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