1999–2000 Toyota Hilux HI-LUX KZN165 1KZ-TE Engine Repair Manual (P/N RM710E)

• Toyota Publication No. RM710E, issued August 1999: a 407-page English-language PDF covering the 1KZ-TE diesel engine installed in the HILUX KZN165 series.
• Covers compression testing, valve-clearance service, injection-timing and engine-speed adjustment, intake-constrictor checks, timing-belt replacement, timing-gear repair, cylinder-head overhaul, and cylinder-block inspection and reassembly.
• Details injection-nozzle removal, disassembly, inspection, opening-pressure and spray-pattern testing, reassembly, and installation, together with injection-pump removal, partial internal service, reassembly, and reinstallation.
• Provides Toyota ECD diagnostics with normal- and test-mode trouble-code checks, hand-held tester data, ECU terminal inspections, problem-symptom tables, circuit flowcharts, and engine-control wiring diagrams.
• Includes turbocharger troubleshooting, on-vehicle testing, removal, disassembly, inspection, reassembly, and installation, plus water-pump, thermostat, radiator, oil-pump, oil-cooler, and oil-nozzle service.
• Documents pre-heating diagnosis, starter disassembly and bench testing, charging-system inspection, and alternator disassembly, component checks, replacement, and reassembly.
• Lists Toyota SSTs and SSMs, component-specific torque data, fluid capacities, pressure-test specifications, machining and wear limits, clearance data, and electrical test values. Full HILUX vehicle wiring is not included; Toyota references a separate electrical publication.

Inside the 1KZ-TE Mechanical Sections

The engine-mechanical section moves from routine checks and adjustments into full component repair. The cylinder-head chapter covers removal, disassembly, warpage and valve inspection, guide and seat service, parts replacement, reassembly, and installation. Cylinder-block coverage includes pistons, rings, connecting rods, crankshaft, bearings, balance shafts, oil clearances, and seal replacement. Component overview drawings identify non-reusable parts, precoated fasteners, seal locations, and the torque points tied to each assembly.

Replacement head-gasket grade is tied to piston-protrusion measurement rather than simply copying the removed gasket. The timing-gear and turbocharger chapters preserve spring preload and housing alignment with service-bolt and matchmark controls, warning that damaged gear teeth, a bent turbo shaft, or wheel-to-housing contact can compromise the repair.

How the ECD Diagnostics Are Organized

The 1KZ-TE diagnostic material follows Toyota’s fault-isolation workflow: customer problem analysis, symptom confirmation, normal/test-mode DTC retrieval, intermittent-fault simulation, the trouble-code chart, a problem-symptom table, parts locations, ECU terminal data, and circuit inspection. Sensor-circuit flowcharts cover crankshaft position, engine speed, water, intake-air and fuel temperature, turbo pressure, throttle position, and vehicle speed. Separate procedures address timing control, starter and first-gear inputs, ECU power supplies, TE1/TE2 terminals, pre-heating control, and the spill-control relay.

Representative visuals include the engine ECU terminal map, crankshaft/engine-speed sensor circuit diagram, turbo-pressure sensor wiring, pre-heating and spill-control relay flowcharts, the timing-gear exploded assembly, and the injection-pump component layout. The Electronic Control Diesel section adds direct inspection procedures for the throttle body, timing and spill-control valves, ECD relays, intake-constrictor VSVs, sensors, the injection-pump correction resistor, and engine ECU voltage checks.

Fuel-system coverage is specific about its limits. The nozzle chapter includes cleaning, needle and body inspection, opening-pressure adjustment, spray-pattern and leakage testing, and reassembly. The injection-pump chapter covers removal and installation plus partial disassembly around the delivery valves, distributive-head plugs, timing-control valve, and fuel-temperature sensor. It is not a complete diesel-pump bench-calibration manual.

Toyota SSTs, Specifications, and Scope Limits

The Preparation section identifies Toyota tools by part number. For engine and ECU work, it lists compression gauge attachment 09992-00500, valve-clearance adjusting tool 09248-64011, diagnosis check wire 09843-18020, and turbocharger pressure gauge 09992-00242. Fuel-system repair calls out injection-pump stand set 09241-76022 and injection-pump tool set 09260-54012. Separate Service Specifications pages consolidate torque tables, component dimensions, wear and machining limits, injection-nozzle data, turbocharger checks, cooling and lubrication tests, and starter, alternator, sensor, relay, and actuator specifications.

This is an engine repair manual, not a complete HILUX vehicle manual. It does not include a vehicle-level engine-removal chapter or repair coverage for the transmission, axles, steering, brakes, suspension, or body. Toyota identifies Publication No. EWD307F as the separate HILUX Electrical Wiring Diagram. Follow the manual’s safety precautions before repair: support the vehicle on rigid stands, disconnect the battery before electrical work, and keep hands clear of injection-nozzle spray during tester use.