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,
1 1 1, 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
as relevant service manuals to the components and systems in
this engine.
All information contained in thismanual
is the most up-to-date
at 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
mi
TURBOCHARGER SYSTEM
FUEL SYSTEM
COOLING SYSTEM
LUBRICATION SYSTEM
la
STARTING SYSTEM
CHARGING SYSTEM
SERVICE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS
SST AND SSM
0 1994 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be
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
To assist you in finding your way through this manual, the Sec-
tion Title and major heading are given
at the top of every page.
An
INDEX is 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
is 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 a step-by-stepformat:
&
a The illustration shows what to do and where todo it.
a The task heading tells what to do.
a 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 7 (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, 64 N-m)
\
Specification
This format provides the experienced technician with a FAST
TRACK to the information needed. The upper case task head-
ing can be read
at a glance when necessary, and the text below
it provides detailed information. Important specifications and
warnings always stand out in bold type.
REFERENCES
References have been kept to a 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:
a CAUTIONS are presented in bold type, and indicatethere is
a 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 is 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
it is necessary to disconnectthe battery for inspec-
tion or repair, always disconnect the cable from the
negative
(-) terminal which is grounded to the vehi-
cle body.
(c) To prevent damage to the battery terminal post, loos-
en the terminal nut and raise the cable straight up
withouttwisting or prying
it.
(d) Clean the battery terminal posts and cable terminals
with
a shop rag. Do not scrape them with a 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
a hammer to tap the terminal onto the post.
(f) Be sure the cover for the positive
(+) terminal is 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
" 4 " symbol.
Precoated parts
Precoated parts are bolts and nuts, etc. These are coated
with
a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosenedor caused
to move in any way,
it must be recoated with the
specifiedadhesive.

INTRODUCTION - General Repair I nstructions
IN-5
(b) Recoatingof Precoated Parts c
(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.
(c) Precoated parts are indicated in the componentillus-
trations bythe
" *" symbol.
7. When necessary, use a sealer on gaskets toprevent leaks.
8. Carefully observe all specifications for bolt torques.
Always use atorquewrench.
9. 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
is the correct
amperage. DO NOT exceed the rating or
use one of a
lower rating.
11. Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle
at the
proper locations.
(a)
Ifthe vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to en-
sure safety.
(b) After the vehicle is jacked up, be sure to support it on
stands.
It is extremely dangerous to do any work on
the vehicle raisedon
a jack alone, even for a 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 as
sensors or relays. Ifthey are droppedon a hard floor,
they should be replacedand not reused.
WRONG CORRECT
(b) When separating electrical connectors, pull on the
connector itself, notthe wires.
(c) When disconnecting vacuum hoses, pull on the end
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
at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(g) When using
a vacuum gauge, never force the hose on-
to
a connector that is too large. Use a step-down
adapter instead. Once the hose has been stretched,
it
may leak.
13. Tag hoses beforedisconnectingthem:
(a)
When disconnecting vacuum hoses, use tags to iden-
tify how they should be reconnected.
(b) After completing
a 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
F
l PG Formed inPlace Gasket
F L Fusible Link
H AC HighAltitude Compensation
IN Intake (manifold, valve)
LH Left-Hand
01s Oversized
PI
J Pilot Injection Device
RH Right-Hand
SSM Special ServiceMaterials
SST Special ServiceTools
STD Standard
TDC Top Dead Center
U
IS Undersize
VSV Vacuum Switching Valve
w/ With
wlo. Without

ENGINE MECHANICAL
REFER TO 2L . 3L ENGINE REPAIR MANUAL
(Pub
. No . RM123E)
NOTE: The following pages contain only the points which
differ from the above listed manual
.
DESCRIPTION ....................................................
TROUBLESHOOTING ...........................................
Diesel Engine Diagnosis ....................................
Diesel Electrical System Diagnosis
[2L-T Austria]
..............................................
Diesel Electrical System Diagnosis
[2L-T Others]
...............................................
ENGINE.TUNE4.JP ...............................................
.............
INTAKE VENTURI SYSTEM (LN 2L-T only)
COMPRESSION CHECK
.......................................
.......................................
CYLINDER HEAD (2L-T)
CYLINDER BLOCK
...............................................
Page
EM-2
EM-4
EM-4
EM-1
3
EM-16
EM-18
EM-30
EM-33
EM-35
EM-46

EM-2 ENGINE MECHANICAL - Description
DESCRIPTION
The 2L-Tengine is an in-line4-cylinder 2.4 liter OHC engine.
The
3L engine is an in-line4-cylinder 2.8 liter OHC engine.
2 L-T

ENGINE MECHANICAL - Description EM-3
The 2L-T and 3L engines are in-line4-cylinder
engines with the cylinders numbered
1 - 2 - 3 - 4
from the front. The crankshaft
is supported by 5
bearings on the inside of the crankcase. These
bearings are made of aluminum. The crankshaft
is
integrated with 8 weights which are cast along with
it for balancing. Oil holes are built intothe center
of the crankshaft for supplying oil to the connect-
ing rods.
This engine's injection order
is 1 - 3 - 4 - 2.
The cylinder head is made of cast ironwith a cross
flow type intakeand exhaust layout and with swirl
type combustion chambers. The glow plugs are
located inthe combustionchambers.
Exhaust and intake valves are equipped with
.
irregular pitch springs which are capable of follow-
ingthe valves even at highengine speeds.
The camshaft
is driven by the timingbelt. There
are
2 types of camshaft bearing, No. 1 and No. 2.
No. 1 bearing is integrated with the thrust washer.
The camshaft journal
is supported at 5 places be-
tween the valve lifters of each cylinder and on the
cylinder head of front end. Lubrication of the
camshaft journal and cam
is accomplished by oil
being supplied through the oiler port in the No.
1
camshaft journal.
Adjustment of the valve clearance
is done by
means of an outer shim type system, inwhich valve
adjusting shims are located above the valve lifters.
This permits replacement of the shims without
removalof the camshafts.
Pistons are made of highly temperature-resistant
aluminumalloy.
Piston pins are the full-floating type, with the
pins fastened to neither the piston boss nor the*
connecting rods. Instead, snap rings are fitted on
both ends of the pins, preventing the pins from
falling out.
The No.
1 compression ring is made of steel and
the No.
2 compression ring is made of cast iron.
The oil ring
is made of steel. The outer diameter
of each piston ring
is slightly larger than the dia-
meter of the piston and the flexibility of the rings
allows them to hug the cylinder walls when they
are mounted on the piston. Compression rings
No.
1 and No. 2 work to prevent the leakage of
gas from the cylinder and the oil ring works to
scrape oil off the cylinder walls to prevent
it from
enteringthe combustion chamber.
The cylinder block
is made of cast iron. It has 4
cylinders which are approximately
2 times the
length of the piston stroke. The top of each cy-
linder
is closed off by the cylinder head and the
lower end of cylinder becomes the crankcase, in
which the crankshaft
is installed. Inaddition, the
cylinder block contains a water jacket, through
which coolant
is pumpedtocool the cylinders.
The oil pan
is boltedonto the bottom of the cy-
linder block. The oil pan
is an oil reservoir made
of pressed steel sheet.
A dividing plate is included
inside the oil pan to keep sufficient oil inthe bot-
tom of the pan even when the vehicle
is tilted.
This dividing plate also prevents the oil from
makingwaves when the vehicle
is stoppedsuddenly
and thus shifting the oil away from the oil pump
suction pipe.

GENERAL
1. Diesel engine problems are usually caused by the engine or fuel system. The injection pump is very
rarelythe cause of fuel system problems.
2. Before beginning fuel system tests, first check that the engine compression, valve timing and other
majorsystems are within specifications.
' I
PRELIMINARY CHECKS
Before performing fuel system checks, ensure that the engine is in good runningcondition. If neces-
sary, first check the compression, timing and majorcomponentsor systems.
Check the air filter, and clean or replace
it if necessary.
Check that there
is sufficient fuel in the tank.
Check if the fuel
is contaminatedwith gasoline or other foreign elements. Only good-qualitydiesel fuel
should be used.
Bleedair from the system by pumpingthe priming.
Check for water inthe fuel filter and fuel tank, and drain
as necessary.
Ifthe engine will notcrank or if
it cranks slowly, first troubleshoot the electricalsystem.
EM-4
ENGINE MECHANICAL - Troubleshooting(DieselEngineDiagnosis)
TROUBLESHOOTING
Diesel Engine Diagnosis

ENGINE MECHANICAL - Troubleshooting(DieselEngine Diagnosis) EM-5
PRECAUTION:
&
1. The basic troubleshooting procedures for the diesel engine (valve clearance, compression, bearings,
valves, pistons, etc.) are the same checks you would make for gasoline engine.
2.
Repair of the injection pump requires considerable skill and use of aspecial test bench.
ENGINEWILL NOTCRANK
(PossibleCause) (Check Procedure and Correction Method)
1. LOOSE OR CORRODED
BATTERY CABLES
I
Check cables from battery to starter and make nec-
essary repairs.
-
1 2. DISCHARGED BAT-
ENGINE CRANKS SLOWLY-WILL NOTSTART
Check alternator output and drive belt.
If necessary, repair. (See page CH-3)
3. INOPERATIVESTARTER
1
HINT: Minimumcrankingspeed:
Cold 100rpm
Hot 150rpm
Check for batteryvoltage
at starter terminals30
and
50.
Ifokay, see STARTING SYSTEM for repairpro-
cedure.
,
(Possible Cause) (Check Procedure and CorrectionMethod)
Check alternator output and drive belt.
Ifnecessary, repair. (See page CH-3)
1. LOOSE OR CORRODED
BATTERY CABLES Check cables from batterytostarter and make nec-
essary repairs.
7
3. IMPROPER ENGINE OIL i
Check engine oil.
Ifimproper viscosity, drain and refill with oil of vis-
cosity recommended by manufacturer.
(See page
LU-4)

EM-6 ENGINE MECHANICAL
- Troubleshooting(DieselEngine Diagnosis)
-
ENGINE CRANKS NORMALLY BUTWILL NOTSTART
(Possible Cause) (Check Procedureand CorrectionMethod)
Loosen any one injection pipeunion nutfrom
its
nozzle holder.
2. NO FUEL CUT SOLENOID
I OPERATION
Crank engine for about
5 seconds while confirming
that fuel
is being discharged from pipe.
Iffuel
is coming out, begin diagnosis from item 4.
Ifnot, beginfrom item 2.
With starter switchturned ON, check for fuel cut
solenoid operation noise (clickingsound) while re-
peatedly connectingand disconnectingfuel cut
solenoid.
Ifno noise, check ifthere
is batteryvoltage tosole-
noidwhen starter switch
is ON.
Ifbattery voltage
is confirmed, fuel cut solenoid is
faulty and should be replaced. Ifnovoltage, refer
to ELECTRICAL DIAGNOSISand make necessary
repairs.
Disconnect inlet hoses from fuel filter, and feed
clean fuel from separate container directly intofuel
pump.
HINT: When feeding fuel tank directly intopump,
keep container
at same level as vehicle fuel tank.
Ifengine starts, either fuel filter or line between
fuel tank and filter
is clogged and should be repaired
accordingly.
Ifengine
still does not start (nofuel intake),check
fuel line between filter and pump,
Ifnormal, pump
is faulty and should be replaced.
5. INOPERATIVE PRE-HEATING
I OPERATION
4. FUEL LEAKAGE FROM
INJECTION PIPES
With starter switchturned ON and glow plugindi-
cator light illuminated, check that there
is voltage
appliedtoglow plug.
Ifnot, refer to ELECTRICAL DIAGNOSISand re-
pair
as necessary.
Check for loose unions or cracks.
Ifleaking, tighten tostandard torque or, ifnecessary,
replace pipe(s).

ENGINE MECHANICAL - Troubleshooting(DieselEngine Diagnosis) EM-7
6. FAULTY GLOW PLUG
I OPERATION Check glow plugfor continuity.
Ifno continuity,
a brokenwire is indicatedand glow
I plugshould be replaced.
I
1 7. IMPROPER INJECTION TIMING b Check injection timing. (See page EM-24 or 25)
Plungerstroke:
-
2L-T(Austria) Within the marks of belt case
and pumpflange. (See page
EM-24)
2L-T (Others) 0.54
- 0.66 mm
(0.0213 - 0.0260 in.)
3L 0.84
- 0.96 mm
(0.0331
- 0.0378 in.)
Ifnot
as above, injection pump is improperly
adjusted.
Check injection pressure with
a nozzletester.
Opening pressure: 145
- 155kg/cm2
(2,062
- 2,205 psi)
(14,220
- 15,200 kPa)
Ifnot
as above, nozzle adjustment is improper and
pressure should be readjusted.
Ifpressure cannot be adjustedtospecification,
replace injection nozzle.
8. (2L-T)
IMPROPER COLD START
ADVANCE AND FAST
IDLE
Check timer pistonstroke and fast idle lever opening
angle with an injection pump tester when cold start
advance
is operated.

EM-8 ENGINE MECHANICAL
- Troubleshooting(DieselEngine ~iagnosis)
ROUGH IDLE WITH WARM ENGINE
(Possible Cause) (Check Procedureand CorrectionMethod)
1. IMPROPER ADJUSTMENT OF
ACCELERATOR CABLE
I
5. IMPROPER OPERATION OF
INJECTION NOZZLES OR
DELIVERY VALVES
With acceleratorpedal released, check that adjusting
lever
is incontactwith idle speed adjusting screw.
Also check ifacceleratorcable or linkage
is catching
on something.
Ifnecessary, adjust so that lever
is incontact with
screw, or make other requiredrepairs.
3. FUEL LEAKAGE
Refer tostep
7 of ENGINE CRANKS NORMALLY
BUT WILL NOT START, above.
I
-
I
2. IDLE SPEED Check idle speed. (See page EM-27)
Idlespeed: 2L-T 700
- 800 rpm
3L 650
- 750 rpm
HINT: Ifless than standard, idlingwould normally
be rough.
Ifnot
as above, adjust with idle speed adjusting
screw.
Check for leaks
at injection pumpconnections, pump
distributive head bolt, injection nozzlesand delivery
valve holders.
Tighten any loose connectionsto specified torque or
replaceparts
as necessary.
With engine idling, loosen injection pipe to each
cylinder inorder, and check if idle speed changes.
Ifnochange,
a faulty cylinder is indicated.
Check according tofollowing procedure.
Faulty injection nozzle
Check injection nozzlewith
a nozzletester.
Opening pressure: 145
- 155kg/cm2
(2,062
- 2,205 psi)
(14,220
- 15,200 kPa)
Ifnot
as above, nozzle adjustment is improperand
pressure should be readjusted.
Ifpressurecannot be adjusted to specification, re-
place injection nozzle.
Faulty deliveryvalve
Ifinjection pressure
is as specified, delivery valve is
defective and should be replaced.

ENGINE MECHANICAL - Troubleshootina (DieselEnnine Diagnosis) EM-9
)r
ENGINE SUDDENLY STOPS
(PossibleCause) (Check Procedure and CorrectionMethod)
Check tosee ifengine re-startsaccordingtopre-
scribedprocedure.
Ifnot, refer to ENGINE CRANKS NORMALLY BUT
WILLNOT START, above, and repair
as necessary.
Referto ROUGH IDLEWITH WARM ENGINE and
repair accordingly.
3. MALFUNCTION OF FUEL CUT
SOLENOID WILL NOT START, above, and check accordingly.
HINT: Nooperation noise from fuel cut solenoid
may be due to loose electricalconnections, so check
connectors beforeproceedingwith further repairs.
LACK OF POWER
4. NO FUEL INTO INJECTION
PUMP
HINT:
First check that the air cleaner is not clogged & the engine overheating.
Not applicable if the customer desires an output power higher than specified for that vehicle. For ac-
curacy, adjust with
a chassis dynamo.
Refer to step
3 of ENGINE CRANKS NORMALLY
BUT WILL NOT START, above.
(PossibleCause) (CheckProcedure and CorrectionMethod)
Ifnecessary, adjust so that lever
is incontact with
screw, or make other requiredrepairs.
1. IMPROPER ADJUSTMENT OF
ACCELERATOR CABLE
2. INSUFFICIENT MAXIMUM
SPEED
With acceleratorfully depressed, check that adjusting
lever
is incontact with maximum speed adjusting
screw. Also check ifaccelerator cable or linkage
is
catchingon something.
Check maximum,speed. (Seepage EM-27)
Maximumspeed:
2 L-T 4,700
- 4,900 rpm
3L(HongKong, Singapore and Malaysia)
4,300
- 4,500 rpm
3L (Others) 4,500
- 4,700 rpm
If not
as above, adjust with maximum speed adjust-
ing screw.

EM-10 ENGINE MECHANICAL
- Troubleshootinn (DieselEngine Diaanosis)
1 5. CLOGGED FUEL FILTER
3. INTERCHANGED OVERFLOW
SCREW (OUT) AND INLET
(NO MARK) FITTING
Disconnect inlet hose tofuel filter, and feed clean
fuel directly intopump.
HINT: When feedingfuel directly intopump, keep
container at same level as vehicle fuel tank.
Ifengine condition improves, fuel filter
is clogged
and should be replaced.
Ifno increase inengine condition after replacingfuel
filter, check priming pump (handpump) or perform
other necessary repairs.
HINT: Overflow screw
is marked "OUT" and has
an inner jet. Although bothfittings are same size,
they must not be interchanged.
Refertostep 3 of ROUGH IDLEWITH WARM
ENGINE.
16. IMPROPER INJECTION TIMING I
EXCESSIVE EXHAUST SMOKE
Referto step 7 of ENGINE CRANKS NORMALLY
BUTWILL NOT START.
7. FAULTY INJEC
HINT:
Check that the air cleaner is not clogged.
Referto step
9 of ENGINE CRANKS NORMALLY
BUTWILL NOT START.
Check with the customer whether or notoil consumption has been excessive.
(Possible Cause) (Check Procedureand Correction Method)
I 1. IMPROPER IN-I
1 2. CLOGGED FUEL FILTER
I
Refer tostep 7 of ENGINE CRANKS NORMALLY
BUTWILL NOT START.
HINT: Black smoke indicatesadvanced timing
while white smoke indicates retardedtiming.
Adjustments should be made accordingly.
Referto step
5 of LACK OF POWER.
HINT: At highspeed (2,000
- 3,000 rpm), a
cloggedfilter tends to make exhaust smoke white.
HINT: Excessiveexhaust smoke
is often caused by