLT


ft.*lbf)
ILLUSTRATION
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*A except Cold Specification Vehicles *B w/ DPF

*1 EXHAUST MANIFOLD *2 NO. 1 EGR PIPE SUB-ASSEMBLY
*3 NO. 1 WATER BY-PASS PIPE *4 NO. 3 WATER BY-PASS PIPE
*5 PCV HOSE *6 TURBO OIL OUTLET PIPE
*9 COLLAR *10 GASKET
*11 PLATE WASHER *12 TURBO OIL OUTLET HOSE
*13 WIRE HARNESS *14 STUD BOLT

ft.*lbf)
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ILLUSTRATION
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*A for Cold Specification Vehicles *B w/o DPF

*1 COMPRESSOR INLET ELBOW *2 COMPRESSOR OUTLET ELBOW
*3 NO. 1 TURBO WATER PIPE SUB-ASSEMBLY *4 TURBO OIL INLET PIPE SUB-ASSEMBLY
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*5 TURBO WATER HOSE *6 TURBOCHARGER SUB-ASSEMBLY

*7 STUD BOLT *8 COMPRESSOR INLET ELBOW STAY
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*9 GASKET *10 UNION BOLT

ft.*lbf)
ILLUSTRATION

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*A except Cold Specification Vehicles *B w/ DPF

*1 COMPRESSOR INLET ELBOW *2 COMPRESSOR OUTLET ELBOW
*3 NO. 1 TURBO WATER PIPE SUB-ASSEMBLY *4 TURBO OIL INLET PIPE SUB-ASSEMBLY
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*5 TURBO WATER HOSE *6 TURBOCHARGER SUB-ASSEMBLY

*7 STUD BOLT *8 COMPRESSOR INLET ELBOW STAY
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*9 GASKET *10 UNION BOLT

*11 HOSE CLAMP - -

ft.*lbf)
ILLUSTRATION

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*1 TURBOCHARGER NOZZLE VANE CONTROL *2 TURBOCHARGER VANE CONTROL ROD SUB-

ACTUATOR ASSEMBLY
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COMPRESSOR WITH BEARING HOUSING SUB-

*3 *4 E-WASHER
ASSEMBLY
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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER DISASSEMBLY
PROCEDURE
1.REMOVE TURBOCHARGER VANE CONTROL ROD SUB-ASSEMBLY
a.
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Secure the flange of the turbine housing sub-assembly of the turbocharger sub-assembly in a vise between
aluminum plates.
NOTICE:
Do not tighten the vise more than necessary, as doing so will damage the flange of the turbine housing
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sub-assembly.
b.
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Remove the 2 E-washers from the variable nozzle vane motor assembly and turbocharger vane control link
sub-assembly.
NOTICE:
Do not reuse the E-washer.
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c. Remove the turbocharger vane control rod sub-assembly.

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2.REMOVE TURBOCHARGER NOZZLE VANE CONTROL ACTUATOR
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a.
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Remove the 3 bolts and turbocharger nozzle vane control actuator.
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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER INSPECTION
PROCEDURE
1.VISUALLY CHECK TURBOCHARGER SUB-ASSEMBLY 17201
a.
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*1 Compressor Impeller
Check for deformation and cracks in the compressor impeller on the intake side.
If the compressor impeller is cracked or deformed, replace the turbocharger sub-assembly.
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b.
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*1 Turbine Wheel
Check for deformation and cracks in the turbine wheel on the exhaust side.
If the turbine wheel is cracked or deformed, replace the turbocharger sub-assembly.
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2.INSPECT AXIAL PLAY OF TURBINE SHAFT 17201
a.
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Using a dial indicator, insert the needle of the dial indicator into the exhaust side of the turbine shaft.
NOTICE:
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Turbocharger sub-assembly and dial indicators are surely fixed when performing measurement.
b. Move the turbine shaft in an axial direction and measure the axial play of the turbine shaft.
Maximum axial play:
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0.11 mm (0.00433 in.)
If the axial play is more than the maximum, replace the turbocharger sub-assembly.
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3.CHECK TURBINE SHAFT ROTATION 17201
a.
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Rotate the turbine wheel on the exhaust side with your finger and check that it rotates smoothly.
HINT:
Even if it takes a little effort to rotate the turbine wheel, this is not a problem.
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If the turbine wheel does not rotate smoothly, replace the turbocharger sub-assembly.
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4.INSPECT TURBOCHARGER NOZZLE VANE CONTROL ACTUATOR

Tester Specified
Condition
1-2 20°C (68°F) 1 to 100 Ω

HINT:
The temperature indicated in "Condition" is the temperature of the turbocharger nozzle vane control
actuator.
If the result is not as specified, replace the turbocharger nozzle vane control actuator.
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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION
PROCEDURE
1.INSTALL STUD BOLT
NOTICE:
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a.
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Using an E10 "TORX" socket wrench, install the 3 stud bolts at the positions shown in the illustration.
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Torque:
14.7 N*m (150 kgf*cm, 11 ft.*lbf)
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Torque:
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c.
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Torque:
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5.5 N*m (56 kgf*cm, 49 in.*lbf)
2.INSTALL COMPRESSOR OUTLET ELBOW 17275

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a. except Cold Specification Vehicles:
Install the hose clamp with the bolt.
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Torque:
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b. Install a new gasket.
c. Install a new gasket and the compressor outlet elbow with the 2 nuts.
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Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
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3.INSTALL COMPRESSOR INLET ELBOW 17274

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a. Using an E8 "TORX" socket wrench, install a new gasket and the compressor inlet elbow with the stud bolt.
Torque:
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b. Install the compressor inlet elbow to the turbocharger sub-assembly with the 2 nuts.
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Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
c. Install the compressor inlet elbow stay with the 2 bolts.

Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)

4.INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY 16027
a. Install a new gasket.
b. Temporarily install the turbo water pipe sub-assembly with the bolt and 2 nuts.
c. Tighten the bolt and 2 nuts.

Torque:
13 N*m (133 kgf*cm, 10 ft.*lbf)
d. Connect the No. 1 turbo water hose and No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly
and slide the 2 hose clips to secure the hoses.
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*a NG
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*b OK
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Install a new gasket as shown in the illustration.

NOTICE:
Do not install the gasket upside down.
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b. Temporarily install the turbo oil inlet pipe sub-assembly with the 2 nuts.
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6.TEMPORARILY INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB- 17141

ASSEMBLY
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a. Install 2 new gaskets to the exhaust manifold and turbocharger sub-assembly.

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b. Temporarily install the exhaust manifold to turbocharger sub-assembly with 3 new nuts.
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*A w/ DPF
*B w/o DPF
*1 Collar
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Engine Side
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Temporarily install the exhaust manifold with turbocharger sub-assembly, 8 collars and the 8 plate washers
to the cylinder head sub-assembly with 8 new nuts.
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NOTICE:
Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.
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d. Install a new gasket on the union bolt side to turbo oil inlet pipe sub-assembly.
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e. Temporarily install the union bolt.

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a. Install a new gasket to the turbo oil outlet pipe.

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NOTICE:
The claws of the gasket must face the turbo oil outlet pipe.
b. Install the turbo oil outlet pipe with the 2 bolts.

Torque:
c. Connect the turbo oil outlet hose to the turbo oil outlet pipe, turbo oil inlet pipe and slide the 2 hose clips to
secure the hoses.

a. Temporarily install the turbocharger stay to the turbocharger sub-assembly, with 3 bolts and nut.
a.
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*A w/ DPF
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*B w/o DPF
Tighten the exhaust manifold with turbocharger sub-assembly, to the cylinder head sub-assembly with 8
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nuts.
Torque:
40 N*m (408 kgf*cm, 30 ft.*lbf)
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HINT:
Tighten the nuts in the order shown in the illustration.
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b. Tighten the turbocharger sub-assembly, to the exhaust manifold with the 3 nuts.
Torque:
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73 N*m (744 kgf*cm, 54 ft.*lbf)
c. Tighten the 2 nuts and then union bolt of the turbo oil inlet pipe sub-assembly.
Torque:
for nut : 13 N*m (133 kgf*cm, 10 ft.*lbf)
for union bolt : 36 N*m (367 kgf*cm, 27 ft.*lbf)
NOTICE:
If the connecting part of the union bolt gasket is cracked, remove the connecting part.

a.
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Torque:
24 N*m (245 kgf*cm, 18 ft.*lbf)
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Tighten the 3 bolts and nut of the turbocharger stay in the order shown in the illustration.
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Heater)
a. Temporarily install the No. 1 viscous heater bracket sub-assembly with 4 bolts.
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Tighten the 4 bolts and of the No. 1 viscous heater bracket sub-assembly in the order shown in the
illustration.
Torque:
24.5 N*m (250 kgf*cm, 18 ft.*lbf)

12.INSTALL WIRE HARNESS CLAMP BRACKET (for Manual Transmission)
a. w/o DPF:
Connect the wire harness with the bolt.
Torque:
18.6 N*m (190 kgf*cm, 14 ft.*lbf)
b. w/ DPF:
Connect the wire harness clamp and install the bolt.
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Torque:
18.6 N*m (190 kgf*cm, 14 ft.*lbf)
c. w/ DPF:
Connect the oil cooler tube bracket with the bolt.
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Torque:
13.5 N*m (138 kgf*cm, 10 ft.*lbf)
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13.INSTALL OIL COOLER TUBE BRACKET AND WIRE HARNESS CLAMP BRACKET (for Automatic
Transmission)
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a. w/o DPF:
Connect the wire harness with the bolt.
Torque:
18.6 N*m (190 kgf*cm, 14 ft.*lbf)
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b. w/ DPF:
Attach the 2 wire harness clamps and connect the wire harness.
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c. for Automatic Transmission:

Connect the oil cooler tube bracket with the bolt.
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Torque:
13.5 N*m (138 kgf*cm, 10 ft.*lbf)
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15.CONNECT TURBO WATER HOSE 16284

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a. Connect the No. 1 turbo water hose and No. 2 turbo water hose to the water outlet sub-assembly, engine
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water pump assembly and slide the 2 hose clips to secure the hoses.
NOTICE:
The turbocharger sub-assembly may be damaged if the No. 1 turbo water hose and No. 2 turbo water
hose are connected to the wrong locations.
Click hereEngine / Hybrid System>1GD-FTV COOLING>WATER PUMP>INSTALLATION

a. Attach the clamp and install the PCV hose.
b. Slide the 2 hose clips to secure the hoses.
a. Connect the PCV pipe to the compressor inlet elbow, cylinder head cover sub-assembly and slide the 2 hose
clips to secure the hoses.
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b. Install the PCV pipe with the bolt to the compressor outlet elbow.
Torque:
c. Connect the No. 19 water by-pass hose to the compressor inlet elbow and slide the hose clip to secure the
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hoses.
d. Install the No. 20 water by-pass hose to the PCV pipe and No. 1 water by-pass pipe, and slide the 2 hose
a.
19.INSTALL NO. 3 WATER BY-PASS PIPE
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16279
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b. Install the No. 3 water by-pass pipe with the bolt.

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c. for Cold Specification Vehicles:

Install the water hose to the compressor inlet elbow and No. 3 water by-pass pipe, and slide the 2 hose
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20.INSTALL VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous 87120G
Heater)
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22.INSTALL AIR CLEANER CASE SUB-ASSEMBLY 17701

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a. Install the air cleaner case sub-assembly with the 3 bolts.

Torque:
6.0 N*m (61 kgf*cm, 53 in.*lbf)
b. Connect the 3 wire harness clamps.

a. Install the air cleaner filter element sub-assembly to the air cleaner case.
24.INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE 17705
a. Attach the 4 clips to install the air cleaner cap sub-assembly with air cleaner hose.

Torque:
4.0 N*m (41 kgf*cm, 35 in.*lbf)
c. Connect the mass air flow meter connector and attach the 2 wire harness clamps.
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· w/ DPF: Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHIC CONVERTER(w/

DPF)>INSTALLATION
· w/o DPF: Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHIC
CONVERTER(w/o DPF)>INSTALLATION
34.ADD ENGINE OIL

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39.INSPECT FOR EXHAUST GAS LEAK
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40.INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 51410
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41.PERFORM INITIALIZATION
Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>INITIALIZATION

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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER PRECAUTION
MAINTENANCE PRECAUTION
a. Do not stop the engine immediately after pulling a trailer, driving at a high speed, or driving uphill. Let the
engine idle for 20 to 120 seconds before turning the ignition switch off. According to the driving conditions,
vary the idling time.
b. Avoid quick acceleration or quickly increasing the engine speed immediately after starting a cold engine.
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c. If the turbocharger sub-assembly is found to be defective, it must be replaced. Also, inspect the source of
the trouble including the conditions under which the turbocharger sub-assembly was used. Repair or
replace the following as necessary:
i. Engine oil (level and quality)
ii. Oil lines leading to the turbocharger sub-assembly
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d. Pay due attention when removing and reinstalling the turbocharger sub-assembly. Do not drop, strike, or
grasp easily-deformed assembly parts.
NOTICE:
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Do not hold the actuator or control rod.

·
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When storing the turbocharger sub-assembly, do not store the assembly with the actuator facing
down.
· Make sure foreign matter does not enter the intake and exhaust ports and oil passage.
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*1 Oil Inlet Pipe Sub-assembly
*a Sludge
If replacing the turbocharger sub-assembly, check for deposits in the turbo oil inlet pipe sub-assembly.
If necessary, replace the turbo oil inlet pipe sub-assembly.
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f. Thoroughly remove any old gasket material sticking to the lubrication oil pipe flange or turbocharger sub-
assembly oil flange.
g. If replacing the bolts or nuts, use TOYOTA genuine parts to prevent breakage or deformation.
h.
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*1 Turbocharger Sub-assembly Oil Inlet Hole
If replacing the turbocharger sub-assembly, add 20 cc (1.2 cu. in.) of fresh oil into the turbocharger sub-
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assembly oil inlet hole and turn the turbine wheel by hand to spread oil over the bearing.
i. If overhauling or replacing the engine, cut the fuel supply after reassembly and crank the engine for 30
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seconds to distribute oil throughout the engine.

Then reconnect the fuel supply and allow the engine to idle for 60 seconds.
j. Since the turbine wheel runs at an extremely high speed, if the engine is running without the air cleaner,
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air cleaner cap and hose, the turbine wheel will be damaged due to the entry of foreign particles.
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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER REASSEMBLY
PROCEDURE
1.INSTALL TURBOCHARGER NOZZLE VANE CONTROL ACTUATOR
a. Install the turbocharger nozzle vane control actuator with the 3 bolts.
Torque:
12.3 N*m (125 kgf*cm, 9 ft.*lbf)
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2.INSTALL TURBOCHARGER VANE CONTROL ROD SUB-ASSEMBLY
a. Install the turbocharger vane control rod sub-assembly.
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b. Install 2 new E-washers to the variable nozzle vane motor assembly and turbocharger vane control link
sub-assembly.
NOTICE:
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Do not reuse the E-washer.

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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL
parts are removed, installed, or replaced during the turbocharger sub-assembly removal/installation are shown
below.
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throttle body
assembly
· Replacement of
valve assembly
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· Replacement of
turbocharger sub- Perform initialization - ( )
assembly
· Replacement of
turbocharger sub-
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assembly or
nozzle motor
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CAUTION:
·
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· To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while
the engine is hot.
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PROCEDURE
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· w/ DPF: Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHIC CONVERTER(w/

DPF)>REMOVAL
· w/o DPF: Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHIC
CONVERTER(w/o DPF)>REMOVAL
2.REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY 51410
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4.DRAIN ENGINE OIL
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9.DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

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13.REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE 17705
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a.
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Disconnect the mass air flow meter sub-assembly connector and detach the 2 harness clamps.

b.
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Detach the 4 clips.
c. Loosen the hose clamp and remove the air cleaner cap sub-assembly with air cleaner hose.
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a.
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Remove the air cleaner element sub-assembly from the air cleaner case.
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15.REMOVE AIR CLEANER CASE SUB-ASSEMBLY 17701
a.
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Disconnect the 3 wire harness clamps.

b.
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Remove the 3 bolts and air cleaner case sub-assembly.
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17.REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous 87120G
Heater)
Click hereVehicle Interior>HEATING / AIR CONDITIONING>VISCOUS HEATER>REMOVAL

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for Cold Specification Vehicles:

Slide the 2 clips and remove the water hose from the compressor inlet elbow and No. 3 water by-pass pipe.
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b.
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*A for Cold Specification Vehicles
*B except Cold Specification Vehicles
Slide the 2 clips and disconnect the 2 water hoses from the oil cooler assembly and No. 2 water by-pass
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pipe.
c. Remove the bolt and No. 3 water by-pass pipe.

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a.
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Slide the 2 clips and disconnect the No. 20 water by-pass hose from the compressor inlet elbow and No. 3
water by-pass pipe.
b. Slide the clip and disconnect the No. 19 water by-pass hose from the compressor inlet elbow.

c.
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Remove the bolt and disconnect the PCV pipe from the compression outlet elbow.
d.
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Slide the 2 clips and remove the PCV pipe.
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a.
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Slide the 2 clips.

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b. Slide the 2 clips, detach the clamp and remove the PCV hose.
22.DISCONNECT TURBO WATER HOSE 16284

a.
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Slide the 2 clips and disconnect the No. 1 turbo water hose and No. 2 turbo water hose from the water
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outlet sub-assembly and water pump assembly.
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23.DISCONNECT BRACKET OIL COOLER TUBE BRACKET AND WIRE HARNESS CLAMP BRACKET
(for Automatic Transmission)
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a.
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Remove the bolt and disconnect the oil cooler tube bracket.

b.
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w/ DPF:
Detach the 2 clamps and disconnect the wire harness.
c.
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w/o DPF:
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Remove the bolt and disconnect the wire harness.
24.DISCONNECT WIRE HARNESS CLAMP BRACKET (for Manual Transmission)

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w/ DPF:
Remove the bolt, detach the clamp and disconnect the wire harness.

b.
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w/o DPF:
Remove the bolt and disconnect the wire harness.
25.REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area 87101
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Specification Vehicles)
a.
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Remove the bolt, detach the clamp and disconnect the wire harness.
b.
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Remove the 4 bolts and the No. 1 viscous heater bracket sub-assembly.

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Remove the 3 bolts, nut and the turbocharger stay.
27.REMOVE TURBO OIL OUTLET PIPE
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a.
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Slide the 2 clips and disconnect the turbo oil outlet hose from the turbo oil outlet pipe.
b. Remove the 2 bolts and turbo oil outlet pipe and gasket.
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a.
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Remove the union bolt and gasket.
b.
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Remove the 2 nuts and the turbo oil inlet pipe sub-assembly.
NOTICE:
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Do not loosen the nut labeled A.

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c. Remove the gasket.

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*A w/ DPF
*B w/o DPF
Remove the 3 nuts and turbocharger sub-assembly.

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b. Remove the gasket from the exhaust manifold.

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31.REMOVE EXHAUST MANIFOLD 17141

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*A w/ DPF
*B w/o DPF
Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold.

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32.REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY 16027

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*A w/ DPF
*B w/o DPF
Slide the 2 hose clips and disconnect the No. 1 turbo water hose and No. 2 turbo water hose from the turbo
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water pipe sub-assembly.
b. Remove the bolt.

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Remove the 2 nuts, turbo water pipe sub-assembly and gasket.

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33.REMOVE COMPRESSOR INLET ELBOW 17274

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Remove the 2 bolts and compressor inlet elbow stay.

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b.
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Remove the 2 nuts and compressor inlet elbow from turbocharger sub-assembly.
c.
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Using an E8 "TORX" socket wrench, remove the stud bolt shown in the illustration together with the
compressor inlet elbow and gasket.
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34.REMOVE COMPRESSOR OUTLET ELBOW 17275

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Remove the 2 nuts and compressor outlet elbow.

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except Cold Specification Vehicle:

Remove the bolt and hose clamp.
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35.REMOVE STUD BOLT
NOTICE:

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Using an E5 "TORX" socket wrench, remove the 4 stud bolts shown in the illustration.
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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER SYSTEM DESCRIPTION
This section should be used as a guide for troubleshooting when the turbocharger sub-assembly is suspected as
the cause of a problem.
OUTLINE OF TURBOCHARGER FAILURE
a. State of Turbocharger Failure Repair:

It is well known that turbocharger sub-assembly malfunctions cause many symptoms as shown below.
However, the mechanisms resulting in these symptoms that indicate turbocharger sub-assembly
malfunctions are not well understood. As a result, many unnecessary turbocharger sub-assembly
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replacements and other repairs are being performed due to lack of knowledge about the turbocharger sub-
assembly and turbocharger sub-assembly failure. Therefore, knowing the facts regarding turbocharger sub-
assembly malfunctions is useful for making effective repairs and saving time.
b. Turbocharger Failure Classification

Symptom Symptom Description See page
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Continuous high pitch · "NOISE" listed
Whistling noise noise proportional to below
engine speed · Flowchart
Noise "Turbocharger
Relatively low pitch Noise" (Click
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Whining noise noise compared to
whistling noise here ( ))
Oil leak on surface of

turbocharger visible
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External oil leak
from outside of
turbocharger · "OIL LEAK AND
Oil leak from inside of WHITE SMOKE"
Oil leak listed below
bearing housing to
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inside of either · Flowchart
Internal oil leak "Turbocharger
compressor housing or
turbine housing through Oil Leak and
seal ring White Smoke"
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Oil smoke is emitted (Click here (

Oil smoke ))
from exhaust pipe
White smoke Unburned fuel smoke is
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Unburned fuel smoke emitted from exhaust

pipe
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· "BLACK SMOKE"
listed below
Black smoke is emitted · Flowchart "Black
Black smoke
from exhaust pipe Smoke Emitted"
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(Click here( ))
Vehicle does not reach · "LACK OF

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target speed POWER AND

Poor acceleration HESITATION"
listed below
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Lack of power or hesitation · Flowchart "Lack

Shock during of Power or
acceleration Hesitation"
(Click here( ))
Control Solenoid Circuit

P0046
Range / Performance
Boost Control "A" Circuit
P0047
Low
Boost Control "A" Circuit
P0048
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High
P0299 Underboost
Overboost Condition
P1251
(Too High)
VN Turbo Controller Diagnostic Trouble Code
MIL turns on P1264
Malfunction
DTC Chart (Click here( ))
Position Sensor "A"
P2563 Circuit
Range/Performance
Position Sensor "A"
P2564
Circuit Low
Position Sensor "A"
P2565
Circuit High
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Position Sensor "B"
P2588
Circuit Low
Position Sensor "B"
P2589
Circuit High
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HINT:
This table shows only typical problems related to the turbocharger sub-assembly.
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NOISE
Description
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Probable Cause Probable Failed Component
Turbine shaft imbalance Turbocharger
Leakage from intake line Intake line
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· Gear inside engine
Gear noise · Transmission gear
(Mistaken for turbocharger noise) · Vacuum pump gear
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HINT:
It is easy to confirm whether the turbocharger sub-assembly is the cause of the noise or not, and confirming this
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before inspecting the turbocharger sub-assembly or removing it from the engine is an effective way to reduce
troubleshooting time.
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b. Start the engine and warm it up.

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c. Turn the GTS on.
d. Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VN Turbo Open.
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Powertrain > Engine and ECT > Active Test

Tester Display
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Activate the VN Turbo Open
Execute
e. Perform the Active Test and rev the engine up several times.
f. Check whether the noise is reduced or not compared with the noise under the condition that the Active Test
is not performed.
Result
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Result Cause of Noise

The noise is reduced (or disappears) Turbocharger
The noise does not change Not turbocharger (other parts)
HINT:
Refer to the flowchart "Turbocharger Noise" (Click hereEngine / Hybrid System>1GD-FTV ENGINE
CONTROL>ECD SYSTEM>Turbocharger Noise).
OIL LEAK AND WHITE SMOKE
Description
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Oil Leak Type Description Main Trouble Area
· Oil leak from bearing

housing to either
compressor housing (intake
side) or turbine housing · Compressor side seal ring
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(exhaust side) through seal · Turbine side seal ring
rings. · Clogging of oil drain
Internal oil leak · This type of oil leak is not · Shaft breakage
(White smoke) visible from outside of · Shaft or bearing seizure
turbocharger. · Compressor impeller
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· If oil leak occurs from damage
turbine side seal, large
amount of white smoke is
emitted from exhaust pipe.
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· Oil leak from inside of
· FIPG sealing part
turbocharger to outside of
· Oil pipe flange
turbocharger.
External oil leak · Oil pipe union
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· Includes oil leaks visible
· Hose connection of intake
from outside of
pipe
turbocharger.
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*1 Compressor Housing *2 Seal Ring

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*3 Compressor Inlet *4 Compressor Impeller

*5 Bearing Housing *6 Turbine Shaft
*7 Oil Drain (Outlet) *8 FIPG Sealing Part
*9 Turbine Housing *10 Turbine Wheel
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*a Internal oil leak to compressor housing *b Internal oil leak to turbine housing
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HINT:
· Above illustration is an example.
· When there is an internal oil leak, white smoke is emitted from the exhaust pipe and oil is consumed
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excessively. However, the cause of white smoke or excessive oil consumption can vary. Therefore, do not
assume that the turbocharger sub-assembly is the cause of the failure when there is white smoke
emission or excessive oil consumption.
· When there is an external oil leak, the sources of the oil leak are limited to the points mentioned in the
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table above. If oil leaks from a FIPG sealing part, replace the turbocharger sub-assembly. If oil leaks
from an oil pipe flange or a hose connection, do not replace the turbocharger sub-assembly, but confirm
and repair the flange or hose.
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· Refer to the flowchart "Turbocharger Oil Leak and White Smoke" (Click hereEngine / Hybrid
System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>Turbocharger Oil Leak and White Smoke).
BLACK SMOKE
a. Malfunctions are classified into 2 types as shown below.

Description
Malfunction Main Fault

Insufficient mass air flow due to, for example,

excessively low boost pressure, which results in
Intake air volume shortage
fuel injection volume being relatively excessive
with respect to mass air flow.
Excessive injection volume or incorrect injection
Excessive injection volume
timing due to fuel system trouble.
b. Main Components Related to Black Smoke:

Possible Faulty Component Main Fault
Turbocharger Abnormally low boost pressure
Leakage between turbocharger and intake
Intake system
manifold
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· Excessive fuel injection volume
Fuel system · Incorrect fuel injection timing
EGR valve Stuck or does not close completely

Diesel throttle Stuck or does not move smoothly
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HINT:
The components listed above are only the main ones. Not all the components potentially related to black
smoke are listed. For details regarding the troubleshooting of black smoke, refer to the flowchart "Black
Smoke Emitted" (Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>Black
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Smoke Emitted).
c. Relation between Turbocharger and Black Smoke:

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If the boost pressure is lower than normal due to a turbocharger sub-assembly failure, black smoke may
occur due to a lack of mass air flow. However, abnormally low boost pressure can be caused by the failure
of various components such as intake lines, the EGR valve, etc. Therefore, do not assume that the
turbocharger is the cause of abnormally low boost pressure, but check all the components possibly related
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to abnormally low boost pressure. Components related to abnormal boost pressure are shown in a chart
listed in the On-vehicle Inspection for Intake System (Click hereEngine / Hybrid System>1GD-FTV INTAKE /
EXHAUST>INTAKE SYSTEM>ON-VEHICLE INSPECTION). For simple and effective troubleshooting, refer to
the chart before starting troubleshooting.
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LACK OF POWER AND HESITATION

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a. Malfunctions are classified into 2 types as shown below.

Description
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Malfunction Main Fault

Insufficient mass air flow due to, for example,
Intake air volume shortage excessively low boost pressure, which results in
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fuel injection volume being restricted.

Abnormal injection volume or timing due to fuel
Abnormal injection volume
system trouble.
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b. Main Components Related to Lack of Power and Hesitation:

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Possible Faulty Component Main Fault
· Abnormal boost pressure

Turbocharger · VN does not move smoothly
· Leakage between turbocharger and intake

Intake system manifold
· Clogging or blockage of intake line
· Abnormal injection volume

Fuel system · Incorrect fuel injection timing
EGR valve Stuck or does not close completely

Diesel throttle Stuck or does not move smoothly
Exhaust system Clogging of exhaust line
HINT:
· The components listed above are only the main ones. Not all the components potentially related
to lack of power and hesitation are listed. For details regarding the troubleshooting of lack of
power and hesitation, refer to the flowchart "Lack of Power or Hesitation" (Click hereEngine /
Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>Lack of Power or Hesitation).
· If obvious malfunction (lack of power) has not been reproduced, perform test driving another
vehicle, which is the same model and has the same engine, and compare the engine conditions
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and performance. If a great difference is not present in engine performance, explain to the
customer that lack of power the customer mentioned is not abnormal.
c. Relation between Turbocharger and Abnormal Boost Pressure:

If the boost pressure is lower than normal due to a turbocharger sub-assembly failure, lack of power could
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occur due to an intake air volume shortage. However, abnormal boost pressure can be caused by the failure
of various components such as intake lines, the EGR valve, etc. Therefore, do not assume that the
turbocharger sub-assembly is the cause of abnormal boost pressure, but check all the components possibly
related to abnormal boost pressure. Components related to abnormal boost pressure are shown in a chart
listed in the On-vehicle Inspection for Intake System (Click here Engine / Hybrid System>1GD-FTV INTAKE
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/ EXHAUST>INTAKE SYSTEM>ON-VEHICLE INSPECTION). For simple and effective troubleshooting, refer to
the chart before starting troubleshooting.
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MIL TURNS ON
If a DTC related to a turbocharger sub-assembly malfunction is stored, refer to the troubleshooting section for
each DTC (Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>DIAGNOSTIC TROUBLE
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CODE CHART).
BRIEF OUTLINE OF TURBOCHARGER OPERATION AND CONSTRUCTION

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a. A turbocharger is a component used to supply a larger air volume to the cylinders by recovering exhaust
gas energy using a turbine coaxially connected to a compressor.
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b. Principle of Turbocharging:
Boost pressure is proportional to turbocharger speed, because the intake air is accelerated by centrifugal
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force generated by the rotation of the compressor and the increased kinetic energy, i.e. the velocity of the
intake air, is converted to pressure energy by the diffuser located around the outlet of the compressor
impeller. The compressor is driven by the turbine connected coaxially by the turbine shaft. The turbine is
driven by exhaust gas energy. Therefore, when the turbocharger begins boosting the intake air, a larger air
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volume is supplied to the cylinders and more fuel can be injected. As a result, more exhaust energy will be
available and the turbocharger boost increases.
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*1 Compressor *2 Turbine
*3 Air Cleaner *4 Exhaust Manifold
*5 Intake Manifold *6 Intercooler
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*7 Diffuser *8 Compressor
*a See HINT below *b Intake air flow
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HINT:
· *a: If sufficient exhaust gas energy is not available, the turbocharger cannot generate the
required boost pressure even when the turbocharger does not have a malfunction.
· Considering the fact that the turbocharger is driven by exhaust gas energy, if sufficient exhaust
gas is not available due to abnormal injection volume, etc., the required boost pressure will not be
available even when the turbocharger does not have a malfunction. Therefore, when boost
pressure is abnormally low, checking all the related components using the correct troubleshooting
procedure is necessary for to perform repairs simply and effectively.

c. Boost Pressure Control:

The amount of energy the turbine can obtain from the exhaust gas is proportional to the expansion ratio,
which is defined as the ratio of the turbine inlet exhaust gas pressure to the pressure at the turbine outlet.
To control boost pressure, a Variable Nozzle (VN) is used just upstream of the turbine wheel inlet, and
controls the expansion ratio. If the VN is closed, the gap between neighboring vanes is narrowed and the
turbine inlet exhaust gas pressure, and correspondingly the expansion ratio, increases. Therefore, when the
VN is closed, the turbine receives more energy, and the turbine speed and boost pressure increase. If the
VN is opened, the turbine inlet exhaust gas pressure decreases and the turbine speed and boost pressure
decrease.
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*1 VN (Variable Nozzle) *2 Turbine Wheel
*3 Narrow Gap *4 Wide Gap
*a VN Closed *b VN Opened
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*c Exhaust Gas Flow - -

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HINT:
· If the VN becomes stuck open, the necessary boost pressure will not be available. If the VN
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becomes stuck closed, overboost will occur.

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d. Mechanical Construction of Turbocharger:

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*1 VN Actuator (DC Motor) *2 VN Actuating Rod

*3 Bearing Housing *4 Turbine Shaft
*5 Turbine Side Seal Ring *6 Turbine Housing
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*7 Turbine Wheel *8 Thrust Bearing

*9 Compressor Side Seal Ring *10 Compressor Housing
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*11 Compressor Impeller *12 Radial Bearing

*13 Oil Drain *14 VN (Variable Nozzle)
*a See HINT below *b See HINT below
Exhaust Gas Flow Intake Air Flow
HINT:


· *a: A certain amount of oil mist from PCV gas is contained in the intake air. Therefore, a certain
amount of oil at the inlet of the compressor is normal, and is not an oil leak.
· *b: The seal rings are C-shaped rings just like piston rings, and have a gap. Therefore, complete
sealing is impossible by the seal rings alone. The oil is sealed in with the aid of the boost pressure
in the compressor housing, and the exhaust gas pressure in the turbine housing. These pressures
prevent oil from exiting the bearing housing through the gap of the seal rings. Therefore, if the
turbine shaft is inclined from the horizontal, oil may flow out through the gap of a seal ring. This
should not be interpreted as an oil leak due to seal ring failure.
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1GD-FTV INTAKE / EXHAUST EXHAUST PIPE INSTALLATION
PROCEDURE
a.
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Using a vernier caliper, measure the free length of the compression spring.
Minimum length:
40 mm (1.57 in.)
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If the free length is less than the minimum, replace the compression spring.
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*1 Gasket
*2 Exhaust Manifold Converter Sub-assembly
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Install a new gasket to the exhaust manifold converter sub-assembly.

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NOTICE:
· Be sure to install the gasket so that it faces the correct direction.
· Do not reuse the gasket.
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· Do not damage the gasket.

· When connecting the front exhaust pipe assembly, do not push in the gasket with the front
exhaust pipe assembly.
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c.
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*1 Gasket
*a Wooden Block
Using a plastic-faced hammer and wooden block, tap on a new gasket until its surface is flush with the
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d. Install the front exhaust pipe assembly and 2 compression springs with the 2 bolts. Alternately tighten the
bolts in several passes.
Torque:
43 N*m (438 kgf*cm, 32 ft.*lbf)
2.INSTALL TAILPIPE ASSEMBLY

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a. Install the tailpipe assembly to the 4 exhaust pipe supports.
b. Install a new gasket and connect the tailpipe to the front exhaust pipe assembly with the 2 bolts and 2 new
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nuts. Alternately tighten the bolts in several passes.
Torque:
43 N*m (438 kgf*cm, 32 ft.*lbf)
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NOTICE:
Do not reuse the gasket.
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3.INSPECT FOR EXHAUST GAS LEAK

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1GD-FTV INTAKE / EXHAUST EXHAUST PIPE REMOVAL
CAUTION:
·
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To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while
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the engine is hot.
· Wear protective gloves when removing the exhaust pipe assembly.
· The exhaust pipe assembly is extremely hot immediately after the engine has stopped.
· Confirm that the exhaust pipe assembly has cooled down before removing it.
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PROCEDURE
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1.REMOVE TAILPIPE ASSEMBLY 17430

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a. Remove the 2 bolts and 2 nuts.
b. Disconnect the tailpipe assembly from the front exhaust pipe assembly and remove the gasket.
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c. Remove the tailpipe assembly from the 4 exhaust pipe supports.

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a. Remove the 2 bolts and 2 compression springs.
b. Disconnect the front exhaust pipe assembly from the exhaust manifold converter sub-assembly and remove
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the gasket.

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1GD-FTV INTAKE / EXHAUST INTAKE MANIFOLD COMPONENTS
ILLUSTRATION
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*A w/ DPF - -
*1 ENGINE OIL LEVEL DIPSTICK GUIDE *2 FUEL INLET PIPE SUB-ASSEMBLY
*3 INTAKE MANIFOLD *4 MANIFOLD STAY
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*5 NO. 2 FUEL PIPE *6 NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

*9 VACUUM CONTROL VALVE SET *10 WIRING HARNESS CLAMP BRACKET
*11 NO. 1 INJECTION PIPE CLAMP *12 NO. 2 INJECTION PIPE CLAMP
*13 ENGINE OIL LEVEL DIPSTICK *14 ENGINE WIRE
*15 WIRE HARNESS *16 VACUUM HOSE
*19 UNION BOLT *20 SUPPLY PUMP HOLLOW SCREW

ft.*lbf)
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ILLUSTRATION
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*A w/o DPF - -
*1 ENGINE OIL LEVEL DIPSTICK GUIDE *2 FUEL INLET PIPE SUB-ASSEMBLY
*3 INTAKE MANIFOLD *4 MANIFOLD STAY
*5 NO. 2 FUEL PIPE *6 NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY
*7 WIRING HARNESS CLAMP BRACKET *8 NO. 1 INJECTION PIPE CLAMP
*9 NO. 2 INJECTION PIPE CLAMP *10 ENGINE OIL LEVEL DIPSTICK
*11 ENGINE WIRE *12 WIRE HARNESS
*13 VACUUM HOSE *14 GASKET
*15 O-RING - -


ft.*lbf)
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1GD-FTV INTAKE / EXHAUST INTAKE MANIFOLD INSPECTION
PROCEDURE
1.INSPECT INTAKE MANIFOLD (w/ DPF) 17111
NOTICE:
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Do not adjust the adjusting screw or 2 actuator installation bolts.
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Check the operation of the swirl control valve.

i. Check that the valve is fully opened under normal conditions.
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ii. Connect a vacuum pump to the control valve. Check that the valve is fully closed when a negative
pressure of 66.7 kPa (500 mmHg, 19.7 in.Hg) is applied.
iii. Leave it for 1 minute and check that the vacuum pump needle does not move.
If the result is not as specified, replace the intake manifold.
2.INSPECT VACUUM SWITCHING VALVE (for Swirl Control Valve)
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Tester Specified
Condition
1-2 20°C (68°F) 33 to 39 Ω
1 - Body
ground 10 kΩ or
20°C (68°F)
2 - Body higher
ground
b.
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*a
*b
Port E
Filter
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Airflow
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Check the operation according to the value(s) in the table below.

i. Check that air flows from port E to the filter.
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ii.
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*a Port E
*b Port F
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Airflow
Apply battery voltage across the terminals.
iii. Check that air flows from port E to port F.

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1GD-FTV INTAKE / EXHAUST INTAKE MANIFOLD INSTALLATION
NOTICE:
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cylinders)
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PROCEDURE
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*a Protrusion
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Install a new gasket to the cylinder head sub-assembly.

HINT:
Install the gasket with the protrusion the rear side of the vehicle as shown in the illustration.
b. Temporarily install the intake manifold with the 7 bolts and 2 nuts.
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c.
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*A w/ DPF
*B w/o DPF
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Bolt
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Nut
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Tighten the 7 bolts and 2 nuts in the order shown in the illustration.
Torque:
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23 N*m (235 kgf*cm, 17 ft.*lbf)

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d. w/o DPF:
Connect the vacuum hose assembly to the vacuum transmitting pipe sub-assembly.
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e. Connect the wire harness bracket with the bolt.

Torque:
18.6 N*m (190 kgf*cm, 14 ft.*lbf)
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2.INSTALL VACUUM CONTROL VALVE SET (w/ DPF) 25804
a. Install the vacuum control valve set with bolt to the cylinder head sub-assembly.
Torque:
b. Connect the 2 vacuum hoses to the vacuum control valve set and vacuum transmitting pipe sub-assembly.
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c. Connect the wire harness clamp and vacuum control valve set connector.
a. Install the No. 2 nozzle leakage pipe assembly with the 2 bolts.
Torque:
b. Connect the No. 6 fuel hose to the No. 3 nozzle leakage pipe assembly and slide the clamp to secure the
hoses.
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c. Install the No. 4 fuel hose and No. 5 fuel hose to the No. 2 nozzle leakage pipe assembly, and slide the 4
clamps to secure the hose.
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NOTICE:
When replacing the fuel supply pump assembly, it is necessary to replace the fuel inlet pipe sub-assembly, No. 1
injection pipe clamp and No. 2 injection pipe clamp with a new one.
Keep the fuel inlet pipe sub-assembly free of foreign matter.
a.
b.
Temporarily install the fuel inlet pipe sub-assembly.
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Install new No. 1 injection pipe clamp and No. 2 injection pipe clamp with the 2 bolts.
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Torque:
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Using SST, tighten the fuel inlet pipe sub-assembly union nut on the common rail side sub-assembly.
SST
09245-11010
Torque:
HINT:

length of 180 mm (7.09 in.)): 31 N*m (316 kgf*cm, 23 ft.*lbf)
d.
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Using a 19 mm union nut wrench, tighten the fuel inlet pipe sub-assembly union nut on the fuel supply
pump assembly side.
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Torque:
HINT:
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length of 180 mm (7.09 in.)): 41 N*m (418 kgf*cm, 30 ft.*lbf)
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a. Install the manifold stay with the 2 bolts.

Torque:
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21 N*m (214 kgf*cm, 15 ft.*lbf)

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b. Install the wiring harness clamp bracket with the bolt.

Torque:
12.6 N*m (128 kgf*cm, 9 ft.*lbf)
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a. Temporarily install the No. 3 fuel pipe and 2 new gaskets with the union bolt and supply pump hollow
screw.
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b. Tighten the union bolt and supply pump hollow screw.

Torque:
42 N*m (428 kgf*cm, 31 ft.*lbf)

c.
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*a Paint Mark
*b 0 to 2 mm (0 to 0.0787 in.)
Install the fuel pipe clamp to the fuel filter assembly and No. 3 fuel pipe.
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NOTICE:
Be careful that the fuel pipe clamp and No. 4 fuel pipe sub-assembly do not interfere with each other.
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HINT:
Make sure the fuel pipe clamp is oriented as shown in the illustration.
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a. Temporarily install the No. 4 fuel pipe sub-assembly and 2 new gaskets with the 2 union bolts and bolt.
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b.
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Union Bolt
Bolt
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Tighten the 2 union bolts and bolts in the order shown in the illustration.
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Torque:
union bolt : 42 N*m (428 kgf*cm, 31 ft.*lbf)
bolt : 10 N*m (102 kgf*cm, 7 ft.*lbf)
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c. Connect the No. 4 fuel pipe sub-assembly to the No. 1 fuel pipe.
Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL SYSTEM>PRECAUTION
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a. Install the wiring harness clamp bracket with the bolt.

Torque:
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b. Attach the 2 wire harness clamps.
c. Connect the diesel throttle body assembly connector and pre-stroke control valve connector.
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a. Connect the No. 2 fuel pipe and with the bolt.

Torque:

a. Apply a light coat of engine oil to a new O-ring.
b. Install the O-ring to the engine oil level dipstick guide.
c. Install the engine oil level dipstick guide with the bolt.
Torque:
d. Connect the vacuum hose to the intake manifold.
e. Install the engine oil level dipstick.
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NOTICE:
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(Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION)

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1GD-FTV INTAKE / EXHAUST INTAKE MANIFOLD REMOVAL
NOTICE:
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cylinders)
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PROCEDURE
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1. PRECAUTION
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NOTICE:
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(Click here General>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION)

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NOTICE:
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(Click here General>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION)
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a.
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*A w/ DPF
*B w/o DPF
Remove the engine oil level dipstick.

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b. Disconnect the vacuum hose from the intake manifold.

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c. Remove the bolt and engine oil level dipstick guide.
d. Remove the O-ring from the engine oil level dipstick guide.
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5.DISCONNECT NO. 2 FUEL PIPE 23812D

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a.
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Remove the bolt and disconnect the No. 2 fuel pipe.

a.
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Disconnect the diesel throttle body assembly connector and pre-stroke control valve connector.
b.
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Detach the 2 wire harness clamps.
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c. Remove the bolt and wiring harness clamp bracket.

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Remove the bolt and disconnect the wiring harness clamp bracket from the intake manifold stay.

b.
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Remove the 2 bolts and manifold stay.
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Union Bolt
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Bolt
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Disconnect the No. 4 fuel pipe sub-assembly from the No. 1 fuel pipe.
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Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL SYSTEM>PRECAUTION
b. Remove the bolt from the intake manifold.
c. Remove the 2 union bolts and 2 gaskets from the supply pump assembly and fuel filter.

a.
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Union Bolt
Supply Pump Hollow Screw

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Remove the union bolts, supply pump hollow screw and 2 gaskets from the supply pump assembly and fuel
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filter.
b. Remove the 2 fuel pipe clamps from the No. 3 fuel pipe and fuel filter.
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a.
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*a Common Rail Assembly Side

*b Fuel Supply Pump Assembly Side

Remove the 2 bolts, No. 1 injection pipe clamp and No. 2 injection pipe clamp.
b.
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Using SST, loosen the fuel inlet pipe sub-assembly union nut of the common rail assembly side.
NOTICE:
If the No. 1 or No. 2 injection pipe clamp is removed from the inlet pipe sub-assembly, replace the No. 1
or No. 2 injection clamp with a new one.
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c. Using a 19 mm union nut wrench, loosen the inlet pipe sub-assembly union nut of the fuel supply pump
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assembly side.

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Slide the clamps and remove the No. 4 fuel hose from the No. 2 nozzle leakage pipe assembly and common
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rail assembly.
b. Slide the 2 clamps and remove the No. 5 fuel hose from the No. 1 nozzle leakage pipe assembly and No. 2
nozzle leakage pipe assembly.

c.
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Slide the clamp and disconnect the No. 6 fuel hose from the No. 3 nozzle leakage pipe assembly.
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d. Remove the 2 bolts and No. 2 nozzle leakage pipe assembly.
12.REMOVE VACUUM CONTROL VALVE SET (w/ DPF) 25804

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a. Disconnect the wire harness clamp and vacuum control valve set connector.
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b. Disconnect the 2 vacuum hoses from the vacuum control valve set and vacuum transmitting pipe sub-
assembly.
c. Remove the bolt and vacuum control valve set from the intake manifold.
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a. Remove the bolt and disconnect the wire harness bracket.

b.
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w/o DPF:
Disconnect the vacuum hose from the vacuum transmitting pipe sub-assembly.
c.
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*A w/ DPF
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*B w/o DPF
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Bolt
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Nut
Remove the 7 bolts, 2 nuts, intake manifold and gasket.

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1GD-FTV INTAKE / EXHAUST INTAKE SYSTEM ON-VEHICLE INSPECTION
PROCEDURE
1.INSPECT INTAKE SYSTEM
a. Check that there is no air suction or leaks at the points shown in the illustration.
· For engine room area:
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*A for LHD - -
· For engine area:
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*A w/ DPF - -
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*A w/o DPF - -
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2.CHECK INTAKE AIR CONTROL SYSTEM

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a. Check for leakage or clogging between the air cleaner housing and turbocharger sub-assembly inlet, and
between the turbocharger sub-assembly outlet and cylinder head sub-assembly.
Condition Operation
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Clean or replace
Clogged air cleaner
element
Hoses collapsed or
Repair or replace
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deformed
Leakage from Check each connection
connections and repair
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Check and repair or

Cracks in components
replace
3.CHECK EXHAUST SYSTEM
a. Check for leakage or clogging between the cylinder head sub-assembly and turbocharger sub-assembly
inlet and between the turbocharger sub-assembly outlet and exhaust pipe assembly.
Condition Operation

Deformed components Repair or replace

Foreign material in
Remove
passages
Leakage from
Repair or replace
components
Check and repair or
Cracks in components
replace
4.CHECK BOOST PRESSURE
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b. Start the engine and turn the GTS on.

HINT:
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Be sure to perform the inspection when the engine coolant temperature is between 75 and 90°C (167 and
194°F).
d. Enter the following menus: Powertrain / Engine / Data List / All Data.
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Powertrain > Engine > Data List
Tester Display
MAF
MAP
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Accel Position
Actual Throttle Position
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Fuel Press
Actual EGR Valve Pos
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EGR Close Lrn. Status

Target Booster Pressure
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Execute
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e. Take a snapshot of the Data List items with the GTS.

HINT:
The condition of the turbocharger sub-assembly can be determined by fully depressing the accelerator
pedal while driving at 15 km/h (9 mph) in 2nd gear to accelerate the vehicle (obey all laws and
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regulations, and pay attention to driving conditions while driving the vehicle), and then comparing MAP
with Target Booster Pressure at an engine speed of 3000 rpm.
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f. Compare MAP with Target Booster Pressure.

HINT:
The specification below stands for the difference between the absolute pressure values.
Standard:
MAP is within 25 kPa of Target Booster Pressure when accelerating with accelerator pedal fully
depressed.
HINT:
If the driving inspection using the GTS above cannot be performed (e.g. due to road conditions), perform

the following inspection.
i. Warm up the engine.

HINT:
Be sure to perform the inspection when the engine coolant temperature is between 75 and 90°C (167
and 194°F).
ii.
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*1 No. 1 Gas Filter
*2 Manifold Absolute Pressure Sensor
*a 3-Way Connector
pressure sensor and the No. 1 gas filter.

SST
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Using a 3-way connector, connect SST (turbocharger pressure gauge) between the manifold absolute
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09992-00242
iii. Measure the boost pressure.

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· for Manual Transmission:
While depressing the clutch pedal, fully depress the accelerator pedal down. Measure the boost
pressure at maximum engine speed (4450 to 4750 rpm).
Standard pressure (Gauge pressure for Manual Transmission):
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11.4 to 47.2 kPa (0.1 to 0.5 kgf/cm2, 1.7 to 6.8 psi)
· for Automatic Transmission:

Move the shift lever to P or N, and then fully depress the accelerator pedal. Measure the boost
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pressure at maximum engine speed (4450 to 4750 rpm).

Standard pressure (Gauge pressure for Automatic Transmission):
11.4 to 47.2 kPa (0.1 to 0.5 kgf/cm2, 1.7 to 6.8 psi)
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If the pressure is lower than the standard, the following problems may be present.
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· The intake system or exhaust system has leakage or blockage.

· The turbocharger sub-assembly is malfunctioning.
· The electric EGR control valve assembly does not close.
· The diesel throttle body assembly does not open.
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· The vacuum hose connected to the manifold absolute pressure sensor is cracked or
disconnected.
· The mass air flow meter sub-assembly is malfunctioning.
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· An injector assembly is malfunctioning.
If the pressure is higher than the standard, check the turbocharger sub-assembly and/or boost control
components (manifold absolute pressure sensor, wire harness, etc.).
g. Chart showing the suspected trouble areas when the boost pressure is lower than the standard.
HINT:
· ○: If a problem listed in the leftmost column of the chart exists, or if the part in the leftmost
column of the chart has a malfunction, the value of the Data List item in the uppermost row of the
chart will meet the conditions shown in the row labeled "Value which represents a malfunction".

· The values in the chart are applicable when the engine coolant temperature is between 75 and
90°C (167 and 194°F).
· The values in the chart are valid in an area with an absolute atmospheric pressure higher than 95
kPa. (Standard atmospheric pressure is 101 kPa. Atmospheric pressure decreases by 1 kPa for
every 100 m increase in altitude, and is also affected by the current weather conditions.)
· When the altitude increases, atmospheric pressure and MAP decrease.
EGR Close
MAP Lrn. Status
MAF
(Absolute (EGR valve Injection
(Intake Actual Actual
pressure Accel fully Fuel Feedback
Item air Throttle EGR Valve
inside Position closed Press Val #1
flow Position Pos.
intake position (to #4)
rate)
manifold) learning
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status)
Values taken
from an
actual 133 -3 to +3
- 99.60% 0% 0% OK -
normal g/sec mm3/st
vehicle
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*1
Fuel
Pressure
is lower
than
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Actual Target
MAP is Throttle Common
Accel
lower than MAF is Position Actual EGR NG Rail
Values which Position
Target less is not Valve Pos. (Determined Pressure Outside of
represent a is less
Booster than within is more after by 10 the above
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malfunction than
*1 Pressure 105 5% of than 5% performing MPa or range
90% *3
by 35 kPa g/sec *2 Target learning) more
or more Throttle (Check
Position while the
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system is
in a
steady
condition)
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Turbocharger ○ ○ - - - - - -
○
EGR valve ○
(Problem
does not (EGR valve
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with EGR
close or has ○ ○ - - does not - -
valve
problem with close)
movement) *4
movement *4
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Problem with ○
diesel (Intake
○ - ○ - - - -
throttle airflow
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movement decreases)
Accelerator
pedal cannot
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be fully
depressed or
problem with - ○ ○ - - - - -
accelerator
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pedal
position
sensor exists
Intake air
system
○ ○ - - - - - -
leakage or
blockage
Exhaust gas
leakage
before ○ ○ - - - - - -
turbocharger

or blockage
Manifold
absolute
○ ○ - - - - - -
pressure
sensor
Manifold
absolute
pressure
○ ○ - - - - - -
sensor hose
is
disconnected
Mass air flow
- ○ - - - - - -
meter
○
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(Fuel
injector
leakage,
Fuel system decrease
(injector, in
○
supply pump ○ ○ - - - - pressure *5
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or common discharge
rail) valve
relief
pressure
or valve
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is stuck)
HINT:
· *1: These values are measured when the transmission is in 2nd gear, the accelerator pedal is fully
depressed, the vehicle is accelerating, and the engine speed is 3000 rpm.
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· *2: Accel Position is the accelerator opening angle (%) used for engine control. The value
indicates 99.60% when the accelerator pedal is fully depressed. If the value indicates less than
90% when the accelerator pedal is fully depressed, the accelerator pedal position sensor circuit or
the pedal itself is malfunctioning. When the MIL is illuminated, if Accel Position is below 70% even
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with the accelerator pedal fully depressed, it means the fail-safe is restricting the accelerator.
· *3: Check that Actual EGR Valve Pos. is around 0% when the Target EGR position value indicates
0%. The EGR valve may be malfunctioning if the value is stuck or does not fluctuate smoothly.
However, in some cases the EGR valve may be malfunctioning even if the Actual EGR Valve Pos.
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value is normal. Inspect the EGR valve for any defects (deposits, valve sticking, poor movement,
etc.) if necessary.
· *4: DTC P042E may be stored at this time. If the actual EGR valve position follows the target EGR
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valve position slowly, a feeling of hesitation may occur.

· *5: If Injection Feedback Val # of a cylinder is not within -3 to +3 mm3/st, the corresponding
cylinder may have a malfunction (injector or compression). However, in some cases the cylinder
may be malfunctioning even if the value is within -3 to +3 mm3/st because these values are
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injection volume correction values calculated by the ECM when the engine is idling and not
correction values for the high engine load condition related to boost pressure control and engine
output performance.
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5.INSPECT TURBOCHARGER SUB-ASSEMBLY (w/o DPF) 17201
CAUTION:
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· Wear protective gloves to prevent injuries and burns when checking the turbocharger sub-assembly.
· The engine compartment becomes hot when the engine is running.
a. Remove the No. 1 exhaust manifold heat insulator (Click hereEngine / Hybrid System>1GD-FTV EMISSION
CONTROL>MONOLITHIC CONVERTER(w/o DPF)>REMOVAL).
b. Remove the No. 1 turbo insulator (Click hereEngine / Hybrid System>1GD-FTV EMISSION
CONTROL>MONOLITHIC CONVERTER(w/o DPF)>REMOVAL).

c. Make sure that the connector is properly connected.
d.
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*1 DC Motor
*a Ignition switch ON
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*b Ignition switch ON to engine idling
Turn the ignition switch off while the engine
*c is idling
*b → *c → *d
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*d Ignition switch off

*e 13.9 mm (0.547 in.)
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Check the motor movement when turning the ignition switch to ON, when starting the engine, and then
when turning the ignition switch off.
OK:
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Vane actuation link and motor rod move smoothly when moving from position *b to position *c,
and from position *c to position *d.
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NOTICE:
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*1 Lock Nut
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Never loosen or tighten the lock nut of the fully closed stopper.
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If the result is not as specified, check the ECM (Click hereEngine / Hybrid System>1GD-FTV ENGINE
CONTROL>ECD SYSTEM>TERMINALS OF ECM).
e. Install the No. 1 turbo insulator (Click hereEngine / Hybrid System>1GD-FTV EMISSION
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CONTROL>MONOLITHIC CONVERTER(w/o DPF)>INSTALLATION).
f. Install the No. 1 exhaust manifold heat insulator (Click hereEngine / Hybrid System>1GD-FTV EMISSION
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CONTROL>MONOLITHIC CONVERTER(w/o DPF)>INSTALLATION).

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1GD-FTV INTAKE / EXHAUST INTAKE SYSTEM PARTS LOCATION
ILLUSTRATION
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*A w/ DPF - -
*1 DIESEL THROTTLE BODY *2 ENGINE COOLANT TEMPERATURE SENSOR
*3 TURBOCHARGER SUB-ASSEMBLY *4 INTAKE AIR TEMPERATURE SENSOR
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*5 INTAKE MANIFOLD (for Swirl Control Valve) *6 INTERCOOLER ASSEMBLY

*7 MANIFOLD ABSOLUTE PRESSURE SENSOR *8 MASS AIR FLOW METER
*9 CRANKSHAFT POSITION SENSOR *10 EXHAUST MANIFOLD
ILLUSTRATION
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*A w/o DPF - -

*1 DIESEL THROTTLE BODY *2 ENGINE COOLANT TEMPERATURE SENSOR

*3 TURBOCHARGER SUB-ASSEMBLY *4 INTAKE AIR TEMPERATURE SENSOR
*5 INTAKE MANIFOLD *6 INTERCOOLER ASSEMBLY
*7 MANIFOLD ABSOLUTE PRESSURE SENSOR *8 MASS AIR FLOW METER
*9 CRANKSHAFT POSITION SENSOR *10 EXHAUST MANIFOLD
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1GD-FTV INTAKE / EXHAUST INTAKE SYSTEM PRECAUTION
Expression
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1GD-FTV INTAKE / EXHAUST INTAKE SYSTEM SYSTEM DIAGRAM
INTAKE AIR CONTROL SYSTEM ILLUSTRATION (w/ DPF)
The swirl control valve is mounted on the intake manifold. The Vacuum Switching Valve (VSV) for swirl control
valve changes the vacuum to actuate the actuator.
First, the ECM determines the opening angle of the swirl control valve. Then it uses the swirl control valve VSV to
change the vacuum applied to the actuator's diaphragm to open and close the swirl control valve.
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*1 Accelerator Pedal Sensor *2 ECM

*3 Intercooler Assembly *4 Intake Air Temperature Sensor
*5 Diesel Throttle Body Assembly *6 Manifold Absolute Pressure Sensor
Vacuum Switching Valve (for Swirl Control
*7 *8 Swirl Control Valve Actuator
Valve)
*9 Swirl Control Valve *10 Engine Coolant Temperature Sensor
*11 Turbocharger Sub-assembly *12 Mass Air Flow Meter Sub-assembly
*13 Air Cleaner Assembly *14 Crankshaft Position Sensor
INTAKE AIR CONTROL SYSTEM WIRING DIAGRAM (w/ DPF)
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TURBOCHARGER SYSTEM ILLUSTRATION
· The turbocharger system is comprised of the Variable Nozzle (VN) type turbocharger sub-assembly and
ECM.
· The turbocharger sub-assembly has a nozzle vane which opens and closes to control the volume of the
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exhaust gas flowing to the turbine. This, in turn, controls the boost pressure. When the nozzle vane moves
in the closing direction, the pressure increases. When the vane moves in the opening direction, the
pressure decreases.
· The turbocharger actuator built onto the compressor housing side actuates the nozzle vane. The nozzle
vane position sensor built onto the actuator detects the opening angle of the nozzle vane. The ECM
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receives a nozzle vane position sensor signal. Based on this signal, the ECM operates the DC motor and
controls the nozzle vane opening angle.
· The ECM controls the nozzle vane position according to the driving conditions in order to create the optimal
pressure.
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*1 Accelerator Pedal Sensor *2 ECM

*3 Air Cleaner Assembly *4 Mass Air Flow Meter Sub-assembly
*5 Intercooler Assembly *6 Diesel Throttle Body Assembly
*7 Manifold Absolute Pressure Sensor *8 Turbocharger Sub-assembly
Turbocharger Actuator
*9 Engine Coolant Temperature Sensor *10 - Turbocharger Variable Nozzle Motor
- Variable Nozzle Position Sensor
*11 Crankshaft Position Sensor *12 Intake Air Temperature Sensor
*13 Camshaft Position Sensor - -

TURBOCHARGER SYSTEM WIRING DIAGRAM
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1GD-FTV INTAKE / EXHAUST INTERCOOLER COMPONENTS
ILLUSTRATION
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*1 GROMMET *2 HOOD LOCK SUPPORT SUB-ASSEMBLY

*3 INTERCOOLER ASSEMBLY *4 NO. 1 AIR HOSE
*5 NO. 1 AIR TUBE *6 NO. 2 AIR TUBE
*7 NO. 4 AIR HOSE *8 RADIATOR SIDE DEFLECTOR LH
*9 RADIATOR SIDE DEFLECTOR RH *10 NO. 2 AIR HOSE
*11 VACUUM HOSE *12 WIRE HARNESS

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1GD-FTV INTAKE / EXHAUST INTERCOOLER INSTALLATION
PROCEDURE
1.INSTALL GROMMET
a. Install the 2 grommets to the lower radiator support assembly.
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2.INSTALL INTERCOOLER ASSEMBLY 17940D
a. Attach the 2 grommets and connect the 2 guides to intercooler assembly.
b. Install the intercooler assembly to the lower radiator support assembly with the 2 bolts.
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Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)
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3.CONNECT HOOD LOCK SUPPORT SUB-ASSEMBLY 53208A
a. Connect the hood lock sub-assembly with the 3 bolts.

Torque:
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12.5 N*m (127 kgf*cm, 9 ft.*lbf)
HINT:
Do not bend the hood lock cable.
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b. Attach the 5 wire harness clamps and connect the wire harness to the hood lock support sub-assembly.
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c. Connect the 3 connectors.

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*a Protrusion
*b Embossed Mark
*c 0 to 2 mm (0 to 0.0787 in.)
Install the No. 2 air tube to the intercooler assembly with the 2 bolts.
NOTICE:
Before installation, remove any oil residue from the inside of the No. 2 air tube and intercooler assembly.
Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)
HINT:
· Align the protrusion of the No. 2 air tube with the embossed mark of the intercooler assembly.
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· Position the hose clamps as shown in the illustration.
· Position the hose so that the distance from the stopper is 0 to 2 mm (0 to 0.0787 in.).
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Torque:
6.5 N*m (66 kgf*cm, 58 in.*lbf)
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c. Attach 4 clamps and connect the oil return hose.

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6.INSTALL NO. 1 AIR TUBE 17361J

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a. Install the No. 2 air hose to the No. 1 air tube with the hose clamp.
NOTICE:
Before installation, remove any oil residue from the inside of the No. 1 air tube and No. 2 air hose.
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b. Install the No. 1 air tube to the intercooler assembly with the 2 bolts.
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Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)
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NOTICE:
Before installation, remove any oil residue from the inside of the intercooler assembly.
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*a Front Side
*b Upper Side
*c 90°
Tighten the 2 hose clamps.

Torque:
6.5 N*m (66 kgf*cm, 58 in.*lbf)
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HINT:
Position the hose clamps as shown in the illustration.
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8.INSTALL RADIATOR SIDE DEFLECTOR RH 53293C

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9.INSTALL RADIATOR SIDE DEFLECTOR LH 53294C

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10.INSTALL FRONT BUMPER COVER 52119A

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1GD-FTV INTAKE / EXHAUST INTERCOOLER ON-VEHICLE INSPECTION
PROCEDURE
1.INSPECT FINS FOR BLOCKAGE 17940D
a. Visually check the intercooler assembly.

i.
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*a OK
*b NG
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If the intercooler assembly fins are dirty as shown in the illustration, clean them.
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b. Remove the No. 1 radiator grille retainer (Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT
BUMPER(for Steel Type Bumper)>REMOVAL).
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c.
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Check that the intercooler assembly is not blocked with leaves, dirt or insects.
If the fins are blocked, wash them with water or a steam cleaner.
NOTICE:
· If the distance between the steam cleaner and core is too close, the fins may be damaged.
· When cleaning the intercooler assembly, make sure no water enters its interior.
· Keep the following injection distance.
Standard Injection Distance:

Specified
Injection Pressure
Condition
2942 to 4903 kPa
(30 to 50 kgf/cm2, 300 mm (11.811 in.)
427 to 711 psi)
4903 to 7845 kPa
(50 to 80 kgf/cm2, 500 mm (19.685 in.)
711 to 1138 psi)
· If the fins are bent, straighten them with a screwdriver or pliers.

· Never apply water directly to the electronic components.
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HINT:
Above illustration is an example.
d. Dry the fins with compressed air.
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e. Install the No. 1 radiator grille retainer (Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT
BUMPER(for Steel Type Bumper)>INSTALLATION).
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1GD-FTV INTAKE / EXHAUST INTERCOOLER REMOVAL
PROCEDURE
1.REMOVE FRONT BUMPER COVER 52119A
2.REMOVE RADIATOR SIDE DEFLECTOR LH 53294C
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3.REMOVE RADIATOR SIDE DEFLECTOR RH 53293C
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5.REMOVE NO. 1 AIR TUBE 17361J
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Remove the 2 bolts from the No. 1 air tube.
b. Loosen the hose clamp and remove the No. 1 air tube from the intercooler assembly.
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c. Loosen the hose clamp and remove the No. 2 air hose from the No. 1 air tube.

a.
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Detach the 4 clamps and disconnect the oil return hose.
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Remove the 2 bolts from the No. 2 air tube.

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c. Loosen the hose clamp and remove the No. 2 air tube from the intercooler assembly.
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8.DISCONNECT HOOD LOCK SUPPORT SUB-ASSEMBLY 53208A

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a.
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Disconnect the 3 connectors from the high pitched horn assembly, low pitched horn assembly and hood
lock assembly.
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b. Detach the 5 wire harness clamps and disconnect the wire harness.
c.
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Remove the 3 bolts and disconnect the hood lock support sub-assembly.
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HINT:
Do not bend the hood lock cable.
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9.REMOVE INTERCOOLER ASSEMBLY 17940D

a.
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Remove the 2 bolts.
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b. Detach the 2 guides and remove the intercooler assembly from the lower radiator support assembly.
HINT:
Tilt the intercooler assembly and lift up to remove it.
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10.REMOVE GROMMET
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a. Remove the 2 grommets from the lower radiator support assembly.

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1GD-FTV STARTING ENGINE SWITCH(for RHD) COMPONENTS
ILLUSTRATION
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*1 ENGINE SWITCH *2 NO. 1 SWITCH HOLE BASE
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1GD-FTV STARTING ENGINE SWITCH(for RHD) INSPECTION
PROCEDURE
1.INSPECT ENGINE SWITCH 89611
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*a
(Engine Switch)

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5 (SS1) - 6
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(AGND) 10 kΩ or
Not pushed
1 (SS2) - 6 higher
(AGND)
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5 (SS1) - 6
(AGND)
Pushed Below 1 Ω
1 (SS2) - 6
(AGND)
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If the result is not as specified, replace the engine switch.

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b. Apply battery voltage between the terminals of the engine switch, and check the illumination condition of
the engine switch.
OK:
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Measurement
Specified Condition
Condition
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Battery positive (+) →

Terminal 9 (SWIL)
Illuminates
Battery negative (-) →
Terminal 6 (AGND)
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NOTICE:
· If the positive (+) lead and the negative (-) lead are incorrectly connected, the engine switch
indicator will not illuminate.
· If the voltage is too low, the indicator will not illuminate.
If the result is not as specified, replace the engine switch.
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1GD-FTV STARTING ENGINE SWITCH(for RHD) INSTALLATION
PROCEDURE
1.INSTALL ENGINE SWITCH 89611
a. Attach the 2 claws to install the engine switch.
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2.INSTALL NO. 1 SWITCH HOLE BASE 55446A
Click hereVehicle Interior>INTERIOR PANELS / TRIM>LOWER INSTRUMENT PANEL>REASSEMBLY
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1GD-FTV STARTING GLOW PLUG COMPONENTS
ILLUSTRATION
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*1 GLOW PLUG ASSEMBLY *2 NO. 1 GLOW PLUG CONNECTOR

*3 GLOW PLUG SCREW GROMMET - -
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1GD-FTV STARTING GLOW PLUG INSTALLATION
NOTICE:
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or dropped.
PROCEDURE
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1.INSTALL GLOW PLUG ASSEMBLY 19850
NOTICE:
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· Measure the resistance of the glow plug when reinstalling it. If the result is not as specified, replace the
glow plug with a new one.
· Replace the glow plug with a new one when it has been dropped or subjected to a physical impact.
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· Remove any carbon deposits from the glow plug hole when reinstalling the glow plug.
a. Clean the glow plug hole.

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i. Wrap tape around a drill bit with a diameter of 4.8 mm (0.189 in.), 108.7 mm (4.28 in.) from its tip.
ii. Insert the drill bit 108.7 mm (4.28 in.) into the glow plug hole (up to the tape) and remove any carbon
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deposits by turning the drill bit by hand.
iii. Insert a drill bit with a diameter of 3.9 mm (0.154 in.) into the glow plug hole and remove any carbon
deposits from the end of the glow plug hole by turning the drill bit by hand.
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b. Using a 10 mm deep socket wrench, install the 4 glow plug assemblies.

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Torque:
17.5 N*m (178 kgf*cm, 13 ft.*lbf)
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NOTICE:
Do not use any tools, such as air tools, which are liable to cause an impact to the glow plugs when
installing them.
2.INSTALL NO. 1 GLOW PLUG CONNECTOR 19871
a. Temporarily install the No. 1 glow plug connector with the 4 nuts.

b. Tighten the 4 nuts.

Torque:
2.2 N*m (22 kgf*cm, 19 in.*lbf)
c. Install the 4 glow plug screw grommets.
d. Using an E8 "TORX" socket wrench, install the stud bolt to the intake manifold.
Torque:
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Click hereEngine / Hybrid System>1GD-FTV FUEL>COMMON RAIL>INSTALLATION
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NOTICE:
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1GD-FTV STARTING GLOW PLUG ON-VEHICLE INSPECTION
PROCEDURE
1.CHECK GLOW PLUG
a. Remove the glow plug connector.

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b.
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Tester Specified
Condition
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Glow plug
Approximately
terminal - 20°C (68°F)
1.0 Ω
Body ground
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If the result is not as specified, replace the glow plug assembly.

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NOTICE:
· Be careful not to damage the glow plug assemblies, as this may cause an open circuit or shorten
the life of the glow plug assemblies.
· Do not allow oil or gasoline to contact the glow plug assembly when cleaning it.
· Clean off any oil on the terminal with a dry cloth.
· Do not apply more than 11 V to the glow plug assembly, as this may cause an open circuit.
c. Install the glow plug connector.


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1GD-FTV STARTING GLOW PLUG REMOVAL
CAUTION:
·
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· To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while
the engine is hot.
· Make sure to wear protective gloves when performing work to avoid burns.
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NOTICE:
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PROCEDURE
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1. WARM UP ENGINE
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CAUTION:
To protect the glow plug assembly from damage, before removing the glow plug assembly, make sure to warm
up the engine.
Click hereEngine / Hybrid System>1GD-FTV FUEL>COMMON RAIL>REMOVAL

3.REMOVE NO. 1 GLOW PLUG CONNECTOR 19871
CAUTION:
Make sure to wear protective gloves when performing work to avoid burns.
a.
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Using an E8 "TORX" socket wrench, remove the stud bolt from the intake manifold.
b.
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Remove the 4 glow plug screw grommets.
c.
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Remove the 4 nuts and No. 1 glow plug connector.
4.REMOVE GLOW PLUG ASSEMBLY 19850
CAUTION:
Make sure to wear protective gloves when performing work to avoid burns.

a.
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Using a 10 mm deep socket wrench, remove the 4 glow plug assemblies.
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1GD-FTV STARTING GLOW PLUG CONTROLLER COMPONENTS
ILLUSTRATION
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*A for LHD - -
*1 GLOW PLUG CONTROLLER *2 WIRE HARNESS
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ILLUSTRATION
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*A for LHD - -
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*1 GLOW PLUG CONTROLLER *2 NO. 1 GLOW PLUG CONTROLLER BRACKET
*3 NO. 2 GLOW PLUG CONTROLLER BRACKET - -

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ILLUSTRATION
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*A for RHD - -
*1 GLOW PLUG CONTROLLER *2 WIRE HARNESS

ILLUSTRATION
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*A
*1
for RHD
GLOW PLUG CONTROLLER
-
*2
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NO. 1 GLOW PLUG CONTROLLER BRACKET
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*3 NO. 2 GLOW PLUG CONTROLLER BRACKET - -

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1GD-FTV STARTING GLOW PLUG CONTROLLER INSTALLATION
PROCEDURE
1.INSTALL NO. 2 GLOW PLUG CONTROLLER BRACKET 28559A
a. Install the No. 2 glow plug controller bracket to the glow plug controller with the 2 screws.
Torque:
3.0 N*m (31 kgf*cm, 27 in.*lbf)
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2.INSTALL NO. 1 GLOW PLUG CONTROLLER BRACKET 28559
a. Install the No. 1 glow plug controller bracket to the glow plug controller with the 2 screws.
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Torque:
3.0 N*m (31 kgf*cm, 27 in.*lbf)
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3.INSTALL GLOW PLUG CONTROLLER 28551
a. for LHD:
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i. Install the glow plug controller with the 2 bolts.
Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)
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b. for RHD:
i. Install the glow plug controller with the bolt.
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Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)
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c. Connect the 4 connectors and attach the clamp.

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4.CONNECT CABLE TO BATTERY TERMINAL

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NOTICE:
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1GD-FTV STARTING GLOW PLUG CONTROLLER REMOVAL
PROCEDURE
1. PRECAUTION
NOTICE:
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2.DISCONNECT CABLE FROM BATTERY TERMINAL
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NOTICE:
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3.REMOVE GLOW PLUG CONTROLLER 28551
a.
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for LHD:
i. Disconnect the 4 connectors and detach the clamp from the glow plug controller.
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ii.
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Remove the 2 bolts and glow plug controller.

b.
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for RHD:
i. Disconnect the 4 connectors and detach the clamp from the glow plug controller.
ii.
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Remove the bolt and glow plug controller.
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4.REMOVE NO. 1 GLOW PLUG CONTROLLER BRACKET 28559

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a. Remove the 2 screws and No. 1 glow plug controller bracket from the glow plug controller.
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5.REMOVE NO. 2 GLOW PLUG CONTROLLER BRACKET 28559A

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a. Remove the 2 screws and No. 2 glow plug controller bracket from the glow plug controller.
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1GD-FTV STARTING IGNITION SWITCH COMPONENTS
ILLUSTRATION
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STEERING LOCK ACTUATOR OR UPPER
*1 IGNITION SWITCH ASSEMBLY *2
BRACKET ASSEMBLY
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*3 TAPERED-HEAD BOLT - -
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1GD-FTV STARTING IGNITION SWITCH INSPECTION
PROCEDURE
1.INSPECT IGNITION SWITCH ASSEMBLY 84450
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*a
(Ignition Switch Assembly)

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10 kΩ or
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- LOCK
higher
7 (ACC) - 5
ACC Below 1 Ω
(AM1)
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8 (IG1) - 5
(AM1)
7 (ACC) - 5
ON Below 1 Ω
(AM1)
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4 (AM2) - 3
(IG2)
8 (IG1) - 5
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(AM1)
6 (ST1) - 5
(AM1)
START Below 1 Ω
4 (AM2) - 3
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(IG2)
4 (AM2) - 2
(ST2)
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If the result is not as specified, replace the ignition switch assembly.

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1GD-FTV STARTING IGNITION SWITCH INSTALLATION
PROCEDURE
1.INSTALL IGNITION SWITCH ASSEMBLY 84450
a. Attach the 2 screws and install the ignition switch assembly.
b. Connect the connector.
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2.INSTALL STEERING LOCK ACTUATOR OR UPPER BRACKET ASSEMBLY 45020B
Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>REASSEMBLY
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3.INSTALL STEERING COLUMN ASSEMBLY
Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>INSTALLATION
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Print-Toyota Service Information 11/3/17, 7'04 pm
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1GD-FTV STARTING IGNITION SWITCH REMOVAL
PROCEDURE
1.REMOVE STEERING COLUMN ASSEMBLY
Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>REMOVAL
2.REMOVE STEERING LOCK ACTUATOR OR UPPER BRACKET ASSEMBLY 45020B
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Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>DISASSEMBLY
3.REMOVE IGNITION SWITCH ASSEMBLY 84450
a.
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Detach the 2 screws and remove the ignition switch assembly.

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1GD-FTV STARTING PRE-HEATING SYSTEM ON-VEHICLE INSPECTION
NOTICE:
Turn the ignition switch off for 60 seconds before performing the following inspections.
PROCEDURE
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1.INSPECT ILLUMINATION DURATION OF GLOW INDICATOR LIGHT
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*a Glow Indicator Light Illumination Time

*b Engine Coolant Temperature
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*c When atmospheric pressure is 100 kPa (1.0

kgf/cm2)
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Turn the ignition switch to ON and measure the length of time that the light remains illuminated.
Light illumination duration:
Refer to the graph
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HINT:
Depending on the engine coolant temperature, the indicator light illumination time changes as shown in
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the illustration.
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2.INSPECT PRE-HEATING FUNCTION
a. Measure the voltage applied to the glow plug assemblies.

Standard voltage:
11 to 14 V at 25°C (77°F) or less
b. Measure the length of time that voltage is applied to the glow plug assemblies while the ignition switch is
ON.
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Standard Pre-heating Time:

Condition Pre-heating Time
Battery voltage at 14.5
1 second
V or higher
Engine coolant
temperature 40°C 1 second
(104°F) or higher
Other than above 15 seconds
3.INSPECT AFTER GLOW
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a. Measure the voltage applied to the glow plug assemblies after the engine is started.
Standard Voltage:
Measurement
Specified Condition
Condition
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Engine coolant
temperature 20°C 11 to 14 V
(68°F) or less
Engine coolant
temperature 20°C 0 to 14 V
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(68°F) to 41°C (106°F)
Engine coolant
temperature 41°C 0V
(106°F) or higher
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HINT:
The maximum amount of time that voltage is applied to the glow plug assemblies is 20 minutes.
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1GD-FTV STARTING PRE-HEATING SYSTEM PARTS LOCATION
ILLUSTRATION
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*A for LHD - -
*1 GLOW PLUG *2 GLOW RELAY
*3 EFI NO. 1 FUSE *4 ECM
*5 GLOW PLUG CONTROLLER *6
ASSEMBLY
RELAY BLOCK JUNCTION BLOCK
*7 - GLOW FUSE *8 COMBINATION METER ASSEMBLY
- ECU-B NO. 1 FUSE
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ILLUSTRATION
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*A for RHD - -
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*1 GLOW PLUG *2 GLOW RELAY

*3 EFI NO. 1 FUSE *4 ECM
*5 GLOW PLUG CONTROLLER *6 INSTRUMENT PANEL JUNCTION BLOCK

ASSEMBLY
RELAY BLOCK JUNCTION BLOCK
*7 - GLOW FUSE *8 COMBINATION METER ASSEMBLY
- ECU-B NO. 1 FUSE
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1GD-FTV STARTING PRE-HEATING SYSTEM SYSTEM DIAGRAM
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1GD-FTV STARTING STARTER(for 2.2 kW Type) COMPONENTS
ILLUSTRATION
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ILLUSTRATION
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*C for Automatic Transmission *D for Manual Transmission
*1 CLUTCH RELEASE CYLINDER ASSEMBLY *2 FRONT FENDER SEAL LH
*3 STARTER ASSEMBLY *4 GROUND CABLE
*5 STARTER CONNECTOR *6 STARTER TERMINAL CAP
*7 STARTER WIRE - -

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1GD-FTV STARTING STARTER(for 2.2 kW Type) INSPECTION
PROCEDURE
1.INSPECT STARTER ASSEMBLY 28100
CAUTION:
As a large electric current passes through the cable during this inspection, a thick cable must be used.
Otherwise, the cable may become hot and cause injury.
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NOTICE:
These tests must be performed within 3 to 5 seconds to prevent the coil from burning out.
a. Mount the starter assembly in a vise between aluminum plates.
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b. Perform pull-in test.
i. Remove the nut and disconnect the lead wire from terminal C.
ii.
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*a Starter Body
*b Terminal 50
*c Terminal C
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Connect the battery to the magnet starter switch assembly as shown in the illustration. Then check that
the clutch pinion gear moves outward.
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If the clutch pinion gear does not move, replace the magnet starter switch assembly.
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c. Perform holding test.
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i.
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*a Terminal C
Disconnect
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When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-)
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lead from terminal C. Check that the pinion gear remains out.
If the clutch pinion gear returns inward, replace the magnet starter switch assembly.
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d. Inspect clutch pinion gear return.
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Disconnect
Return Inward

Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns
inward.
If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.
e. Perform operation test without load.

i.
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Connect the lead wire to terminal C with the nut.
Torque:
9.8 N*m (100 kgf*cm, 87 in.*lbf)
ii.
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*a Starter Body
*b Terminal 50
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*c Terminal 30
*d AC/DC 400A Probe
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Connect the battery and an ammeter (AC/DC 400A probe) to the starter assembly as shown in the
illustration.
iii. Check that the starter rotates smoothly and steadily while the clutch pinion gear is extended. Then
measure the current.
Standard current:
120 A or less at 11 V
If the result is not as specified, replace the starter assembly.

2.INSPECT STARTER DRIVE HOUSING
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Free
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Lock
a.
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Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear
counterclockwise and check that it locks.
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If the result is not as specified, replace the starter drive housing.
b. Turn the clutch pinion gear by hand while applying inward force and check the movement of the bearing.
If resistance is felt or the bearing sticks, replace the starter drive housing.
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1GD-FTV STARTING STARTER(for 2.2 kW Type) INSTALLATION
PROCEDURE
a. for Automatic Transmission:

i.
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ii. Tighten bolt A and nut B.
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Temporarily install the starter assembly and ground cable with the nut and 2 bolts.
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Torque:
68 N*m (693 kgf*cm, 50 ft.*lbf)
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b. for Manual Transmission:

i. Temporarily install the starter assembly and ground cable with the 2 bolts.
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ii. Install the clutch release cylinder assembly with the 2 bolts.
Torque:
11.8 N*m (120 kgf*cm, 9 ft.*lbf)
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iii. Tighten the 2 bolts.

Torque:
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68 N*m (693 kgf*cm, 50 ft.*lbf)

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c. Connect the starter wire with the nut.

Torque:
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9.8 N*m (100 kgf*cm, 87 in.*lbf)

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d. Connect the starter connector.
e. Install the starter terminal cap.
2.INSTALL FRONT FENDER SEAL LH 53882K
a. for 4WD and Pre-Runner:

Install the front fender seal LH with 6 new clips.
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MWKC.html?PUB_TYPE=RM&MODE=1 Page 1 of 2

b. for 2WD:
Install the front fender seal LH with 5 new clips.
3.INSTALL NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner) 51442
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NOTICE:
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1GD-FTV STARTING RELAY ON-VEHICLE INSPECTION
PROCEDURE
1.INSPECT NO. 1 STARTER RELAY ASSEMBLY (ST NO. 1) 28300
a.
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Tester Specified
Condition
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Battery voltage
not applied to 10 kΩ or
terminals 1 higher
and 2
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3-5
Battery voltage
applied to
Below 1 Ω
terminals 1
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and 2
If the result is not as specified, replace the No. 1 starter relay assembly.
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2.INSPECT GLOW RELAY (GLOW) 28610

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a.
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Tester Specified
Condition
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…anual/repair/contents/RM100000000MWJV.html?PUB_TYPE=RM&MODE=1 Page 1 of 2

Battery voltage
10 kΩ or
not applied to
higher
terminals 1
3-5 and 2
Battery voltage
applied to
Below 1 Ω
terminals 1
and 2
If the result is not as specified, replace the glow relay.
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1GD-FTV STARTING STARTER(for 2.2 kW Type) REMOVAL
PROCEDURE
1. PRECAUTION
NOTICE:
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NOTICE:
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3.REMOVE FRONT FENDER SEAL LH 53882K
a. for 4WD and Pre-Runner:

Remove the 6 clips and front fender seal LH.
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b. for 2WD:
Remove the 5 clips and front fender seal LH.
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5.REMOVE NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner) 51442
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6.DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transmission)

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a. Remove the 2 bolts and disconnect the clutch release cylinder assembly.
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a. Remove the starter terminal cap.

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b. Disconnect the starter connector.

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c.
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Remove the nut and disconnect the starter wire.
d.
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Remove the nut, 2 bolts and starter assembly and disconnect the ground cable.
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e. for Manual Transmission:

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Remove the bolt and disconnect the clutch flexible hose bracket.
ii. Remove the bolt and starter assembly and disconnect the ground cable.
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1GD-FTV STARTING STARTER(for BOSCH Made) COMPONENTS
ILLUSTRATION
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ILLUSTRATION
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*1 CLUTCH RELEASE CYLINDER ASSEMBLY *2 FRONT FENDER SEAL LH
*3 STARTER ASSEMBLY *4 GROUND CABLE
*5 STARTER CONNECTOR *6 STARTER TERMINAL CAP
*7 STARTER WIRE - -
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1GD-FTV STARTING STARTER(for BOSCH Made) INSPECTION
PROCEDURE
1.INSPECT STARTER ASSEMBLY 28100
CAUTION:
As a large electric current passes through the cable during this inspection, a thick cable must be used.
Otherwise, the cable may become hot and cause injury.
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NOTICE:
The following tests must each be performed within 3 to 5 seconds to prevent the coil from burning out.
a. Mount the starter in a vise between aluminum plates.
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*1 Terminal 50
*2 Terminal C
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Moves outward
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Perform a pull-in test.

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i. Remove the nut, and then disconnect the lead wire from terminal C.
ii. Connect the battery to the magnet starter switch as shown in the illustration. Then check that the
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clutch pinion gear moves outward.

If the clutch pinion gear does not move, replace the magnet starter switch assembly.
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c.
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*1 Terminal C
Disconnect
Perform a holding test. ke

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i. Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test
above being maintained. Check that the pinion gear remains out.
If the clutch pinion gear returns inward, replace the magnet starter switch assembly.
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Disconnect
Returns inward

Inspect the clutch pinion gear return.

i. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns
inward.
If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.
e. Perform an operation test without load.

i. Connect the lead wire to terminal C.
Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)
ii.
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*1 Terminal 30
*2 Terminal 50
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Connect the battery and an ammeter to the starter as shown in the illustration.
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iii. Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then
measure the current.
Standard current:
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123 A or less at 10.9 V
If the result is not as specified, replace the starter assembly.

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1GD-FTV STARTING STARTER(for BOSCH Made) INSTALLATION
PROCEDURE
a. for Automatic Transmission:

i.
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ii. Tighten the bolt A and nut B.
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Temporarily install the starter assembly and ground cable with the nut and 2 bolts.
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Torque:
68 N*m (693 kgf*cm, 50 ft.*lbf)
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b. for Manual Transmission:

i. Temporarily install the starter assembly and ground cable with the bolt.
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ii. Temporarily install the clutch flexible hose bracket with the bolt.
iii. Tighten the 2 bolts.

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Torque:
68 N*m (693 kgf*cm, 50 ft.*lbf)
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c. Connect the starter wire with the nut.

Torque:
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9.8 N*m (100 kgf*cm, 87 in.*lbf)

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d. Connect the starter connector.
e. Install the starter terminal cap.

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2.CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transmission)
Click hereDrivetrain>CLUTCH>CLUTCH RELEASE CYLINDER>INSTALLATION
3.INSTALL FRONT FENDER SEAL LH 53882K
a. Install the front fender seal LH with new 6 clips.
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4.INSTALL NO. 2 ENGINE UNDER COVER 51442
5.INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 51410
NOTICE:
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1GD-FTV STARTING STARTER(for BOSCH Made) REMOVAL
PROCEDURE
1. PRECAUTION
NOTICE:
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NOTICE:
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3.REMOVE FRONT FENDER SEAL LH 53882K
a. Remove the 6 clips and front fender seal LH.

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4.REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY 51410
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5.REMOVE NO. 2 ENGINE UNDER COVER 51442
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6.DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transmission)
Click hereDrivetrain>CLUTCH>CLUTCH RELEASE CYLINDER>REMOVAL

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a. Remove the starter terminal cap.
b. Disconnect the starter connector.

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c.
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Remove the nut and disconnect the starter wire.
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d.
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Remove the nut, 2 bolts, starter assembly and disconnect the ground cable.
e. for Manual Transmission:

i.
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Remove the bolt and disconnect the clutch flexible hose bracket.
ii. Remove the bolt, starter assembly and disconnect the ground cable.
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1GD-FTV STARTING STARTING SYSTEM PARTS LOCATION
ILLUSTRATION
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*C w/ Entry and Start System *D w/o Entry and Start System
*E for LHD - -
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*1 ENGINE SWITCH *2 IGNITION SWITCH ASSEMBLY
*3 PARK / NEUTRAL POSITION SWITCH *4 ST NO. 1 RELAY

ASSEMBLY
ENGINE ROOM RELAY BLOCK AND JUNCTION
BLOCK ASSEMBLY
*5 STARTER ASSEMBLY *6
- ST NO. 1 FUSE
- STRG LOCK/ AM2 NO. 1 FUSE
*7 CERTIFICATION ECU *8 CLUTCH START SWITCH ASSEMBLY
*9 ECM - -
*a Refer to Service Bulletin for the installation - -

position of the part
ILLUSTRATION
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*C w/ Entry and Start System *D w/o Entry and Start System
*E for RHD - -
*1 ENGINE SWITCH *2 IGNITION SWITCH ASSEMBLY
*3 PARK / NEUTRAL POSITION SWITCH *4 ST NO. 1 RELAY

ASSEMBLY
*5 STARTER ASSEMBLY *6 BLOCK ASSEMBLY
- ST NO. 1 FUSE
- STRG LOCK/ AM2 NO. 1 FUSE
*7 CERTIFICATION ECU *8 CLUTCH START SWITCH ASSEMBLY

*9 ECM - -
*a Refer to Service Bulletin for the installation - -

position of the part
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1GD-FTV STARTING STARTING SYSTEM PRECAUTION
Expression
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1GD-FTV STARTING STARTING SYSTEM SYSTEM DIAGRAM
w/o Entry and Start System:
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w/ Entry and Start System:
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CRUISE CONTROL CRUISE CONTROL MAIN SWITCH COMPONENTS
ILLUSTRATION
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*1 CRUISE CONTROL MAIN SWITCH *2 CRUISE CONTROL SWITCH WIRE
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CRUISE CONTROL CRUISE CONTROL MAIN SWITCH INSPECTION
PROCEDURE
1.INSPECT CRUISE CONTROL MAIN SWITCH 84632
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*a - -
(Cruise Control Main Switch)
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Tester Connection Switch Condition Specified Condition

Cruise control main switch (ON-
1 MΩ or higher
OFF button) released
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Cruise control main switch (ON-

Below 2.5 Ω
1 (ECC) - 3 (CCS) OFF button) pushed
+RES switch ON 236 to 244 Ω
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-SET switch ON 618 to 642 Ω

CANCEL switch ON 1510 to 1570 Ω
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If the result is not as specified, replace the cruise control main switch.
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CRUISE CONTROL CRUISE CONTROL MAIN SWITCH INSTALLATION
PROCEDURE
1.INSTALL CRUISE CONTROL MAIN SWITCH 84632
a. Connect the connector and install the cruise control switch wire to the cruise control main switch.
b.
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*1
*a
Cruise Control Switch Wire
Rib
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Pass the cruise control switch wire under the rib as shown in the illustration, and temporarily install the
cruise control main switch with the 2 screws.
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c. Tighten the 2 screws in the order as shown in the illustration to install the cruise control main switch.
Torque:
2.4 N*m (24 kgf*cm, 21 in.*lbf)
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d. Connect the connector.

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2.INSTALL HORN BUTTON ASSEMBLY 45130

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Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>STEERING PAD>INSTALLATION

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CRUISE CONTROL CRUISE CONTROL MAIN SWITCH REMOVAL
The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after
parts are removed, installed or replaced during the cruise control main switch removal/installation are shown
below.
CAUTION:
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SRS airbag system before servicing.
· for Type A:
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Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the
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Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>AIRBAG SYSTEM(for Type
A)>PRECAUTION
· for Type B:
Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>AIRBAG SYSTEM(for Type
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B)>PRECAUTION
PROCEDURE
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1.REMOVE HORN BUTTON ASSEMBLY 45130
Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>STEERING PAD>REMOVAL

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2.REMOVE CRUISE CONTROL MAIN SWITCH 84632

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a.
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Remove the 2 screws.
b. Disconnect the connector and remove the cruise control main switch.
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c.
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Disconnect the connector and remove the cruise control switch wire from the cruise control main switch.
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Inspection Procedure - Toyota Service Information 11/3/17, 6(58 pm
Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM Clutch Switch Circuit
DESCRIPTION
While depressing the clutch pedal, the clutch switch sends a signal to terminal D of the ECM. The ECM cancels
cruise control when terminal D receives the signal.
WIRING DIAGRAM
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NOTICE:
Inspect the fuses for circuits related to this system before performing the following inspection procedure.
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PROCEDURE
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1.INSPECT CLUTCH SWITCH ASSEMBLY

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a. Remove the clutch switch assembly.

Click hereDrivetrain>CLUTCH>CLUTCH PEDAL SWITCH>REMOVAL
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b. Inspect the clutch switch assembly.

Click hereDrivetrain>CLUTCH>CLUTCH PEDAL SWITCH>INSPECTION
Result:
Proceed to
OK
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OK
2.CHECK HARNESS AND CONNECTOR (CLUTCH SWITCH ASSEMBLY - BATTERY)
NG
REPLACE CLUTCH SWITCH ASSEMBLY
Click hereDrivetrain>CLUTCH>CLUTCH PEDAL SWITCH>REMOVAL
2.CHECK HARNESS AND CONNECTOR (CLUTCH SWITCH ASSEMBLY - BATTERY)
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*a
Front view of wire harness connector
(to Clutch Switch Assembly)
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Disconnect the clutch switch assembly connector.
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b. Measure the voltage according to the value(s) in the table below.
Standard Voltage:
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B1-1 - Body Ignition Switch
11 to 14 V
ground ON
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B1-1 - Body Ignition Switch

Below 1 V
ground off
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Result:
Proceed to
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OK
NG
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OK
3.CHECK HARNESS AND CONNECTOR (CLUTCH SWITCH ASSEMBLY - ECM)
NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
3.CHECK HARNESS AND CONNECTOR (CLUTCH SWITCH ASSEMBLY - ECM)

a. for 1GD-FTV, 2GD-FTV

i. Disconnect the B1 clutch switch assembly connector.
ii. Disconnect the C57 ECM connector.
iii. Measure the resistance according to the value(s) in the table below.
Tester Specified
Condition
B1-2 - C57-14
Always Below 1 Ω
(D)
B1-2 or C57-
10 kΩ or
14 (D) - Body Always
higher
ground
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b. for 2TR-FE
i. Disconnect the B1 clutch switch assembly connector.
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ii. Disconnect the G45 ECM connector.
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Tester Specified
Condition
B1-2 - G45-18
Always Below 1 Ω
(D)
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B1-2 or G45-
10 kΩ or
18 (D) - Body Always
higher
ground
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Result:
Proceed to
OK
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NG
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OK
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REPLACE ECM
for 2TR-FE: Click hereEngine / Hybrid System>2TR-FE ENGINE CONTROL>ECM>REMOVAL

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for 1GD-FTV: Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECM>REMOVAL

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CRUISE CONTROL CRUISE CONTROL SYSTEM Cruise Control Switch Circuit
DESCRIPTION
The cruise control main switch is used to turn the cruise control system on and off, as well as operate 7 functions:
SET, - (COAST), TAP-DOWN, RES (RESUME), + (ACCEL), TAP-UP and CANCEL. The SET, TAP-DOWN and - (COAST)
functions, and the RES (RESUME), TAP-UP and + (ACCEL) functions are operated with the same switch. The cruise
control main switch is an automatic return type switch which turns on only while operating it in the direction of
each arrow and turns off after releasing it. The internal contact points of the cruise control main switch turn on
with switch operation. Then the ECM reads the voltage value that has been changed by the switch operation to
control the SET, - (COAST), RES (RESUME), + (ACCEL), and CANCEL functions.
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WIRING DIAGRAM
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NOTICE:
The vehicle is equipped with a Supplemental Restraint System (SRS) which includes components such as
airbags. Before servicing (including removal or installation of parts), be sure to read the precaution for
Supplemental Restraint System.
for Type A: Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>AIRBAG SYSTEM(for Type
A)>PRECAUTION
for Type B: Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>AIRBAG SYSTEM(for Type
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B)>PRECAUTION
PROCEDURE
1.READ VALUE USING GTS
c. Turn the GTS on.
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d. Enter the following menus: Powertrain / Cruise Control / Data List.
e. Read the Data List according to the display on the GTS.

Powertrain > Cruise Control > Data List
Measurement Normal
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Tester Display Range Diagnostic Note
Item Condition
ON: Cruise control
Cruise control main switch on
Main SW M-CPU main switch signal ON or OFF OFF: Cruise -
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(Main CPU) control main
switch off
ON: CANCEL
CANCEL switch switch on
Cancel Switch ON or OFF -
signal OFF: CANCEL
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switch off
ON: -SET switch
on
SET/COAST Switch -SET switch signal ON or OFF -
OFF: -SET switch
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off
ON: +RES switch
on
RES/ACC Switch +RES switch signal ON or OFF -
OFF: +RES switch
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off

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Tester Display
Main SW M-CPU
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Cancel Switch
SET/COAST Switch
RES/ACC Switch
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Execute
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OK:
When the cruise control main switch is operated, the display changes as shown above.
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Result:
Proceed to
OK
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OK

PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE
Click hereEngine / Hybrid System>CRUISE CONTROL>CRUISE CONTROL SYSTEM>PROBLEM

SYMPTOMS TABLE
NG
2.INSPECT CRUISE CONTROL MAIN SWITCH
2.INSPECT CRUISE CONTROL MAIN SWITCH
a. Remove the cruise control switch.

Click hereEngine / Hybrid System>CRUISE CONTROL>CRUISE CONTROL MAIN SWITCH>REMOVAL
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b. Inspect the cruise control switch.
Click hereEngine / Hybrid System>CRUISE CONTROL>CRUISE CONTROL MAIN SWITCH>INSPECTION
Result:
Proceed to
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OK
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OK
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3.CHECK CRUISE CONTROL MAIN SWITCH
NG
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REPLACE CRUISE CONTROL MAIN SWITCH
Click hereEngine / Hybrid System>CRUISE CONTROL>CRUISE CONTROL MAIN

SWITCH>REMOVAL
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3.CHECK CRUISE CONTROL MAIN SWITCH

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a.
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(to Spiral with Sensor Cable Sub-assembly
*a (w/ Vehicle Stability Control System))

(to Spiral Cable Sub-assembly (w/o Vehicle

Stability Control System))
*b
(to Cruise Control Main Switch)
Disconnect the spiral with sensor cable sub-assembly*1 or spiral cable sub-assembly*2 connector.
*1: w/ Vehicle Stability Control System
*2: w/o Vehicle Stability Control System
b. Disconnect the cruise control main switch connector.
c. Measure the resistance according to the value(s) in the table below.
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Tester Specified
Condition
z4-3 (CCS) -
Always Below 1 Ω
A-3 (CCS)
z4-4 (ECC) -
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Always Below 1 Ω
A-1 (ECC)
z4-3 (CCS) or
A-3 (CCS) - Always 10 kΩ or higher
Body ground
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z4-4 (ECC) or
A-1 (ECC) - Always 10 kΩ or higher
Body ground
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Result:
Proceed to
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OK
NG
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OK
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4.INSPECT SPIRAL WITH SENSOR CABLE SUB-ASSEMBLY OR SPIRAL CABLE SUB-

ASSEMBLY
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NG
REPLACE CRUISE CONTROL SWITCH WIRE

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4.INSPECT SPIRAL WITH SENSOR CABLE SUB-ASSEMBLY OR SPIRAL CABLE SUB-ASSEMBLY

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a. Remove the spiral with sensor cable sub-assembly*1 or spiral cable sub-assembly*2.
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Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>SPIRAL CABLE>REMOVAL
b. Inspect the spiral with sensor cable sub-assembly*1 or spiral cable sub-assembly*2.
Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>SPIRAL CABLE>INSPECTION

Result:
Proceed to
OK
NG
OK
5.CHECK HARNESS AND CONNECTOR (SPIRAL WITH SENSOR CABLE SUB-ASSEMBLY

OR SPIRAL CABLE SUB-ASSEMBLY - ECM AND BODY GROUND)
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NG
REPLACE SPIRAL WITH SENSOR CABLE SUB-ASSEMBLY OR SPIRAL CABLE SUB-

ASSEMBLY
Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>SPIRAL CABLE>REMOVAL
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5.CHECK HARNESS AND CONNECTOR (SPIRAL WITH SENSOR CABLE SUB-ASSEMBLY OR SPIRAL
CABLE SUB-ASSEMBLY - ECM AND BODY GROUND)
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a. for 2TR-FE
i. Disconnect the G4 spiral with sensor cable sub-assembly*1 or spiral cable sub-assembly*2 connector.
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Tester Specified
Condition
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G4-1 (CCS) -
Always Below 1 Ω
G45-22 (CCS)
G4-2 (ECC) -
G45-21 Always Below 1 Ω
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(ECCS)
G4-1 (CCS) or
10 kΩ or
G45-22 (CCS) Always
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higher
- Body ground
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b. for 1KD-FTV
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Tester Specified
Condition
G4-1 (CCS) -
Always Below 1 Ω
G84-21 (CCS)
G4-2 (ECC) -

Body ground Always Below 1 Ω
G4-1 (CCS) or
10 kΩ or
G84-21 (CCS) Always
higher
- Body ground
c. for 1GD-FTV, 2GD-FTV

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Tester Specified
Condition
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G4-1 (CCS) -
Always Below 1 Ω
G86-26 (CCS)
G4-2 (ECC) -
Always Below 1 Ω
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Body ground
G4-1 (CCS) or
10 kΩ or
G86-26 (CCS) Always
higher
- Body ground
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d. for 1GR-FE
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i. Disconnect the G4 spiral with sensor cable sub-assembly connector.

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Tester Specified
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Condition
G4-1 (CCS) -
Always Below 1 Ω
G88-1 (CCS)
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G4-2 (ECC) -
Always Below 1 Ω
Body ground
G4-1 (CCS) or
10 kΩ or
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G88-1 (CCS) - Always

higher
Body ground
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Result:
Proceed to
OK
NG
OK
REPLACE ECM

for 1GR-FE: Click hereEngine / Hybrid System>1GR-FE ENGINE CONTROL>ECM>REMOVAL

for 1KD-FTV: Click hereEngine / Hybrid System>1KD-FTV ENGINE CONTROL>ECM>REMOVAL
NG
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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM Cruise Main Indicator Light Circuit
DESCRIPTION
· The ECM turns on the cruise control indicator light by sending indicator output demand signals to the
combination meter assembly using CAN communication.
· w/ Multi-information Display:
The cruise control indicator light illuminates when the cruise control system has been turned on using the
cruise control main switch (ON/OFF). If a malfunction is detected, the cruise control indicator light goes off
and a warning message is displayed.
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· w/o Multi-information Display:
The cruise control indicator light in the combination meter assembly changes to yellow when a malfunction
occurs during cruise control driving.
· The cruise control indicator light circuit uses CAN communication. If the cruise control indicator light is not
functioning correctly, check for CAN communication DTCs before troubleshooting this circuit.
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NOTICE:
When replacing the combination meter assembly, make sure to replace it with a new one.
PROCEDURE
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1.PERFORM ACTIVE TEST USING GTS

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c. Turn the GTS on.
d. Enter the following menus: Body Electrical / Combination Meter / Active Test.
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e. According to the display on the GTS, perform the Active Test.

w/ Multi-information Display (for TFT Display Type):
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Body Electrical > Combination Meter > Active Test

Tester Display Measurement Item Control Range Diagnostic Note
Multi-information
Meter Display 1 OFF or All -
display
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Tester Display
Meter Display 1
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Execute
OK:
The multi-information display in the combination meter assembly turns off or completely on
according to the GTS operation
w/ Multi-information Display (for Dot Display Type):

Cruise indicator light
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Indicat. Lamp Cruise (Green) OFF or ON -

Tester Display
Indicat. Lamp Cruise
Execute
OK:
Cruise control indicator light turns ON/OFF
w/o Multi-information Display:
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Indicat. Lamp Cruise OFF or ON -
(Green)
Cruise Indicator OFF or ON -
(Yellow)
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Tester Display
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Indicat. Lamp Cruise
Execute
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OK:
Cruise control indicator light turns ON/OFF
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Result:
Result Proceed to
OK A
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NG B
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A
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2.READ VALUE USING GTS (CCS INDICATOR M-CPU)
B
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GO TO METER / GAUGE SYSTEM
Click hereVehicle Interior>METER / GAUGE / DISPLAY>METER / GAUGE SYSTEM>HOW TO

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PROCEED WITH TROUBLESHOOTING
2.READ VALUE USING GTS (CCS INDICATOR M-CPU)

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a. Enter the following menus: Powertrain / Cruise Control / Data List.
b. Read the Data List according to the display on the GTS.

Measurement Normal
Item Condition
ON: Cruise control
Cruise control indicator light
CCS Indicator M- turns on

CPU indicator light ON or OFF OFF: Cruise -

signal (Main-CPU) control indicator
light turns off

Tester Display
CCS Indicator M-CPU
Execute
Result:
Result Proceed to
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The indicator operates normally
according to the on and off A
operations
The GTS screen display changes
from off to on, but the cruise
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control indicator light in the B
combination meter assembly does
not illuminate
The cruise control indicator light in
the combination meter assembly
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does not illuminate and the GTS C
screen display does not change
from off
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A
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SYMPTOMS TABLE
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B
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REPLACE COMBINATION METER ASSEMBLY
Click hereVehicle Interior>METER / GAUGE / DISPLAY>COMBINATION METER>REMOVAL

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REPLACE ECM
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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM Cruise SET Indicator Light Circuit
DESCRIPTION
· The ECM turns on the SET indicator light by sending indicator output demand signals to the combination
meter assembly using CAN communication.
· The cruise control SET indicator light illuminates when the cruise control system is controlling vehicle
speed.
· The cruise control indicator light circuit uses CAN communication. If the cruise control indicator is not
functioning correctly, check for CAN communication DTCs before troubleshooting this circuit.
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NOTICE:
When replacing the combination meter assembly, make sure to replace it with a new one.
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PROCEDURE
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1.PERFORM ACTIVE TEST USING GTS

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c. Turn the GTS on.

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Multi-information
Meter Display 1 OFF or All -
display
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Tester Display
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Meter Display 1
Execute
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OK:
The multi-information display in the combination meter assembly turns off or completely on
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according to the GTS operation
w/o Multi-information Display (for TFT Display Type):

Indicat. SET SET indicator light OFF or ON -

Tester Display
Indicat. SET
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Execute
OK:
Cruise control SET indicator light turns ON/OFF
Result:
Result Proceed to
OK A
NG B
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A
2.READ VALUE USING GTS (SET/COAST SWITCH)
t.c
Click hereVehicle Interior>METER / GAUGE / DISPLAY>METER / GAUGE SYSTEM>HOW TO
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PROCEED WITH TROUBLESHOOTING
2.READ VALUE USING GTS (SET/COAST SWITCH)

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a. Enter the following menus: Powertrain / Cruise Control / Data List.
b. Read the Data List according to the display on the GTS.

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Measurement Normal
Item Condition
ON: -SET switch
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on
OFF: -SET switch
off
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Tester Display
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SET/COAST Switch
Execute
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OK:
When the cruise control main switch (-SET switch) is operated, the display changes as shown
above.
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Result:
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Result Proceed to
The indicator operates normally
according to the on and off A
operations
The GTS screen display changes
from off to on, but the cruise
control SET indicator light in the B
combination meter assembly does
not illuminate
The cruise control SET indicator

light in the combination meter

assembly does not illuminate, and C
the indication in the GTS screen
display stays at OFF

SYMPTOMS TABLE
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B
REPLACE COMBINATION METER ASSEMBLY
Click hereVehicle Interior>METER / GAUGE / DISPLAY>COMBINATION METER>REMOVAL
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C
REPLACE ECM
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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM DATA LIST / ACTIVE TEST
READ DATA LIST
HINT:
Using the GTS to read the Data List allows the values or states of switches, sensors, actuators and other items
to be read without removing any parts. This non-intrusive inspection can be very useful because intermittent
conditions or signals may be discovered before parts or wiring is disturbed. Reading the Data List information
early in troubleshooting is one way to save diagnostic time.
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c. Turn the GTS on.
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d. Enter the following menus: Powertrain / Cruise Control / Data List.
e. Read the Data List according to the display on the GTS.

HINT:
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· If any DTCs are output, the value for a measurement item may be incorrect.
· If any DTCs are output, perform troubleshooting accordingly. After repair, confirm relevant values
using Data List.
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Measurement Normal
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Item Condition
Min.: 0 km/h (0
mph) Actual vehicle
CCS Vehicle Spd Vehicle speed -
Max.: 255 km/h speed
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(158 mph)
Min.: 0 km/h (0
CCS Mem Vehicle Stored vehicle mph) Actual stored
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-
Spd speed Max.: 255 km/h vehicle speed
(158 mph)
for 1KD-FTV,
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Throttle Opening Required throttle Min.: 0% Required throttle

1GD-FTV, 2GD-
Angle opening amount Max.: 100% opening angle
FTV
ON: Cruise control
Cruise control
activated
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Cruise Control system active ON or OFF -

OFF: Cruise
condition
control deactivated
ON: Cruise control
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Cruise control main switch on

Main SW M-CPU main switch signal ON or OFF OFF: Cruise -
(Main CPU) control main
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switch off
ON: Cruise control
main switch (Main
Cruise control
CPU) SET
system standby
CCS Ready M-CPU ON or OFF OFF: Cruise -
condition (Main-
control main
CPU)
switch (Main CPU)
UNSET
ON: Cruise control
indicator light
Cruise control
CCS Indicator M- turns on
indicator light ON or OFF -
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CPU signal (Main-CPU) OFF: Cruise

control indicator
light turns off
ON: CANCEL
CANCEL switch switch on
signal OFF: CANCEL
switch off
ON: -SET switch
on
OFF: -SET switch
off
ON: +RES switch
on
RES/ACC Switch +RES switch signal ON or OFF -
OFF: +RES switch
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off
ON: Brake pedal
Stop Light Switch Stop light switch depressed
ON or OFF -
1 signal OFF: Brake pedal
released
ON: Brake pedal
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Stop Light Switch Stop light switch depressed
ON or OFF -
2 signal OFF: Brake pedal
released
ON: Shift lever in
Cruise Operation Shift lever position D
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ON or OFF -
Status signal OFF: Shift lever
not in D
Differs according
Cruise Request Cruise request Min.:-51.2 kN to the cruise for 1GR-FE, 2TR-
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Driving Force torque signal Max.: 50.8 kN control system FE
condition
ON: Brake pedal
Brake Cancel Brake cancel depressed
ON or OFF -
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Switch signal OFF: Brake pedal
released
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PERFORM ACTIVE TEST

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HINT:
Using the GTS to perform Active Tests allows relays, VSVs, actuators and other items to be operated without
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removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation
may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one
way to save diagnostic time. Data List information can be displayed while performing Active Tests.
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c. Turn the GTS on.

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HINT:
The ignition switch must be turned to ON to proceed with the Active Test using the GTS.

Meter Display 1 Multi-information OFF or All -
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display
w/ Multi-information Display (for Dot Display Type):

(Green)
Cruise control SET
Indicat. SET OFF or ON -
indicator light

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(Green)
Cruise control SET
Indicat. SET OFF or ON -
indicator light
Cruise Indicator OFF or ON -
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(Yellow)
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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM DIAGNOSIS SYSTEM
DESCRIPTION
The ECM controls the cruise control system of the vehicle. The data and DTCs relating to the cruise control system
can be read from the DLC3 of the vehicle. Use the GTS to check and solve the problem.
HINT:
If a vehicle speed sensor, stop light switch assembly or any other related part malfunctions, the ECM cancels
cruise control operation automatically.
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a. Check the battery voltage with the ignition switch off.
Standard voltage:
11 to 14 V
If the voltage is below 11 V, replace or recharge the battery before proceeding to the next step.
t.c
b. Check the DLC3.
Click hereGeneral>INTRODUCTION>HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS>GENERAL
INFORMATION
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CHECK INDICATOR ar
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*a Master Warning Light

*b Multi-information Display (for TFT Display Type)
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*c Multi-information Display (for Dot Display Type)

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a. w/ Multi-information Display (for TFT Display Type):

When a malfunction occurs in the cruise control system, the system turns off the cruise control indicator
light and the master warning light illuminates at the same time a "pong" sound is heard. Also, "Cruise
control malfunction Visit your dealer" is displayed in the combination meter assembly and the ECM stores
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DTCs.
NOTICE:
· When the system returns to normal, the "Cruise control malfunction Visit your dealer" display in
the combination meter assembly disappears.
· Do not remove any fuses or disconnect any cables from the battery terminals until the data stored
in the ECUs is cleared.
b. w/ Multi-information Display (for Dot Display Type):

When a malfunction occurs in the cruise control system, the system turns off the cruise control indicator
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light and the master warning light illuminates at the same time a "pong" sound is heard. Also, "CRUISE
CONTROL MALFUNCTION VISIT YOUR DEALER" is displayed in the combination meter assembly and the
ECM stores DTCs.
NOTICE:
· When the system returns to normal, the "CRUISE CONTROL MALFUNCTION VISIT YOUR DEALER"
display in the combination meter assembly disappears.
· Do not remove any fuses or disconnect any cables from the battery terminals until the data stored
in the ECUs is cleared.
c.
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*a Cruise Control Indicator Light

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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CHART
Cruise Control System

DTC No. Detection Item Link
P0500 Vehicle Speed Sensor Malfunction
Vehicle Speed Sensor "A"
P0503
Intermittent / Erratic / High
P0571 Brake Switch "A" Circuit
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P0575 Cruise Control Input Circuit
P0607 ECU Internal Malfunction
P1578 Brake System Malfunction

Lost Communication with Vehicle
U0122
Dynamics Control Module
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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM DTC CHECK / CLEAR
CHECK DTC
c. Turn the GTS on.
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d. Enter the following menus: Powertrain / Cruise Control / Trouble Codes.
e. Check for DTCs.

Click hereEngine / Hybrid System>CRUISE CONTROL>CRUISE CONTROL SYSTEM>DIAGNOSTIC TROUBLE
CODE CHART
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Powertrain > Cruise Control > Trouble Codes
Execute
CLEAR DTC
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c. Turn the GTS on.
d. Enter the following menus: Powertrain / Cruise Control / Clear DTCs.

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e. Clear the DTCs.

Powertrain > Cruise Control > Clear DTCs
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Execute
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https://toyotamanuals.com.au/docs/hilux-service-repair-manual-j…manual/repair/contents/RM100000000KZQX.html?PUB_TYPE=RM&MODE=1 Page 1 of 1

Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM FAIL-SAFE CHART
HINT:
If the following conditions are detected while the cruise control system is controlling vehicle speed, the system
clears the vehicle speed stored in the ECM and cancels control of vehicle speed by the cruise control system.
Vehicle Condition Auto Cancel Condition Re-operation Condition
· Open or short in stop light

switch circuit Cruise control system is turned off
· Cruise control indicator
light goes off*5, *6 · Problem with vehicle speed and back on again using the cruise
signal control main switch.
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· A warning message "Cruise
control malfunction Visit
your dealer" is displayed*5 · Problem with stop light
· A warning message switch input circuit
"CRUISE CONTROL · Problem with cruise control
MALFUNCTION VISIT YOUR main switch cancel circuit
DEALER" is displayed*6
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· Malfunction in the brake Ignition switch is turned off and
· "Pong" warning sound is control system
heard*5, *6 back to ON again.
· Communication stop
· Cruise control indicator between skid control ECU
light illuminates in yellow*7 (brake actuator assembly)
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and ECM
· Vehicle speed is lower than

low speed limit
(approximately 40 km/h
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[25 mph]) while driving
with cruise control system
controlling vehicle speed
· Switching between 2WD
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and 4WD*2
· Vehicle stability control
system operates while Cruise control main switch is
Cruise control indicator light
driving with cruise control pressed to +RES.
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remains illuminated (Control of

system controlling vehicle
vehicle speed by cruise control
speed*1
system is canceled)
· TRC operates for certain
amount of time while
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driving with cruise control

system controlling vehicle
speed*1
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· TRC and VSC are off*1
Vehicle speed is lower than stored

Cruise control main switch is
vehicle speed by approximately 16
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pressed to -SET.
km/h (10 mph) or more
· Malfunction in the SFI

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system*3 Cruise control system is turned off

Cruise control indicator light goes
· Malfunction in the ECD and back on again using the cruise
off
system*4 control main switch.
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*2: for 4WD
*3: for 1GR-FE, 2TR-FE
*4: for 1KD-FTV, 1GD-FTV, 2GD-FTV
*5: w/ Multi-information Display (for TFT Display Type)
*6: w/ Multi-information Display (for Dot Display Type)
*7: w/o Multi-information Display
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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM FREEZE FRAME DATA
CHECK FREEZE FRAME DATA (READ BY GTS)
HINT:
The ECU data indicating the vehicle status is stored in the ECU as a freeze frame data simultaneously as the DTC
is stored.
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c. Turn the GTS on.
d. Enter the following menus: Powertrain / Cruise Control / Trouble Codes.
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Execute
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e. From the DTC screen, select the DTC (snow icon displayed) to which freeze frame data is recorded.
LIST OF FREEZE FRAME DATA

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Powertrain > Cruise Control
Measurement
Tester Display Range Normal Condition Diagnostic Note
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Item
Min.: 0 km/h (0
mph)
CCS Vehicle Spd Vehicle speed Actual vehicle speed -
Max.: 255 km/h
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(158 mph)
Min.: 0 km/h (0
CCS Mem Vehicle Stored vehicle mph) Actual stored
-
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Spd speed Max.: 255 km/h vehicle speed

(158 mph)
Throttle Opening Required throttle Min.: 0% Required throttle for 1KD-FTV, 1GD-
.p
Angle opening amount Max.: 100% opening angle FTV, 2GD-FTV

ON: Cruise control
Cruise control
activated
Cruise Control system active ON or OFF -
OFF: Cruise control
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condition
deactivated
ON: Cruise control
Cruise control main
main switch on
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Main SW M-CPU switch signal (Main ON or OFF -

OFF: Cruise control
CPU)
main switch off
ON: Cruise control
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Cruise control main switch (Main

system standby CPU) SET
CCS Ready M-CPU ON or OFF -
condition (Main- OFF: Cruise control
CPU) main switch (Main
CPU) UNSET
ON: Cruise control
Cruise control indicator light turns
CCS Indicator M- system standby on
ON or OFF -
CPU condition (Main- OFF: Cruise control
CPU) indicator light turns
off
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ON: CANCEL switch

CANCEL switch on
signal OFF: CANCEL switch
off
ON: -SET switch on
OFF: -SET switch off
ON: +RES switch on
RES/ACC Switch +RES switch signal ON or OFF OFF: +RES switch -
off
ON: Brake pedal
Stop light switch depressed
Stop Light Switch 1 ON or OFF -
signal OFF: Brake pedal
released
ON: Brake pedal
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Stop light switch depressed
Stop Light Switch 2 ON or OFF -
signal OFF: Brake pedal
released
ON: Shift lever in D
Cruise Operation Shift lever position
ON or OFF OFF: Shift lever not -
Status signal
in D
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Differs according to
Cruise Request Cruise request Min.:-51.2 kN
the cruise control for 1GR-FE, 2TR-FE
Driving Force torque signal Max.: 50.8 kN
system condition
ON: Brake pedal
ke
depressed
Brake Cancel Switch Brake cancel signal ON or OFF -
OFF: Brake pedal
released
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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING
HINT:
· Use the following procedure to troubleshoot the cruise control system.
· *: Use the GTS.
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PROCEDURE
1.VEHICLE BROUGHT TO WORKSHOP
Result:
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Proceed to
NEXT
NEXT
2.INSPECT BATTERY VOLTAGE

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2.INSPECT BATTERY VOLTAGE
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a. Measure the battery voltage.
Standard voltage:
11 to 14 V
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If the voltage is below 11 V, replace or recharge the battery before proceeding to the next step.
Result:
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Proceed to
NEXT
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NEXT
3.CHECK CAN COMMUNICATION SYSTEM*

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3.CHECK CAN COMMUNICATION SYSTEM*

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a. Use the GTS to check if the CAN communication system is functioning normally.
for LHD: Click herePower Source / Network>NETWORKING>CAN COMMUNICATION SYSTEM(for
LHD)>DIAGNOSIS SYSTEM
for RHD: Click herePower Source / Network>NETWORKING>CAN COMMUNICATION SYSTEM(for
RHD)>DIAGNOSIS SYSTEM
Result:
Result Proceed to
CAN communication system DTCs
A
are not output
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CAN communication system DTCs B

are output (for LHD)
CAN communication system DTCs
C
are output (for RHD)
4.CHECK METER / GAUGE SYSTEM*
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GO TO CAN COMMUNICATION SYSTEM (for LHD)
Click herePower Source / Network>NETWORKING>CAN COMMUNICATION SYSTEM(for

LHD)>DIAGNOSIS SYSTEM
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GO TO CAN COMMUNICATION SYSTEM (for RHD)
Click herePower Source / Network>NETWORKING>CAN COMMUNICATION SYSTEM(for

RHD)>DIAGNOSIS SYSTEM
4.CHECK METER / GAUGE SYSTEM*
a.
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Use the GTS to check if the meter / gauge system is functioning normally.
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Click hereVehicle Interior>METER / GAUGE / DISPLAY>METER / GAUGE SYSTEM>DTC CHECK / CLEAR
Body Electrical > Combination Meter > Trouble Codes
Execute
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Result:
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Result Proceed to
Meter / gauge system DTCs are not
A
output
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Meter / gauge system DTCs are

B
output
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A
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5.CHECK BRAKE CONTROL SYSTEM*

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Click hereVehicle Interior>METER / GAUGE / DISPLAY>METER / GAUGE SYSTEM>DIAGNOSTIC

TROUBLE CODE CHART
5.CHECK BRAKE CONTROL SYSTEM*
a. Use the GTS to check if the brake control system is functioning normally.
w/ Vehicle Stability Control System: Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL
SYSTEMS>VEHICLE STABILITY CONTROL SYSTEM>DTC CHECK / CLEAR
w/o Vehicle Stability Control System: Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL

SYSTEMS>ANTI-LOCK BRAKE SYSTEM>DTC CHECK / CLEAR
Chassis > ABS/VSC/TRC > Trouble Codes
Execute
Result:
Result Proceed to
DTCs are not output A
Vehicle stability control system
DTCs are output (w/ Vehicle B
Stability Control System)
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Anti-lock brake system DTCs are
output (w/o Vehicle Stability C
Control System)
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A
6.CHECK FOR DTC*
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B
GO TO VEHICLE STABILITY CONTROL SYSTEM

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Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>VEHICLE STABILITY
CONTROL SYSTEM>DIAGNOSTIC TROUBLE CODE CHART
C
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GO TO ANTI-LOCK BRAKE SYSTEM
Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>ANTI-LOCK BRAKE

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SYSTEM>DIAGNOSTIC TROUBLE CODE CHART
6.CHECK FOR DTC*

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a. Check for DTCs.

Click hereEngine / Hybrid System>CRUISE CONTROL>CRUISE CONTROL SYSTEM>DTC CHECK / CLEAR
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Execute
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b. Clear the DTCs.

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Powertrain > Cruise Control > Clear DTCs
Execute
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c. Recheck for DTCs.

Execute
Result:

Result Proceed to
DTCs are not output A
DTCs are output B
7.PROBLEM SYMPTOMS TABLE
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GO TO DIAGNOSTIC TROUBLE CODE CHART
Click hereEngine / Hybrid System>CRUISE CONTROL>CRUISE CONTROL SYSTEM>DIAGNOSTIC

TROUBLE CODE CHART
7.PROBLEM SYMPTOMS TABLE
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a. Refer to Problem Symptoms Table.
Click hereEngine / Hybrid System>CRUISE CONTROL>CRUISE CONTROL SYSTEM>PROBLEM SYMPTOMS
TABLE
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Result:
Result Proceed to
Fault is not listed in Problem
A
Symptoms Table
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Fault is listed in Problem
B
Symptoms Table
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A
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8.OVERALL ANALYSIS AND TROUBLESHOOTING*
B
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ADJUST, REPAIR OR REPLACE IN ACCORDANCE WITH PROBLEM SYMPTOMS TABLE

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8.OVERALL ANALYSIS AND TROUBLESHOOTING*

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a. Terminals of ECU
Click hereEngine / Hybrid System>CRUISE CONTROL>CRUISE CONTROL SYSTEM>TERMINALS OF ECU
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b. Data List/Active Test

Click hereEngine / Hybrid System>CRUISE CONTROL>CRUISE CONTROL SYSTEM>DATA LIST / ACTIVE
TEST
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Result:
Proceed to
NEXT
NEXT
9.REPAIR OR REPLACE

9.REPAIR OR REPLACE
Result:
Proceed to
NEXT
NEXT
10.CONFIRMATION TEST
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10.CONFIRMATION TEST
Result:
Proceed to
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NEXT
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NEXT
END
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CRUISE CONTROL CRUISE CONTROL SYSTEM PARTS LOCATION
ILLUSTRATION
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*A for LHD *B w/ Vehicle Stability Control System

*C w/o Vehicle Stability Control System *D for 2WD
*E for 4WD *F for 1KD-FTV
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*G for 1GR-FE, 2TR-FE *H for Automatic Transmission
*1 SKID CONTROL ECU (BRAKE ACTUATOR *2 PARK/NEUTRAL POSITION SWITCH ASSEMBLY

ASSEMBLY)
*3 THROTTLE WITH MOTOR BODY ASSEMBLY *4 INJECTOR DRIVER
*5 FRONT SPEED SENSOR RH *6 FRONT SPEED SENSOR LH
*7 REAR SPEED SENSOR RH *8 REAR SPEED SENSOR LH
*9 BLOCK - -
- STOP FUSE
- EFI-B FUSE
ILLUSTRATION
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*A for RHD *B w/ Vehicle Stability Control System

*C w/o Vehicle Stability Control System *D for 2WD
*E for 4WD *F for 1KD-FTV
*G for 1GR-FE, 2TR-FE *H for Automatic Transmission
*1 SKID CONTROL ECU (BRAKE ACTUATOR *2 PARK/NEUTRAL POSITION SWITCH ASSEMBLY

ASSEMBLY)
*3 THROTTLE WITH MOTOR BODY ASSEMBLY *4 INJECTOR DRIVER
*5 FRONT SPEED SENSOR RH *6 FRONT SPEED SENSOR LH
*7 REAR SPEED SENSOR RH *8 REAR SPEED SENSOR LH
BLOCK

*9 - STOP FUSE - -
- EFI-B FUSE
ILLUSTRATION
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*A for LHD *B for 4WD

*C for Manual Transmission *D for Automatic Transmission
*E w/ Vehicle Stability Control System *F w/o Vehicle Stability Control System
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*G for 1KD-FTV - -
*1 ACCELERATOR PEDAL SENSOR ASSEMBLY *2 CRUISE CONTROL MAIN SWITCH
*3 TRANSMISSION FLOOR SHIFT ASSEMBLY *4 STOP LIGHT SWITCH ASSEMBLY
*5 VSC OFF SWITCH *6 CLUTCH SWITCH ASSEMBLY
ASSEMBLY
*7 CRUISE CONTROL SWITCH WIRE *8 - IG1 NO. 1 FUSE
- IG1 NO. 4 FUSE
- IG2 NO. 3 FUSE
*9 NO. 3 INSTRUMENT PANEL RELAY BLOCK *10 NO. 4 INSTRUMENT PANEL RELAY BLOCK
- IG1 NO. 1 RELAY - IG2 RELAY
*11 SPIRAL WITH SENSOR CABLE SUB-ASSEMBLY *12 SPIRAL CABLE SUB-ASSEMBLY
*13 ECM *14 4 WHEEL DRIVE CONTROL ECU
*15 TCM *16 COMBINATION METER ASSEMBLY
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*17 DLC3 - -
ILLUSTRATION
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*A for RHD *B for 4WD

*C for Manual Transmission *D for Automatic Transmission
*E w/ Vehicle Stability Control System *F w/o Vehicle Stability Control System
*G for 1KD-FTV - -
*1 ACCELERATOR PEDAL SENSOR ASSEMBLY *2 CRUISE CONTROL MAIN SWITCH
*3 TRANSMISSION FLOOR SHIFT ASSEMBLY *4 STOP LIGHT SWITCH ASSEMBLY
*5 VSC OFF SWITCH *6 CLUTCH SWITCH ASSEMBLY
ASSEMBLY
*7 CRUISE CONTROL SWITCH WIRE *8 - IG1 NO. 1 FUSE
- IG1 NO. 4 FUSE
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- IG2 NO. 3 FUSE
*9 NO. 3 INSTRUMENT PANEL RELAY BLOCK *10 NO. 4 INSTRUMENT PANEL RELAY BLOCK
- IG1 NO. 1 RELAY - IG2 RELAY
*11 ECM *12 4 WHEEL DRIVE CONTROL ECU
*13 DLC3 *14 COMBINATION METER ASSEMBLY
*15 SPIRAL WITH SENSOR CABLE SUB-ASSEMBLY *16 SPIRAL CABLE SUB-ASSEMBLY
*17 TCM - -
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CRUISE CONTROL CRUISE CONTROL SYSTEM PRECAUTION
a. The type of ignition switch used on this model differs according to the specifications of the vehicle. The
Expression Ignition Switch (Position) Engine Switch (Condition)
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HANDLING PRECAUTION FOR CRUISE CONTROL SYSTEM
a. Push the cruise control main switch off when not using the cruise control system.
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b. Be careful as the vehicle speed increases when driving downhill with the cruise control system on.
c. The RESUME/ACCEL operation changes according to the cruise control system status. When the cruise
control system is operating, ACCEL operates. When the cruise control system is not operating, RESUME
operates.
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d. w/ Multi-information Display:
While the cruise control system is controlling vehicle speed, if the cruise control indicator light goes out and
a warning message is displayed, turn the cruise control main switch off to reset the cruise control system.
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After the reset, if the cruise control main switch cannot be turned on, or the cruise control system is
canceled immediately after turning the cruise control main switch on, the system may have a malfunction.
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e. w/o Multi-information Display:

While the cruise control system is controlling vehicle speed, if the cruise control indicator light illuminates in
yellow, turn the cruise control main switch off to reset the cruise control system. After the reset, if the
cruise control main switch cannot be turned on, or the cruise control system is canceled immediately after
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turning the cruise control main switch on, the system may have a malfunction.
f. Do not use the cruise control system where the road conditions are as follows:
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· In heavy traffic
· On roads with sharp bends
· On winding roads
· On slippery roads, such as those covered with rain, ice or snow
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· On steep hills:
Vehicle speed may exceed the set speed when driving down a steep hill.
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g. Do not use the cruise control system while towing.

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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM PROBLEM SYMPTOMS TABLE
HINT:
· Use the table below to help determine the cause of problem symptoms. If multiple suspected areas are
listed, the potential causes of the symptoms are listed in order of probability in the "Suspected Area"
column of the table. Check each symptom by checking the suspected areas in the order they are listed.
Replace parts as necessary.
· When replacing the combination meter assembly, make sure to replace it with a new one.
· Inspect the fuses and relays related to this system before inspecting the suspected areas below.
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Symptom Suspected Area Link
CAN communication system (for LHD)
CAN communication system (for RHD)
Cruise control switch circuit
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Cruise main indicator light circuit
Cruise control main switch does not turn on
(cruise control indicator light does not ECM (for 1GR-FE)
illuminate)
ECM (for 2TR-FE)
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ECM (for 1GD-FTV)
ECM (for 2GD-FTV)
ECM (for 1KD-FTV)

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Cruise control SET indicator light circuit
Cruise control SET indicator light does not ECM (for 1GR-FE)
illuminate (can be set)
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ECM (for 2TR-FE)
ECM (for 1GD-FTV)

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ECM (for 2GD-FTV)
ECM (for 1KD-FTV)

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ECM (for 1GR-FE)

Cannot set cruise control (cruise control
ECM (for 2TR-FE)
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indicator light illuminates when cruise control

main switch is on, but turns off when cruise ECM (for 1GD-FTV)
control is set)
ECM (for 2GD-FTV)
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ECM (for 1KD-FTV)

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Vehicle stability control system (w/ Vehicle
Anti-lock brake system (w/o Vehicle Stability
Control System)
SFI system (for 1GR-FE)
SFI system (for 2TR-FE)
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ECD system (for 1GD-FTV)
ECD system (for 1GD-FTV w/ DPF)

Cannot set cruise control (cruise control
indicator light stays illuminated) ECD system (for 2GD-FTV w/ DPF)
ECD system (for 1KD-FTV)
Stop light switch circuit
Clutch switch circuit (for Manual Transmission)
Combination meter assembly
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ECM (for 1GR-FE)
ECM (for 2TR-FE)
ECM (for 1GD-FTV)
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ECM (for 2GD-FTV)
ECM (for 1KD-FTV)
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Transmission control switch circuit (for AC60E

Automatic Transmission) (for 1GR-FE)
When cruising, cruise control cancels (cruise Transmission control switch circuit (for AC60E
control indicator light stays illuminated) Automatic Transmission) (for 2TR-FE)
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Automatic Transmission) (for 1GD-FTV)
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Transmission control switch circuit (for AC60F
Automatic Transmission) (2TR-FE)
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Transmission control switch circuit (for A750F

Combination meter assembly
ECM (for 1GR-FE)
ECM (for 2TR-FE)
ECM (for 1GD-FTV)
ECM (for 2GD-FTV)
ECM (for 1KD-FTV)
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Automatic transmission system (for AC60E
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Automatic Transmission) (for 2TR-FE)
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Hunting (vehicle speed does not stabilize) Automatic Transmission) (for 2GD-FTV)
Automatic transmission system (for AC60F
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Automatic Transmission) (for 2TR-FE)
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Transmission control switch circuit (for A750F

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ECM (for 1GR-FE)
ECM (for 2TR-FE)
ECM (for 1GD-FTV)

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ECM (for 2GD-FTV)
ECM (for 1KD-FTV)

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ECM (for 1GR-FE)
ECM (for 2TR-FE)

Cannot cancel by CANCEL switch operation
ECM (for 1GD-FTV)
ECM (for 2GD-FTV)
ECM (for 1KD-FTV)


Control System)
Cannot cancel by vehicle speed (low speed ECM (for 1GR-FE)

limit)
ECM (for 2TR-FE)
ECM (for 1GD-FTV)
ECM (for 2GD-FTV)
ECM (for 1KD-FTV)

Park/Neutral position switch assembly (for
AC60E Automatic Transmission)
AC60F Automatic Transmission)
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A750F Automatic Transmission)
Transmission floor shift assembly (for AC60E
Transmission floor shift assembly (for AC60F
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Cannot cancel by shift lever operation Transmission floor shift assembly (for A750F
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ECM (for 1GR-FE)
ECM (for 2TR-FE)
ECM (for 1GD-FTV)

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ECM (for 2GD-FTV)
ECM (for 1KD-FTV)

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ECM (for 1GR-FE)
ECM (for 2TR-FE)

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Cannot cancel by brake operation

ECM (for 1GD-FTV)
ECM (for 2GD-FTV)

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ECM (for 1KD-FTV)

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ECM (for 1GR-FE)
ECM (for 2TR-FE)

Cannot cancel by clutch operation
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ECM (for 1GD-FTV)
ECM (for 2GD-FTV)

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ECM (for 1KD-FTV)

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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM ROAD TEST
PROBLEM SYMPTOM CONFIRMATION
a. Inspect the SET switch.

i.
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*a Cruise Control Indicator Light
*b ON/OFF
ii.
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Turn the cruise control system on using the cruise control main switch (ON/OFF).
Check that the cruise control indicator light illuminates on the combination meter assembly.
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iii. Drive at a speed between approximately 40 km/h (25 mph) and 200 km/h (124 mph).
iv.
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*a Cruise Control SET Indicator Light

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*b -SET
Push the cruise control main switch to -SET.

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v. Check that the cruise control SET indicator light illuminates at this time.
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vi. After releasing the switch, check that the vehicle maintains the set speed.
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b.
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*a ON/OFF
*b +RES
*c -SET
Inspect the "+" switch.
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i. Turn the cruise control system on using the cruise control main switch (ON/OFF).
ii. Drive at a speed between approximately 40 km/h (25 mph) and 200 km/h (124 mph).
iii. Push the cruise control main switch to -SET.
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iv. Check that vehicle speed increases while the cruise control main switch is pushed to +RES, and that the
vehicle maintains the newly set speed when the switch is released.
v. Push the cruise control main switch to +RES and then release it immediately. Check that vehicle speed
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increases by approximately 1.6 km/h (1 mph) (tap-up control).
c.
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*a ON/OFF
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*b -SET
Inspect the "-" switch.

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i. Turn the cruise control system on using the cruise control main switch (ON/OFF).
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iv. Check that vehicle speed decreases while the cruise control main switch is pushed to -SET, and the
vehicle maintains the newly set speed when the switch is released.
v. Push the cruise control main switch to -SET, and then release it immediately. Check that vehicle speed
decreases by approximately 1.6 km/h (1 mph) (tap-down control).
d. Inspect the CANCEL switch.

i.
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*a ON/OFF
*b -SET
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*a ON/OFF
*b CANCEL
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When any of the following are performed, check that control of vehicle speed by the cruise control
system is canceled and that the normal driving mode (no control of vehicle speed by the cruise control
system) resumes.
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· Depressing the brake pedal.

Depressing the clutch pedal.
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Moving the shift lever to any position except D or S (6th, 5th or 4th gear).
· Pulling the cruise control main switch to CANCEL.
· Turning the cruise control system off using the cruise control main switch (ON/OFF).
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e. Inspect the RES (RESUME) switch.

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*a ON/OFF
*b -SET
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*a ON/OFF
Cancel control of vehicle speed by the cruise control system by performing any of the above operations
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(other than turning the cruise control system off using the cruise control main switch [ON/OFF]).
v.
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*a +RES
After pushing the cruise control main switch to +RES while driving the vehicle at a speed of more than
40 km/h (25 mph), check that the vehicle resumes the speed set prior to cancellation.

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CRUISE CONTROL CRUISE CONTROL SYSTEM SYSTEM DESCRIPTION
CRUISE CONTROL SYSTEM
· for 1GR-FE, 2TR-FE

This system is controlled by the ECM. Control is performed using the throttle position sensor and motor.
The ECM controls the following functions: ON-OFF, SET, COAST, RES, ACCEL, CANCEL, vehicle speed
operation and shift down control*.
The ECM compares the vehicle speed from the speed sensor with the stored vehicle speed set using the
cruise control main switch. The ECM instructs the throttle valve motor of the throttle with motor body
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assembly to close the valve when the vehicle speed is greater than the stored speed, and instructs it to
open the valve when the vehicle speed is less than the stored speed.
*: for Automatic Transmission
· for 1GD-FTV, 2GD-FTV, 1KD-FTV

This system controls the vehicle speed by using the ECM to change the fuel injection quantity. The ECM
controls the following functions: ON-OFF, SET, COAST, RES, ACCEL, CANCEL, vehicle speed operation and
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fuel injection quantity control and shift down control*.
The ECM compares the driving vehicle speed from the vehicle speed sensor with the stored vehicle speed
set through the cruise control main switch. When the actual vehicle speed exceeds the stored vehicle
speed, the ECM decreases the fuel injection quantity. When the actual vehicle speed is less than the stored
vehicle speed, the ECM increases the fuel injection quantity.
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*: for Automatic Transmission
· The ECM receives signals such as ON-OFF, SET, COAST, RES, ACCEL, and CANCEL from the cruise control
main switch and executes the command.
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· The ECM illuminates the combination meter assembly cruise control indicator light when it receives the
cruise control main switch on signal.
· w/ Multi-information Display:
The ECM turns off the combination meter assembly cruise control indicator light and displays a warning
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message when a malfunction occurs during cruise control driving.
· w/o Multi-information Display:
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· The ECM illuminates the combination meter assembly cruise control SET indicator light when vehicle speed
control begins after the cruise control main switch is pushed to -SET while driving.
·
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*1 Cruise Control Indicator Light

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*2 Cruise Control SET Indicator Light
The ECM cancels the cruise control system when the brake pedal is depressed and the ECM receives the
stop light switch signal.
The ECM cancels the cruise control system when the clutch pedal is depressed and the ECM receives the
clutch switch assembly.
The ECM cancels control of vehicle speed when the shift lever is moved from D or S to any other position.
The ECM cancels control of vehicle speed when the shift lever is used to select the 3rd, 2nd or 1st range
with the shift lever in S.
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· The ECM cancels control of vehicle speed when the cruise control main switch is pulled to CANCEL.
· The ECM cancels control of vehicle speed when the cruise control system is turned off using the cruise
control main switch.
LIMIT CONTROL
a. Low speed limit

The lowest possible set speed is approximately 40 km/h (25 mph). The cruise control system cannot be set
when the vehicle speed is below the low speed limit. Control of vehicle speed will be automatically canceled
but the stored vehicle speed will be retained when the vehicle speed drops below the low speed limit while
the cruise control is controlling vehicle speed.
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b. High speed limit
The highest possible set speed is approximately 200 km/h (125 mph). The cruise control system cannot be
set when the vehicle speed is over the high speed limit. Also, +RES cannot be used to increase the speed
beyond the high speed limit.
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OPERATION OF CRUISE CONTROL
The cruise control main switch is used to turn the cruise control system on and off, as well as operate 7 functions:
SET, - (COAST), TAP-DOWN, RES (RESUME), + (ACCEL), TAP-UP, and CANCEL. The SET, TAP-DOWN, and -
(COAST) functions, and the RES (RESUME), TAP-UP, and + (ACCEL) functions are operated with the same switch.
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The cruise control main switch is an automatic return type switch which turns on only while being operated in the
direction of each arrow, and turns off when it is released.
a. SET CONTROL
The vehicle speed is stored and speed control begins when the cruise control main switch is pushed to -SET
while driving with the cruise control system on (while the cruise control indicator light is illuminated), and
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the vehicle speed is within the set speed range (between the low and high speed limits).
b. - (COAST) CONTROL (for 1GR-FE, 2TR-FE)

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When the cruise control system is controlling vehicle speed and the cruise control main switch is pushed to
-SET and held in that position, the cruise control system sends a "throttle valve opening angle 0°" demand
signal to the ECM. Following this, the vehicle speed is stored and maintained when the cruise control main
switch is released.
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HINT:
An actual throttle valve opening angle of 0° is not possible due to items such as idle speed control.
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c. - (COAST) CONTROL (for 1GD-FTV, 2GD-FTV)

When the cruise control main switch is pushed to -SET and held in that position while the cruise control
system is operating, the ECM sends a fuel injection quantity signal. Then, the vehicle speed is stored and
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maintained when the cruise control main switch is released.
d. - (COAST) CONTROL (for 1KD-FTV)

When the cruise control main switch is pushed to -SET and held in that position while the cruise control
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system is operating, the ECM sends a fuel injection quantity signal to the injector driver. Then, the vehicle
speed is stored and maintained when the cruise control main switch is released.
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e. TAP-DOWN CONTROL
When the cruise control system is controlling vehicle speed and the cruise control main switch is tapped to
the -SET side (for approximately 0.6 seconds or less), the stored vehicle speed decreases by approximately
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1.6 km/h (1 mph) for each time the switch is tapped. When the cruise control main switch is tapped to -
SET and the difference between the current and stored vehicle speed is more than approximately 5 km/h (3
mph), the current vehicle speed is stored and speed control is performed.
f. ACCELERATION CONTROL (for 1GR-FE, 2TR-FE)

When the cruise control system is controlling vehicle speed and the cruise control main switch is pushed to
+RES and held in that position, the cruise control system sends a signal to the ECM to operate the throttle
valve motor of the throttle with motor body assembly to open the throttle valve. Following this, the vehicle
speed is stored and maintained when the cruise control main switch is released.
g. ACCELERATION CONTROL (for 1GD-FTV, 2GD-FTV)
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While the cruise control system is in operation, if the cruise control main switch is pushed to +RES, the
ECM increases the fuel injection quantity. When the cruise control main switch is released from +RES, the
vehicle speed is stored and the vehicle is controlled in order to maintain a constant speed.
h. ACCELERATION CONTROL (for 1KD-FTV)

While the cruise control system is in operation, if the cruise control main switch is pressed to +RES, the
injector driver increases the fuel injector quantity. When the cruise control main switch is released from
+RES, the vehicle speed is stored and the vehicle is controlled at a constant speed.
i. TAP-UP CONTROL
When the cruise control system is controlling vehicle speed and the cruise control main switch is tapped to
the +RES side (for approximately 0.6 seconds or less), the stored vehicle speed increases by approximately
1.6 km/h (1 mph) for each time the switch is tapped. When the cruise control main switch is tapped to
+RES and the difference between the current and stored vehicle speed is more than approximately 5 km/h
(3 mph), the stored vehicle speed will not be changed.
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j. RESUME CONTROL
If control of vehicle speed by the cruise control system was canceled due to any of the manual cancel
conditions (other than turning the cruise control system off using the cruise control main switch), and if the
vehicle speed is between the low and high speed limits, the stored vehicle speed from the time of
cancelation will be resumed and maintained when the cruise control main switch is pushed to +RES.
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k. SHIFT DOWN CONTROL (for Automatic Transmission)
When the vehicle is traveling uphill using cruise control, automatic transmission control may cause the
transmission to shift down. During shift down control, when the end of uphill travel is determined, the
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transmission will shift up after a certain period of time. When the transmission shifts down during the
accelerator control or the resume control, the transmission will shift up after the accelerator control or the
resume control ends.
l. CANCEL CONTROL
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Manual cancel
Performing any of the following cancels control of vehicle speed by the cruise control system (the
stored vehicle speed in the ECM is maintained).
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· Depressing the brake pedal.
Depressing the clutch pedal.
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Moving the shift lever to any position except D or S (5th or 4th gear).
· Pulling the cruise control main switch to CANCEL.
· Turning the cruise control system off using the cruise control main switch (ON/OFF) (the stored
vehicle speed in the ECM is not maintained).
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Auto cancel
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Performing any of the following cancels the cruise control system (the stored vehicle speed in the
ECM is maintained).
· Vehicle speed decreases below the low speed limit approximately 40 km/h (25 mph).
· w/ Vehicle Stability Control System:
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VSC operates while the vehicle is in motion.

TRC operates for certain amount of time while driving with cruise control system controlling
vehicle speed.
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TRC and VSC are off.

· for 4WD:
Switching between 2WD and 4WD.
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Performing any of the following cancels the cruise control system (the stored vehicle speed in the
ECM is not maintained).
· Vehicle speed decreases by 16 km/h (10 mph) or more below the speed at which the cruise
control is set.
AUTO CANCEL (FAIL-SAFE)

This system has an automatic cancellation function (fail-safe).

Click hereEngine / Hybrid System>CRUISE CONTROL>CRUISE CONTROL SYSTEM>FAIL-SAFE CHART
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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM SYSTEM DIAGRAM
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Communication Table
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Sender Receiver Signal Line

Combination Meter Assembly
· Cruise Control Indicator Light Cruise control indicator light and
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ECM · Cruise Control SET Indicator cruise control SET indicator light CAN
Light operation signal
Skid Control ECU · Vehicle speed signal

(Brake Actuator ECM · Cruise control cancellation CAN
Assembly) request signal*1
4 Wheel Drive
ECM Cruise control cancel request signal CAN
Control ECU*2


*2: for 4WD
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Print Exit
CRUISE CONTROL CRUISE CONTROL SYSTEM TERMINALS OF ECU
CHECK ECM (for 1GR-FE)
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HINT:
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Each ECM terminal's standard voltage is shown in the table below.
In the table, first follow the information under "Condition". Look under "Terminal No. (Symbol)" for the terminals
to be inspected. The standard voltage between the terminals is shown under "Specified Condition".
Use the illustration above as a reference for the ECM terminals.
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Terminal Specified
Terminal No. (Symbol) Wiring Color Condition
Description Condition
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C13-12 (E1) - Body BR - Body

Ground Always Below 1 Ω
ground ground
Ignition switch ON
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and shift lever in D, 11 to 14 V

D shift position S, "+" or "-"
C15-22 (D) - C13-12 (E1) GR - BR
switch signal Ignition switch ON
and shift lever not in Below 1 V
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D, S, "+" or "-"
Battery (for
G87-24 (BATT) - C13-12 measuring battery
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Y - BR Always 11 to 14 V
(E1) voltage and for ECM
memory)
Ignition switch ON
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11 to 14 V
and shift lever in S
G88-9 (SFTD) - C13-12 Down-shift position
G - BR Ignition switch ON
(E1) switch signal
and shift lever in "-" Below 1 V
(down-shift)
Ignition switch ON
11 to 14 V
G88-15 (SFTU) - C13-12 Up-shift position
W - BR Ignition switch ON
(E1) switch signal
and shift lever in "+" Below 1 V
(up-shift)
Ignition switch ON
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-j…manual/repair/contents/RM100000000KZQV.html?PUB_TYPE=RM&MODE=1 Page 1 of 7

and shift lever in S, 11 to 14 V

S shift position "+" or "-"
G88-22 (S) - C13-12 (E1) L - BR
switch signal
Ignition switch ON
S, "+" or "-"
Cruise control main
1 MΩ or higher
switch off
Cruise control main
G88-1 (CCS) - C13-12 Cruise control switch switch on Below 2.5 Ω
G - BR
(E1) circuit
+RES switch on 235 to 245 Ω
-SET switch on 617 to 643 Ω
CANCEL switch on 1509 to 1571 Ω
Ignition switch ON,
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Stop light switch brake pedal Below 1.5 V
G88-34 (ST1-) - C13-12 assembly signal depressed
GR - BR
(E1) (opposite of voltage
at STP terminal) Ignition switch ON,
7.5 to 14 V
brake pedal released
Brake pedal
G88-35 (STP) - C13-12 Stop light switch 7.5 to 14 V
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L - BR depressed
(E1) assembly signal
Brake pedal released Below 1.5 V
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CHECK ECM (for 2TR-FE)
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HINT:
Terminal Specified
W-B - Body
C52-3 (E1) - Body ground Ground Always Below 1 Ω
ground
Ignition switch ON
11 to 14 V
https://toyotamanuals.com.au/docs/hilux-service-repair-manual-…manual/repair/contents/RM100000000KZQV.html?PUB_TYPE=RM&MODE=1 Page 2 of 7

C54-17 (SFTU) - C52-3 Up-shift position and shift lever in S

W - W-B
(E1)*2 switch signal Ignition switch ON
position (up-shift)
Ignition switch ON
11 to 14 V
C54-27 (SFTD) - C52-3 Down-shift position
G - W-B Ignition switch ON
(E1)*2 switch signal
(down-shift)
Ignition switch ON
C54-30 (S) - C52-3 S shift position "+" or "-"
L - W-B
(E1)*2 switch signal Ignition switch ON
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S, "+" or "-"
Ignition switch ON,
clutch pedal Below 1 V
G45-18 (D) - C52-3
P - W-B Clutch switch signal depressed
(E1)*1
Ignition switch ON,
11 to 14 V
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clutch pedal released
Ignition switch ON
G45-18 (D) - C52-3 D shift position S, "+" or "-"
P - W-B
(E1)*2 signal
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Ignition switch ON
D, S, "+" or "-"
Cruise control main
1 MΩ or higher
switch off
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Cruise control main
G45-22 (CCS) - G45-21 Cruise control switch switch on Below 2.5 Ω
G - BR
(ECCS) circuit
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Battery (for
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Y - W-B Always 11 to 14 V
memory)
Brake pedal
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L - W-B depressed
Brake pedal released Below 1.5 V
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Ignition switch ON,

Stop light switch brake pedal Below 1.5 V
GR - W-B
(E1) (opposite to voltage
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7.5 to 14 V
*1: for Manual Transmission

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*2: for Automatic Transmission

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CHECK ECM (for 1GD-FTV, 2GD-FTV)

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HINT:
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Terminal Specified
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Ignition switch ON,
clutch pedal Below 1 V
C57-14 (D) - C60-1
GR - W-B Clutch switch signal depressed
(E1)*1
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Ignition switch ON,
11 to 14 V
clutch pedal released
Ignition switch ON
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C57-14 (D) - C60-1 D shift position S, "+" or "-"
GR - W-B
(E1)*2 signal Ignition switch ON
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D, S, "+" or "-"
W-B - Body
ground
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Ignition switch ON
G85-13 (S) - C60-1 S shift position "+" or "-"
L - W-B
(E1)*2 switch signal
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Ignition switch ON
S, "+" or "-"
Ignition switch ON
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11 to 14 V
G85-20 (SFTD) - C60-1 Down-shift switch
(E1)*2 signal
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(down-shift)
Ignition switch ON
11 to 14 V
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G85-21 (SFTU) - C60-1 Up-shift switch

W - W-B Ignition switch ON
(E1)*2 signal
(up-shift)
Battery (for
Y - W-B Always 11 to 14 V
memory)
Ignition switch ON,
Stop light switch brake pedal 0 to 1.5 V
GR - W-B (opposite to voltage
(E1)

at STP terminal) Ignition switch ON, 7.5 to 14 V

Brake pedal
L - W-B depressed
Brake pedal released 0 to 1.5 V
Cruise control main
1 MΩ or higher
switch off
Cruise control main
G - W-B
(E1) circuit
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*1: for Manual Transmission
*2: for Automatic Transmission
CHECK ECM (for 1KD-FTV)
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HINT:
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Terminal Specified
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W-B - Body
ground
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Battery (for
measuring the
G83-2 (BATT) - C56-7
Y - W-B battery voltage and Always 11 to 14 V
(E1)
for the ECM
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memory)
Ignition switch ON,
Stop light switch brake pedal 0 to 1.5 V
GR - W-B
(E1) (opposite to voltage
7.5 to 14 V
Brake pedal
L - W-B depressed
Brake pedal released 0 to 1.5 V
Cruise control main 1 MΩ or higher

switch off
Cruise control main
G - W-B
(E1) circuit
CHECK TCM (for 1KD-FTV)
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HINT:
Each TCM terminal's standard voltage is shown in the table below.
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Use the illustration above as a reference for the TCM terminals.
Terminal Specified
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Ignition switch ON
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D shift position S, "+" or "-"

G89-8 (D) - C77-1 (E1) P - W-B
S, "+" or "-"
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W-B - Body
ground
Ignition switch ON
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S shift position "+" or "-"
G90-15 (S) - C77-1 (E1) L - W-B
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S, "+" or "-"
Ignition switch ON
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11 to 14 V
G90-22 (SFTU) - C77-1 Up-shift position
W - W-B Ignition switch ON
(E1) switch signal
position (up-shift)
Ignition switch ON
11 to 14 V
G90-23 (SFTD) - C77-1 Down-shift position
(E1) switch signal
(down-shift)

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1GD-FTV LUBRICATION ENGINE OIL COOLER COMPONENTS

*1 OIL COOLER ASSEMBLY *2 WATER OUTLET PIPE GASKET

N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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1GD-FTV LUBRICATION ENGINE OIL COOLER INSPECTION

1.INSPECT OIL COOLER ASSEMBLY 15710

a. Visually check the oil cooler assembly for cracks or damage.

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1GD-FTV LUBRICATION ENGINE OIL COOLER INSTALLATION

1.INSTALL OIL COOLER ASSEMBLY 15710

a. Apply a light coat of engine oil to the 2 new O-rings.

b. Install the 2 O-rings to the cylinder block sub-assembly.

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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1GD-FTV LUBRICATION ENGINE OIL COOLER REMOVAL

1.REMOVE TURBOCHARGER SUB-ASSEMBLY 17201

Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/

Remove the 2 O-rings from the cylinder block sub-assembly.

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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1GD-FTV LUBRICATION LUBRICATION SYSTEM ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

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1.INSPECT OIL QUALITY

2.INSPECT ENGINE OIL LEVEL

a. Remove the engine oil pressure switch assembly.

*a Oil Pressure Gauge

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Install an oil pressure gauge with the adapter.

c. Warm up the engine.

f. Install the engine oil pressure switch assembly.

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1GD-FTV LUBRICATION OIL AND OIL FILTER COMPONENTS

*A for 4WD and Pre-Runner - -

Tightening torque for "Major areas involving

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● Non-reusable part Engine oil

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1GD-FTV LUBRICATION OIL AND OIL FILTER COMPONENTS

*A for 4WD and Pre-Runner - -

Tightening torque for "Major areas involving

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● Non-reusable part Engine oil

© 2012 TOYOTA MOTOR CORPORATION. All Rights Reserved.

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1GD-FTV LUBRICATION OIL AND OIL FILTER REPLACEMENT

CAUTION / NOTICE / HINT

3.DRAIN ENGINE OIL

a. Remove the oil filler cap assembly.

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4.REMOVE OIL FILTER SUB-ASSEMBLY 15601

5.INSTALL OIL FILTER SUB-ASSEMBLY 15601

a. Check and clean the oil filter sub-assembly installation surface.

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Using SST, tighten the oil filter sub-assembly.

i. Depending on the space available, choose from the following.

7.5 liters (7.9 US qts, 6.6 Imp. qts)

7.INSPECT FOR OIL LEAK

8.INSPECT ENGINE OIL LEVEL

Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>LUBRICATION SYSTEM>ON-VEHICLE INSPECTION

1 OIL COOLER ASSEMBLY 2 WATER OUTLET PIPE GASKET

Nm (kgfcm, ft.*lbf): Specified torque ● Non-reusable part

Nm (kgfcm, ft.*lbf): Specified torque - -

Nm (kgfcm, ft.*lbf): Specified torque - -