Harry Workshop Manual
Harry
2004 Toyota Hilux SR5 · KZN165R · 1KZ-TE turbo diesel
- Drivetrain
- 4x4 dual cab
- Fuel
- Diesel
- Odometer
- 357,000 km last service reference
- Source
- HWM-001 v2.0 Foundation Edition
Harry is built around reliability before performance. Every modification must improve reliability, touring capability, comfort or serviceability.
Current Odometer363,000 km
Next Service360,000 km
Sections10
Generated 30 June 2026, 6:06 am
Vehicle Profile
| Field | Value |
|---|---|
| Name | Harry |
| Model | Toyota Hilux |
| Year | 2004 |
| Trim | SR5 |
| Chassis code | KZN165R |
| Engine | 1KZ-TE turbo diesel |
| Drivetrain | 4x4 dual cab |
| Fuel | Diesel |
| Odometer | 357,000 km last service reference |
| Home base | HWM-001 v2.0 Foundation Edition |
| Notes | Harry is built around reliability before performance. Every modification must improve reliability, touring capability, comfort or serviceability. |
Fluids & Capacities
| System | Specification | Capacity | Current product | Interval | Notes |
|---|---|---|---|---|---|
| Engine oil | Penrite Enviro+ DP 5W-40 Full Synthetic | 6.5 L with filter | Penrite Enviro+ DP 5W-40 | 5,000-7,500 km from manual; 6,000 km workbook cycle | Sump drain torque: 39 N.m. |
| Manual trans (R151F) | Penrite Pro Gear 75W-85 Full Synthetic | Approx. 2.7 L | Penrite Pro Gear 75W-85 | 40,000 km or sooner after water crossings | Fill/drain torque: approx. 49 N.m. |
| Transfer case | Penrite Pro Gear 75W-90 Full Synthetic | Approx. 1.5 L | Penrite Pro Gear 75W-90 | 40,000 km or sooner after water crossings | Fill/drain torque: approx. 49 N.m. |
| Front diff | Penrite Pro Gear 75W-90 Full Synthetic GL-5 | Approx. 1.6 L | Penrite Pro Gear 75W-90 | 40,000 km or sooner after water crossings | Drain torque: approx. 49 N.m. |
| Rear diff (ARB Locker) | Penrite Pro Gear 75W-90 Full Synthetic non-LSD | Approx. 2.8 L | Penrite Pro Gear 75W-90 | 40,000 km or sooner after water crossings | ARB lockers do not require LSD oil. Drain torque: approx. 49 N.m. |
| Coolant | Toyota Super Long Life Coolant Pink | Approx. 9 L | Toyota Super Long Life Coolant | Inspect every service; workbook 48,000 km cooling service | Premixed or 50% concentrate. |
| Brake and clutch fluid | DOT 4 | Penrite Super DOT 4 recommended | Inspect weekly and at service intervals | Record flush date once completed. | |
| Power steering | ATF Dexron II/III | Check weekly / pre-trip | Check level with engine idling. |
Service History
| Date | Odometer | System | Work completed | Parts / fluids | Next due | Notes |
|---|---|---|---|---|---|---|
| 2026-06-01 | Driveline | Major driveline service | Engine oil + Terrain Tamer oil filter; gearbox: Penrite Pro Gear 75W-85; transfer: Penrite Pro Gear 75W-90; front and rear diffs: Penrite Pro Gear 75W-90 | Check upcoming maintenance schedule | Engine oil accidentally overfilled; adjust to FULL mark before further driving. | |
| 2026-06-27 | 363,000 | Transmission / transfer / diffs | Changed transmission, differential and transfer oils | Penrite Pro Gear 75W-85 and Penrite Pro Gear 75W-90 | 369,000 km 12,000 km service | Recorded in maintenance workbook. |
Parts Catalogue
| Category | Part | Part number | Supplier | Status | Notes |
|---|---|---|---|---|---|
| Service | Terrain Tamer oil filter | To confirm | Terrain Tamer | Used June 2026 | Record exact part number from packaging or invoice. |
| Engine | Timing belt kit | To confirm | Major diesel service item | Includes timing belt, idler and tensioner. Replace every 150,000 km major service. | |
| Cooling | Water pump | To confirm | Inspect / replace if required | Inspect during timing belt major service. | |
| Fuel | Diesel fuel filter | To confirm | 96,000 km item / carry spare | Replace at major diesel interval and keep touring spare. | |
| Belts | Accessory / drive belts | To confirm | Inspect / replace | Inspect every 24,000 km; replace during 150,000 km major service. |
Modification Register
| Date | Area | Modification | Reason | Parts used | Status | Notes |
|---|---|---|---|---|---|---|
| 2026-06-01 | Engine | HPD top-mount intercooler and 3-inch turbo-back exhaust | Current known specification from foundation manual | HPD intercooler; 3-inch exhaust | Fitted | Add tuning settings, EGT targets, cooling upgrades and future work. |
| 2026-06-01 | Drivetrain | ARB front and rear air lockers | Touring capability and traction | ARB air lockers | Fitted | Locker maintenance to be documented. Rear diff oil is non-LSD. |
| 2026-06-01 | Suspension | Koni shocks and Dobinson rear leaf springs | Touring load control and ride quality | Koni shocks; Dobinson rear leaf springs | Fitted | Add ride heights, alignment records, torque values and bushing notes. |
| 2026-06-01 | Audio | Helix M Four DSP amplifier and Morel front speakers | Comfort and cabin audio quality | Helix M Four DSP; Morel front speakers | Fitted | Add DSP configuration, crossover and EQ settings. |
| 2026-06-01 | Electrical | Touring electrical system with lithium auxiliary battery | Touring capability and serviceability | Lithium auxiliary battery system | Fitted | Add Redarc, Victron, wiring diagrams and fuse map. |
Torque Specifications
| Assembly | Fastener | Torque | Notes |
|---|---|---|---|
| Engine | Sump drain plug | 39 N.m | From Fluids & Torque workbook sheet. |
| Manual trans (R151F) | Fill / drain plugs | Approx. 49 N.m | From Fluids & Torque workbook sheet. |
| Transfer case | Fill / drain plugs | Approx. 49 N.m | From Fluids & Torque workbook sheet. |
| Front diff | Drain plug | Approx. 49 N.m | From Fluids & Torque workbook sheet. |
| Rear diff | Drain plug | Approx. 49 N.m | From Fluids & Torque workbook sheet. |
| Wheels | Wheel nuts | 131 N.m | Recheck after wheel removal and rough-road driving. |
Timing Belt Tracking
| Last changed date | Last changed odometer | Interval km | Interval years | Next due odometer | Next due date | Notes |
|---|---|---|---|---|---|---|
| 150,000 | Record the confirmed timing belt change date and odometer. The 1KZ-TE major diesel schedule references a 150,000 km timing belt interval. |
Touring Checklist
| Complete | Section | Item | Detail |
|---|---|---|---|
| No | Under-Bonnet | Engine oil level and leaks | |
| No | Under-Bonnet | Coolant level and hose condition | |
| No | Under-Bonnet | Brake and clutch fluid | |
| No | Under-Bonnet | Power steering fluid | |
| No | Under-Bonnet | Drive belts tension/condition | |
| No | Under-Bonnet | Battery terminals and hold-down | |
| No | Undercarriage | Grease U-joints/slip yokes | |
| No | Undercarriage | Check diff/transfer/gearbox for leaks | |
| No | Undercarriage | Shock absorbers and bushes | |
| No | Tyres/Wheels | Tyre pressures including spare | |
| No | Tyres/Wheels | Tread and sidewall condition | |
| No | Electrical | All lights, indicators and horn | |
| No | Electrical | Trailer plug function | |
| No | Cabin & Tools | Spare tyre, jack and wheel brace | |
| No | Cabin & Tools | Compressor and tyre repair kit | |
| No | Cabin & Tools | Basic spares | Belts, filters and fuses. |
| No | Safety | First-aid kit, water and PLB/EPIRB | |
| No | Recovery | Recovery strap/shackles and shovel |
Timing Belt & Major Diesel Checklist
| Complete | Section | Item | Detail |
|---|---|---|---|
| No | Major Diesel | Replace timing belt (1KZ-TE) | |
| No | Major Diesel | Replace idler and tensioner | |
| No | Major Diesel | Inspect/replace water pump | |
| No | Major Diesel | Replace accessory/drive belts | |
| No | Major Diesel | Inspect cam and crank seals | |
| No | Cooling | Cooling system drain/flush/refill | Toyota Red 50%. |
| No | Cooling | Inspect radiator cap and thermostat | |
| No | Engine | Inspect turbo hoses and clamps | Boost/EGT scan if available. |
| No | Mounts | Check engine/gearbox mounts | |
| No | Front hubs | Inspect front hub seals and wheel bearings | Check play and leaks. |
| No | Leaks | Check for oil leaks | Rear of engine area noted in workbook. |
| No | Road test | Verify temps and boost under load | |
| No | Records | Log service and reset timing belt indicator | If fitted. |
Lessons Learned
| Date | Context | Lesson | Action | Tags |
|---|---|---|---|---|
| 2026-06-01 | Driveline oil selection | ARB lockers do not require LSD oil. | Use non-LSD Penrite Pro Gear 75W-90 in rear diff unless future hardware changes require otherwise. | diffs, lockers, fluids |
| 2026-06-01 | R151F gearbox | Penrite 75W-85 provides excellent R151F shift quality. | Keep Penrite Pro Gear 75W-85 as preferred manual gearbox oil. | gearbox, fluids |
| 2026-06-01 | Build philosophy | Reliability is always prioritised over maximum output. | Screen every change against reliability, touring capability, comfort and serviceability. | philosophy, modifications |
| 2026-06-01 | Workshop process | Every modification should be documented. | Record date, reason, parts, supplier, cost and lessons learned for each modification. | process, documentation |
| 2026-06-01 | June 2026 service | Engine oil was accidentally overfilled. | Adjust to FULL mark before further driving and record exact fill quantity next service. | engine, service |
Document Library
| Title | Type | Source | Status | File link | Notes |
|---|---|---|---|---|---|
| HWM-001 Harry Workshop Manual v2.0 Foundation | DOCX | Imported from /Users/adso/Downloads | Imported | /documents/HWM-001_Harry_Workshop_Manual_v2.0_Foundation.docx | Foundation manual created June 2026. Revision 2.0 by Adso & ChatGPT. |
| HiLux 1KZTE Maintenance Workbook Updated | XLSX | Imported from /Users/adso/Downloads | Imported | /documents/HiLux_1KZTE_Maintenance_Workbook_Updated.xlsx | Workbook sheets imported into service history, maintenance schedule, fluids, torque and touring checklist. |