🏷️ Basic Information Identification Make: Toyota Model: Hilux Model Series: KZN165 Series Engine Code: 1KZ-TE Production Year: 1999 👋 Introduction Market Position Market Position: The Toyota Hilux is a globally recognized and highly respected light commercial vehicle, known for its ruggedness, reliability, and off-road capability. This manual caters to owners and technicians working on the 1999 model year equipped with the 1KZ-TE engine, a robust and popular turbodiesel powerplant. Competitive Analysis Competitive Analysis: In 1999, the Hilux competed with other mid-size pickup trucks like the Nissan D22 Navara/Frontier, Mitsubishi Triton/L200, and Ford Ranger. The 1KZ-TE engine offered a balance of performance and fuel efficiency, making it a strong contender in its class. Key Features Key Features: This manual provides factory-level detail for DIY repairs, enabling significant cost savings. Its digital format ensures instant access and easy navigation, supporting efficient diagnostics and maintenance. Target Audience Target Audience: Professional mechanics, DIY enthusiasts, and workshop owners looking for authoritative information on the Toyota Hilux 1KZ-TE engine. 📋 Manual Details Coverage Areas Coverage Areas: Toyota Hilux 1KZ-TE Engine Page Count Page Count: 407 Manual Type Manual Type: Factory Service and Repair Manual Language Language: English Format Format: PDF Requirements Software Requirements: Adobe Acrobat Reader or compatible PDF viewer Compatibility Operating Systems: Windows, macOS, Linux, iOS, Android File Format Distribution Method: Instant Download 📖 Manual Coverage Systems Covered Systems Covered: Engine Mechanical, Turbocharging, Emission Control, Electronic Control Diesel (ECD), Engine Fuel System, Cooling System, Lubrication System, Starting System, Charging System Engine Mechanical Subsystems: Cylinder block, cylinder head, pistons, connecting rods, crankshaft, camshaft, valve train, timing system, engine lubrication, engine cooling. Turbo Charging Subsystems: Turbocharger unit, intercooler, boost pressure control, exhaust manifold, wastegate or VGT actuator. Emission Control Subsystems: Exhaust Gas Recirculation (EGR) system, exhaust components, catalytic converter (if fitted). Electronic Control Diesel Subsystems: ECU (Engine Control Unit) operation, sensors (crankshaft position, camshaft position, temperature, MAP), actuators (injector solenoids, fuel cut-off), diagnostic trouble codes (DTCs), wiring diagrams. Engine Fuel Subsystems: Fuel tank, fuel lines, fuel filter, injection pump, injectors, glow plug system, fuel priming. Cooling Subsystems: Radiator, fan, water pump, thermostat, coolant passages, hoses, coolant reservoir. Lubrication Subsystems: Oil pump, oil pan, oil filter, oil passages, oil cooler (if equipped). Starting Subsystems: Starter motor, battery, ignition switch, starter solenoid, wiring. Charging Subsystems: Alternator, voltage regulator, battery, wiring. Procedures Included Procedures Included: Repair, Operation, Diagnostics, Special Repair Instructions, Maintenance Instructions, Installation and Adjustment, Assembly and Disassembly, Troubleshooting Diagnostics Procedures: Step-by-step diagnostic routines for common engine faults, using scan tools (if applicable for the era), multimeter tests, and visual inspections. Includes symptom-to-cause troubleshooting charts. Repair Procedures: Detailed, illustrated procedures for disassembling, inspecting, repairing, and reassembling all engine components. Covers torque specifications, clearances, and mating surfaces. Maintenance Procedures: Scheduled maintenance tasks, fluid changes, filter replacements, belt adjustments, and general upkeep. Installation Adjustment Procedures: Correct installation and adjustment of components such as timing belt, injectors, fuel pump, and turbocharger. Technical Depth Technical Depth: Comprehensive, including detailed schematics, diagrams, and technical specifications for in-depth repair and maintenance. Technical Depth Detail: The manual provides specific torque values for all fasteners, critical clearances for engine components (e.g., piston ring gap, bearing clearances), diagnostic voltage and resistance values, and detailed engine timing procedures. It's designed for effective engine rebuilding and complex troubleshooting. 📊 Manual Specifications File Format File Format: PDF Features: Printable, searchable text, bookmarks, cross-links for easy navigation. Allows copying and pasting of information. Print Quality Print Quality: High-resolution, allowing for clear printing of all text, illustrations, schematics, and diagrams. Binding Type Binding Type: Digital (PDF) - Not applicable to physical binding. Paper Type Paper Type: Digital (PDF) - Not applicable to physical paper type. ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-Cylinder Turbocharged Diesel Engine Code: 1KZ-TE Performance Displacement: 3.0 Liters (2982 cc) Bore X Stroke: 96.0 mm x 103.0 mm (approx.) Compression Ratio: 21.2:1 (approx.) Horsepower: 125 PS (92 kW) at 3600 rpm (estimated for 1999 model) Torque: 29.0 kgf·m (284 N·m; 209 lb·ft) at 2000 rpm (estimated for 1999 model) Fuel System Fuel System Type: Electronic Control Diesel (ECD) with indirect injection Injection Pump: Bosch VE type rotary distributor, electronically controlled Turbocharger: Variable Geometry Turbocharger (VGT) or Wastegate Turbocharger depending on specific application within the KZN165 series. Glow Plugs: Pre-heating system for cold starts. Engine Block Material Engine Block Material: Cast Iron Cylinder Head Material Cylinder Head Material: Aluminum Alloy 🔧 Transmission Standard Standard Transmission: 5-Speed Manual Transmission (likely R151F or similar) Optional Optional Transmission: 4-Speed Automatic Transmission (likely A340F or similar) Features Transfer Case: Part-time 4WD system with a 2-speed transfer case and locking center differential on some variants. 📐 Dimensions Exterior Body Styles Available: Single Cab, Extra Cab, Double Cab configurations (though manual specifically covers the engine for these models) Weights Curb Weight: Varies by body style and configuration, typically ranging from 1700-2000 kg (approx.) 🛡️ Safety...