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

Toyota’s August 1999 1KZ-TE Engine Repair Manual (P/N RM710E) covers the diesel engine in the Hilux KZN165 series.

PDF Search, Bookmarks, and Diagram Detail

Navigation and diagram detail: Embedded bookmarks link to chapters and individual pages. Some page bookmarks open an adjacent page. The PDF has no text search. Small pin numbers and wire-color codes are clearest when zoomed in, and some wiring diagrams show scan marks.

The ZIP contains one printable 407-page PDF in English, including the original cover, foreword, and table of contents.

Engine Overhaul and Diesel Diagnostics

These selected repair and diagnostic topics show the range of the manual. Other procedures include fuel filter replacement and inspection of the positive crankcase ventilation hoses.

• Engine mechanical: Compression testing, valve clearance service, injection timing adjustment, idle and maximum speed checks, timing belt replacement, timing gear service, and cylinder head and block overhaul.

• Fuel injection: Injection nozzle removal, disassembly, opening-pressure and spray-pattern tests, and partial internal service of the injection pump.

• Electronic Control Diesel (ECD): Normal- and test-mode trouble-code checks, hand-held tester data, symptom tables, ECU terminal checks, and engine-control wiring diagrams.

• Turbocharger: Troubleshooting, on-vehicle boost checks, removal, disassembly, inspection, reassembly, and installation.

• Cooling and lubrication: Water pump and thermostat service, radiator testing, engine oil pressure checks, and service of the oil pump, cooler, and nozzles.

• Starting and charging: Glow plug system checks, starter disassembly and bench testing, on-vehicle charging checks, and alternator overhaul.

Toyota wrote the diagnostic section for service technicians familiar with engine controls and basic electrical testing.

Cylinder Head, Block, and Timing Gears

Cylinder head service covers warpage checks, valve guides, and valve seats. The block chapter covers pistons, rings, connecting rods, crankshaft bearings, balance shafts, oil clearances, and seals. Assembly drawings identify non-reusable parts, precoated fasteners, seal locations, and torque points.

The head-gasket selection table matches the replacement grade to the largest measured piston protrusion. The timing gear procedures use service bolts to hold spring preload and flag the risk of damaging gear teeth during removal. The turbocharger procedures use alignment marks and warn that tilting the bearing housing during assembly can bend the turbine shaft.

ECD Circuit Testing

The diagnostic charts pair fault codes with connector pinouts and ECU test values so a technician can check the circuit before replacing a sensor. Examples include the ECU terminal map, the crankshaft and engine speed sensor schematic, turbo pressure sensor wiring, and the preheating and spill-control relay diagrams.

Circuit checks also cover coolant, intake air and fuel temperature inputs, throttle position, vehicle speed, starter and first-gear signals, ECU power supplies, and the TE1 and TE2 terminals. Component tests cover the throttle body, timing and spill-control valves, ECD relays, intake constrictor vacuum switching valves, and injection pump correction resistors.

Injection Nozzle and Pump Service

The nozzle chapter covers cleaning, needle and body inspection, opening-pressure adjustment, leakage testing, and reinstallation. The injection pump chapter includes removal and reinstallation, with internal service limited to parts such as the delivery valves, distributor head plugs, timing control valve, and fuel temperature sensor. Full pump bench calibration falls outside that service scope.

Special Tools and Service References

The Preparation section identifies Toyota special service tools and materials. It lists compression gauge attachment 09992-00500, valve clearance tool 09248-64011, diagnosis check wire 09843-18020, and turbocharger pressure gauge 09992-00242. The fuel section calls out injection pump stand set 09241-76022 and pump tool set 09260-54012.

The service tables cover torque, fluid capacities, machining and wear limits, pressure tests, and electrical checks. The repair precautions address vehicle support, battery disconnection, and high-pressure nozzle spray. Vehicle-level engine removal and transmission, axle, steering, brake, suspension, and body repairs require separate service information. Toyota lists the Hilux Electrical Wiring Diagram (EWD307F) separately for full-vehicle wiring.

Compression and Valve Clearance Examples

For warm-engine compression testing at a cranking speed of at least 250 rpm, Toyota gives a minimum of 284 psi (1,961 kPa) and a maximum cylinder-to-cylinder difference of 71 psi (490 kPa).

Cold valve clearance is 0.20–0.30 mm (0.008–0.012 in.) on the intake and 0.25–0.35 mm (0.010–0.014 in.) on the exhaust. The manual also shows how to select replacement shims for clearances outside those ranges.