Toyota 2L-T Operating instructions

FOREWORD

This supplement has been prepared to provide information

covering general service repairs for the 2L-T and 3L engines

mounted on the TOYOTA LAND CRUISER, HILUX, and

4RUNNER.

Applicable models:

LJ70, 72, 73, 77, 79 series

LN106,

130, 135series

For basic engine service repair, refer to the following repair

manual.

2L, 3LEngine Repair Manual (Pub. No. RM123E)

Please note that the publications below have also been prepared

relevant service manuals to the components and systems in

this engine.

All information contained in thismanual

the most up-to-date

the time of publication. However, specifications and proce-

dures are subjecttochangewithout notice.

TOYOTA MOTOR CORPORATION

TOYOTA

2L-T, 3L ENGINE

REPAIR MANUAL

SUPPLEMENT

INTRODUCTION

ENGINE MECHANICAL

TURBOCHARGER SYSTEM

FUEL SYSTEM

COOLING SYSTEM

LUBRICATION SYSTEM

STARTING SYSTEM

CHARGING SYSTEM

SERVICE SPECIFICATIONS

STANDARD BOLT TORQUE SPECIFICATIONS

SST AND SSM

1994

TOYOTA MOTOR CORPORATION

reproduced or copied, in whole or in part,

without the written permission of Toyota

Motor Corporation.

INTRODUCTION

Page

HOW TO USE THIS MANUAL

..................................

IN-2

IDENTIFICATIONINFORMATION

..............................

IN-4

GENERAL REPAIR INSTRUCTIONS

...........................

IN-4

ABBREVIATIONS USED IN THIS MANUAL

.................

IN-7

IN-2 INTRODUCTION

How to Use This Manual

HOW TO

USE

THIS

MANUAL

assist

you in finding your way through this manual, the Sec-

tion Title and major heading are given

the top of every page.

INDEX

provided on the 1st page of each section to guide

you to the item to be repaired.

Atthe beginning of each section,

PRECAUTIONS

are given that

pertainto

all

repair operationscontained inthat section.

Read theseprecautions before starting any repair task,

TROUBLESHOOTING

tables are included for each system to

help you diagnose the problem and find the cause. The repair

for each possible cause

referenced in the remedy column to

quickly lead you to the solution.

REPAIR PROCEDURES

Most repair operations begin with an overview illustration. It

identifies the componentsand shows how the partsfit together.

Example:

kg-cm (ft-lb,

~.rn)]

Specifiedtorque

Non-reusablepart

~~2111

INTRODUCTION

Howto Use This Manual

IN-3

The proceduresare presentedin

step-by-stepformat:

The illustration shows

what

to do and

where

todo

it.

The task heading tells

what

to do.

The detailed text tells

how

to perform the task and gives

other information such as specificationsand warnings.

Example:

illustration:

what to do and where

Task heading: what to do

REMOVE

CRANKSHAFT

PULLEY

UsingSST, remove the pulley.

SST

09213-6001

(09213-00060)

/'.

Set part No.

Componentpart No.

Detailed text: how to do task

Install the four injection nozzles.

Torque:

650

kg-cm

(47

ft-lb,

N-m)

Specification

This format provides the experienced technician with

FAST

TRACK to the information needed. The upper case task head-

ing can be read

glance when necessary, and the text below

provides detailed information. Important specifications and

warnings always stand out in bold type.

REFERENCES

References have been kept to

minimum. However; when they

are required, you are given the page to refer to.

SPECIFICATIONS

Specifications are presented in bold type throughout the text

where needed. You never have to leave the procedure to look

up your specifications. They are also found inAppendix A for

quick reference.

CAUTIONS, NOTICES, HINTS:

CAUTIONS are presented in bold type, and indicatethere

possibility of injury to you or other people.

NOTICES are also presented in bold type, and indicate the

possibility of damage to the components being repaired.

HINTS are separated from the text butdo notappear inbold.

They provide additional information to help you efficiently

perform the repair.

IN-4 INTRODUCTION

Identification Information. General Re~airInstructions

Seal

Lock

Adhesive

IN0036

IDENTIFICATION INFORMATION

ENGINE SERIAL NUMBER

The engine serial number

stamped on the left side of the

cylinder block.

GENERAL REPAIR INSTRUCTIONS

Use fender,

seat

and floor covers to keep the vehicle clean

and prevent damage.

During disassembly, keep parts in order to facilitate reas-

sembly.

Observethe following.

(a)

Before performing electrical work, disconnect the

negative

(-)

cablefrom the battery terminal.

(b) If

necessary to disconnectthe battery for inspec-

tion or repair, always disconnect the cable from the

negative

(-)

terminal which

grounded to the vehi-

cle body.

en the terminal nut and raise the cable straight up

withouttwisting or prying

it.

(d) Clean the battery terminal posts and cable terminals

with

shop rag. Do not scrape them with

file or

other abrasive object.

(e) Install the cable terminal to the battery post with the

nut loose, and tighten the nut after installation. Do

not use

hammer to tap the terminal onto the post.

(f) Be sure the cover for the positive

(+)

terminal

pro-

perly inplace.

Check hose and wiring connectors to make sure that they

are.secure and correct.

Non-reusableparts

(a)

Always replace cotter pins, gaskets, O-rings, oil seals,

etc. with new ones.

(b) Non-reusable parts are indicated in the component

illustrations bythe

symbol.

Precoated parts

Precoated parts are bolts and nuts, etc. These are coated

with

seal lock adhesive

the factory.

(a)

precoated part

retightened, loosenedor caused

to move in any way,

must be recoated with the

specifiedadhesive.

INTRODUCTION

General Repair

nstructions

IN-5

(b) Recoatingof Precoated Parts

(1) Clean off the old adhesive from the part's

threads.

(2)

Dry with compressed air.

(3)

Apply the specified seal lock adhesive to the

part's threads.

trations bythe

symbol.

When necessary, use

sealer on gaskets toprevent leaks.

Carefully observe

all

specifications for bolt torques.

Always use atorquewrench.

Use of special service tools (SST) and special service

materials (SSM) may be required, depending on the nature

of the repair. Be sure to use SST and SSM where specified

and follow the proper work procedure. A

list

of SST and

SSM can be foundatthe back of this manual.

10. When replacing fuses, be sure the new fuse

the correct

amperage. DO NOT exceed the rating or

use

one of

lower rating.

11. Care must be taken when jacking up and supporting the

vehicle. Be sure to lift and support the vehicle

the

proper locations.

(a)

Ifthe vehicle is to be jacked up only

the front or

rear end, be sure to block the wheels in order to en-

sure safety.

(b) After the vehicle

jacked up, be sure to support

stands.

extremely dangerous to do any work on

the vehicle raisedon

jack alone, even for

small job

that can be finished quickly.

12. Observe the following precautions to avoid damaging the

parts:

(a)

Be careful not to drop electricalcomponents, such

sensors or relays. Ifthey are droppedon

hard floor,

they should be replacedand not reused.

WRONG CORRECT

(b) When separating electrical connectors, pull on the

connector itself, notthe wires.

of the hose, not the middle.

IN-6 INTRODUCTION

General Re~airInstructions

Example

(d) When steam cleaning an engine, protect the distribu-

tor, coil, air filter, and injection pump from water.

(e) Never use an impact wrench to remove or install

temp. switchesor temp. sensors.

(f) When checking continuity

the wire connector, in-

sert the tester probe carefully to prevent terminals

from bending.

(g) When using

vacuum gauge, never force the hose on-

connector that

too large.

Use

step-down

adapter instead. Once the hose has been stretched,

may leak.

13.

Tag hoses beforedisconnectingthem:

(a)

When disconnecting vacuum hoses, use tags to iden-

tify how they should be reconnected.

(b) After completing

job, double check that the vacu-

um hoses are properly connected. A label under the

hood shows the proper layout.

INTRODUCTION

Abbreviations Used inThis Manual IN-7

ABBREVIATIONS USED IN

THIS

MANUAL,

AIC Air Conditioner

ACSD Automatic ColdStart Device

Approx. Approximately

EGR ExhaustGas Recirculation

EVRV Electronic Vacuum RegulatingValve

EX Exhaust (manifold, valve)

Ex. Except

PG Formed inPlace Gasket

L Fusible Link

AC HighAltitude Compensation

IN Intake (manifold, valve)

LH Left-Hand

01s

Oversized

Pilot Injection Device

RH Right-Hand

SSM Special ServiceMaterials

SST Special ServiceTools

STD Standard

TDC Top Dead Center

IS Undersize

VSV Vacuum Switching Valve

w/ With

wlo. Without

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