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2H
Repair manual
Toyota 2H Repair Manual
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Repair manual
(338 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Engine Serial Number
General Repair Instructions
Engine Mechanical: Table of Contents
Diesel Engine Diagnosis
Preliminary Checks
Engine will Not Crank
Engine Cranks Slowly - will Not Start
Engine Cranks Normally but will Not Start
Rough Idle with Warm Engine
Engine Suddenly Stops
Lack of Power
Excessive Exhaust Smoke
Excessive Fuel Consumption
Engine Noise When Warm
Engine will Not Return to Idle
Engine will Not Shut off with Stop Button or Key
Diesel Electrical System Diagnosis
Pre-Heating System (Super Glow Type)
Pre-Heating System: Inspect Power Supply Section
Inspect Control Section
Turbocharger Diagnosis
Insufficient Acceleration, Lack of Power or Excessive Fuel Consumption
Abnormal Noise
Excessive Oil Consumption or White Exhaust
Turbocharger Electrical System Diagnosis
Troubleshooting of Turbocharger Indicator Light and Warning Light Operation
Engine Tune up
Cleaning of Air Filter
Inspection of Alternater Drive Belt
Inspection of Injection Nozzles
Adjustment of Valve Clearances
Adjustment of Injection Timing
Adjustment of Idle Speed and Maximum Speed
Adjustment of Idle Speed and Maximum Speed (2H A/T and 12H-T)
Adjustment of Power Steering Idle-Up Setting Speed
Adjustment of Air Conditioner Idle-Up Setting Speed (2H M/T)
Adjustment of Air Conditioner Idle-Up Setting Speed (2H A/T and 12H-T)
Inspection of Intake Shutter (2H A/T)
Inspection of Intake Shutter (2H-T)
Compression Check (2H)
Compression Check (12H-T)
Turbocharger (12H-T)
On-Vehicle Inspection of Turbocharger
Inspect Intake Air System
Inspect Exhaust System
Inspect Turbocharger Pressure
Removal of Turbocharger
Remove PCV Pipe
Remove Intake Air Connector
Remove Intake Pipe
Remove Heat Insulators
Remove Oil Pipe
Remove Turbine Outlet Elbow
Inspection of Turbocharger
Inspect Impeller Wheel Rotation
Inspect Axial Play of Impeller Wheel
Installation of Turbocharger
Install Turbocharger
Install Turbocharger Stay
Install Intake Pipe
Install Intake Air Connector
Install PCV Pipe
Cylinder Head: Components
Removal of Cylinder Head (2H)
Remove Glow Plugs
Remove Fuel Filter Assembly
Remove Intake Manifold
Remove Exhaust Manifolds
Separate Exhaust Manifolds
Remove Water Outlet Assembly
Remove Cylinder Head Cover
Remove Valve Rocker Shaft Assembly
Remove Push Rods
Remove Cylinder Head
Removal of Cylinder Head (12H-T)
Disassembly of Cylinder Head
Remove Valves
Remove Combustion Chambers (2H)
Inspection, Cleaning and Repair of Cylinder Head Components
Clean Top of Piston and Top of Block
Remove Gasket Material
Clean Combustion Chambers
Inspect Cylinder Head for Flatness
Inspect Cylinder Head for Cracks
Clean Valves
Inspect Valve Stem and Valve Guide Bushing
Inspect and Grind Valves
Inspect and Clean Valve Seats
Inspect Valve Springs
Inspect Rocker Arm and Shaft
Inspect Push Rods
Inspect Intake and Exhaust Manifolds
Assembly of Cylinder Head
Install Combustion Chambers
Install Valves
Installation of Cylinder Head (2H)
Install Edic Motor
Installation of Cylinder Head (12H-T)
Timing Gears and Camshaft: Components
Removal of Timing Gears and Camshaft
Remove Crankshaft Pulley
Remove Oil Pipe (12H-T)
Remove Timing Gear Cover
Check Backlash of Automatic Timer Drive Gear and Camshaft Timing Gear
Remove Automatic Timer
Remove Camshaft Timing Gear and Camshaft Assembly
Remove Crankshaft Timing Gear
Inspection of Timing Gears and Camshaft
Inspect Camshaft
Inspect Idle Gears
Inspect Valve Lifters
Replacement of Camshaft (or Camshaft Timing Gear)
Remove Camshaft
Install New Camshaft
Replacement of Automatic Timer Drive Gear (12H-T)
Remove Drive Gear
Install New Drive Gear
Replacement of Crankshaft Front Oil Seal
Installation of Timing Gears and Camshaft
Install Timing Gear Cover
Cylinder Block: Components
Disassembly of Cylinder Block
Check Connecting Rod Thrust Clearance
Remove Connecting Rod Caps and Check Oil Clearance
Remove Piston and Connecting Rod Assemblies
Check Crankshaft Thrust Clearance
Remove Main Bearing Caps and Check Oil Clearance
Remove Crankshaft
Inspection of Cylinder Block
Inspect Cylinder Bore Diameter
Remove Cylinder Ridge
Disassembly of Piston and Connecting Rod Assemblies
Inspection of Piston and Connecting Rod Assemblies
Clean Piston
Inspect Piston Diameter and Oil Clearance
Inspect Clearance between Wall of Piston Ring Groove and New Piston Ring
Inspect Piston Ring End Gap
Check Piston Pin Fit
Inspect Connecting Rods
Replacement of Connecting Rod Bushings
Remove Connecting Rod Bushings
Install New Connecting Rod Bushing
Hone Connecting Rod Bushing and Check Piston Pin Fit in Connecting Rod
Boring of Cylinders
Keep Oversized Piston
Calculate Amount to Bore Cylinder
Bore and Hone Cylinders to Calculated Dimensions
Inspection and Repair of Crankshaft
Inspect Crankshaft for Runout
Inspect Main Journals and Crank Pins
Inspection and Repair of Camshaft Bearing and Camshaft
Inspect Camshaft Oil Clearance
Replace Camshaft Bearings
Inspect Valve Lifter Oil Clearance
Inspection of Valve Lifter Bores
Replacement of Crankshaft Rear Oil Seal
Assembly of Piston and Connecting Rod Assemblies
Install Bearings
Assembly of Cylinder Block
Install Main Bearings
Install Main Bearing Caps and Lower Thrust Washers
Install Piston and Connecting Rod Assemblies
Install Connecting Rod Caps
Install Rear Oil Seal Retainer
Install Rear End Plate
Install Flywheel
Fuel System: Table of Contents
Replacement of Fuel Filter
Injection Nozzles (2H)
Removal and Test of Injection Nozzles
Remove Injection Pipes
Remove Nozzle Leakage Pipe
Remove Injection Nozzles
Injection Pressure Test
Leakage Test
Spray Pattern Test
Injection Nozzles: Components
Disassembly, Cleaning and Test of Injection Nozzle
Nozzle Cleaning
Sinking Test
Assembly of Injection Nozzles
Installation of Injection Nozzles
Remove Injection Pipes/Remove Injection Nozzles
Leakage Test/Spray Pattern Test
Injection Nozzles (12H-T): Components
Assembly of Injection Nozzles/Installation of Injection Nozzles
Fuel Feed Pump
Removal and Test of Fuel Feed Pump
Disconnect Inlet and Outlet Pipes from Feed Pump
Remove Feed Pump from Injection Pump
Suction Test
Discharge Test
Fuel Feed Pump: Components
Disassembly of Fuel Feed Pump
Remove Priming Pump and Check Valves
Remove Feed Pump Piston
Remove Feed Pump Tappet
Inspection of Fuel Feed Pump
Inspect Priming Pump
Install Feed Pump Piston
Install Priming Pump and Check Valves
Installation of Fuel Feed Pump
Install Inlet and Outlet Fuel Pipes
Removal of Automatic Timer
Automatic Timer Components
Disassembly of Automatic Timer
Check Thrush Clearance of Driver Gear
Disassemble Automatic Timer
Inspection of Automatic Timer
Inspect Timer Springs
Assembly of Automatic Timer
Check Thrust Clearance of Drive Gear
Adjustment of Automatic Timer
Installation of Automatic Timer
Removal of Injection Pump
Remove Injection Pump
Injection Pump Components
Disassembly of Injection Pump
Check Thrust Clearance of Full Stop Cam
Disassembly Full Load Stopper Housing Assembly
Remove Governor Cover Assembly
Check Thrust Clearance of Steering Lever
Check Thrust Clearance of Cam Plate
Disassemble Governor Cover Assembly
Remove Supporting Levers and Slider
Remote Floating Lever Assembly
Check Thrust Clearance of Floating Arm
Disassemble Floating Lever Assembly
Remove Shackle and Stopper Arm Assembly
Check Fitting Dimensions of Sliding Weight Shaft
Remove Sliding Weight Shaft
Remove Guide Bushings
Check Thrust Clearance of Flyweight
Disassemble Flyweight Assembly
Check Thrust Clearance of Stopper Arm
Remove Stop Lever and Stopper Arm
Disassembly of Pump Body
Remove Pump Cover
Install SST to Tappet Service Holes
Check Thrust Clearance of Camshaft
Remove Plate Plugs
Remove Camshaft and Governor Housing
Check Sliding Resistance of Control Rack
Remove Tappets, Plungers and Pinions
Remove Control Rack
Remove Delivery Valves and Pump Cylinders
Inspection Injection Pump
Inspect Delivery Valves
Inspect Pump Plungers
Inspect Control Rack and Pinion
Inspect Springs
Inspect Tappets
Inspect High Altitude Compensator
Inspect Boost Compensator
Replacement of Bearings and Oil Seals
Replace Bearing of Speed Control Screw
Replace Oil Seal of Lever Shaft
Assembly of Injection Pump
Assembly of Pump Body
Install Pump Cylinders and Delivery Valves
Install Control Rack and Pinions
Install Plungers and Tappets
Install Governor Housing and Camshaft
Install Plate Plugs
Remove SST from Tappet Service Holes
Install Pump Cover
Adjustment of Pump Body
Pre-Test Check and Preparation
Adjust Injection Volume
Assembly of Governor
Install Stop and Adjusting Levers
Install Steel Ball Guide
Install Steel Balls and Slider
Install Speed Control Spring and Governor Cover
Install Governor Diaphragm
Install Governor Main Spring and Governor Diaphragm Housing
Adjustment of Governor (2H M/T)
Check Air-Tight of Vacuum Chamber
Adjust Pneumatic Governor Section
Adjust Mechanical Governor Section
Adjust Speed Control Spring
Adjust Total Injection Volume
Install and Seal Parts
Install Stopper Arm and Stop Lever
Check Thrust Clearance of Damper
Assemble Shackle and Stopper Arm
Install Shackle and Stopper Arm Assembly
Assemble Floating Lever
Install Floating Lever Assembly
Install Slider and Supporting Levers
Assembly Governor Cover
Install Governor Cover Assembly
Assemble Full-Load Stopper Housing
Assemble Full Load Stopper Housing
Assembly and Boost Compensator
Install Idle-Up Actuator
Adjustment of Governor (2H A/T and 12H-T)
Governor Characteristic Diagram
Preset Idle Speed Control
Adjust Idle Speed Control
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Table of
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Table of Contents
Troubleshooting
Turbocharger Electrical System Diagnosis
28
Cooling System: Troubleshooting
226
Lubrication System: Troubleshooting
238
Inspect Intake Heater - Troubleshooting
268
Charging System: Precautions
283
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