Toyota 13B Manuals

Manuals and User Guides for Toyota 13B. We have 1 Toyota 13B manual available for free PDF download: Repair Manual

Toyota 13B Repair Manual (339 pages)

for Land Cruiser, Dyna and Coaster

Brand: Toyota | Category: Engine | Size: 13.09 MB

Repair Procedures
4
Identification Information
6
Engine Serial Number
6
General Repair Instructions
6
Engine Mechanical: Table of Contents
10
Diesel Engine Diagnosis
11
Preliminary Checks
11
Engine will Not Crank
12
Engine Cranks Slowly - will Not Start
12
Engine Cranks Normally but will Not Start
13
Rough Idle with Warm Engine
14
Engine Suddenly Stops
15
Lack of Power
16
Excessive Exhaust Smoke
17
Excessive Fuel Consumption
17
Engine Noise When Warm
18
Engine will Not Shut off with Stop Button or Key
19
Diesel Electrical System Diagnosis
20
Pre-Heating System (Super Glow Type)
20
Diesel Electrical System Diagnosis (11B, 13B and 13B-T)
22
Pre-Heating System (W/Intake Heater)
22
Turbocharger Diagnosis
26
Insufficient Acceleration, Lack of Power or Excessive Fuel Consumption
26
Abnormal Noise
27
Troubleshooting of Turbocharger Indicator Light and Warning Light Operation
28
Cleaning of Air Filter - Oil Bath Type
29
Cleaning of Air Filter - Paper Filter Type
29
Inspection of Alternator Drive Belt
30
Inspection of Glow Plugs
30
Inspection of Intake Heater
30
Inspection of Injection Nozzles
30
Adjustment of Valve Clearances
31
Adjustment of Injection Timing
32
Adjustment of Idle Speed and Maximum Speed
34
Adjustment of Idle Speed and Maximum Speed (11B, 13B, 13B-T)
36
Adjustment of Air Conditioner Idle-Up Setting Speed
37
Adjustment of Air Conditioner Idle up Setting Speed
38
Inspection and Adjustment of Intake Shutter
39
Compression Check (B and 3B)
41
Compression Check (11B, 13B and 13B-T)
42
Turbocharger 13B-T
43
On-Vehicle Inspection of Turbocharger
44
Turbocharger Components
45
Removal of Turbocharger
45
Inspection of Turbocharger
47
Installation of Turbocharger
47
Cylinder Head Components
50
Removal of Cylinder Head
53
Disassembly of Cylinder Head
57
Inspection, Cleaning a Repair of Cylinder Head Components
58
Inspect Cylinder Head for Flatness
59
Inspect Cylinder Head for Cracks
59
Clean Valves
59
Inspect Valve Stem and Valve Guide Bushing
59
If Necessary, Replace Valve Guide Bushing
60
Inspect and Grind Valves
61
Inspect and Clean Valve Seats
62
Inspect Valve Springs
63
Inspect Valve Rocker Shaft Assembly
64
Inspect Push Rods
66
Inspect Intake and Exhaust Manifolds
66
Assembly of Cylinder Head
66
Install Combustion Chambers
66
Install Valves
67
Installation of Cylinder Head
68
Install Push Rods
68
Install Valve Rocker Shaft Assembly
68
Adjust Valve Clearances
69
Install Cylinder Head Cover
69
Install Exhaust Manifold
69
Install Water Outlet Assembly
70
Install Intake Manifold
70
Timing Gears and Camshaft Components
72
Removal of Timing Gears and Camshaft
73
Remove Valve Lifters
74
Remove Crankshaft Pulley
74
Remove Timing Gear Cover
75
Remove Automatic Timer from Timing Gear Cover
75
Check Timing Gear Backlash
75
Check Idle Gear Thrust Clearance
76
Remove Idle Gear
76
Remove Camshaft Timing Gear and Camshaft Assembly
77
Remove Crankshaft Timing Gear
77
Inspection of Timing Gears and Camshaft
78
Inspect Camshaft
78
Inspect Idle Gears
79
Inspect Valve Lifters
79
Replacement of Camshaft (or Camshaft Timing Gear)
80
Remove Camshaft
80
Install New Camshaft
80
Replacement of Crankshaft Front Oil Seal
81
Replace Crankshaft Front Oil Seal
81
Installation of Timing Gears and Camshaft
82
Install Crankshaft Timing Gear
82
Install Camshaft Timing Gear and Camshaft Assembly
82
Install Idle Gear Shaft
82
Install Idle Gear
83
Torque Idle Gear Shaft Union Bolt
83
Install Automatic Timer
83
Install Crankshaft Pulley
85
Install Valve Lifters
86
Install Push Rod Cover
86
Install Vacuum Pipe
86
Cylinder Block Components
88
Disassembly of Cylinder Block
89
Remove Rear Oil Seal Retainer
89
Check Connecting Rod Thrust Clearance
89
Remove Connecting Rod Caps and Check Oil Clearance
90
Remove Piston and Connecting Rod Assemblies
91
Check Crankshaft Thrust Clearance
92
Remove Main Bearing Caps and Check Oil Clearance
92
Remove Crankshaft
93
Inspection of Cylinder Block
94
Remove Gasket Material
94
Clean Cylinder Block
94
Inspect Top of Cylinder Block for Flatness
94
Remove Cylinder Ridge
95
Disassembly of Piston and Connecting Rod Assemblies
95
Check Fit between Piston and Pin
95
Remove Piston Rings
95
Inspection and Repair of Piston and Connecting Rod Assemblies
96
Clean Piston
96
Inspect Piston Diameter and Oil Clearance
97
Inspect Clearance between Wall of Piston Ring Groove and New Piston Ring
98
Inspect Piston Ring End Gap
98
Check Piston Pin Fit
99
Inspect Connecting Rods
99
Replace Connecting Rod Bushings
100
Install New Connecting Rod Bushings
100
Replacement of Cylinder Liners
103
Remove Oil Nozzle
103
Remove Cylinder Liner, Install New Cylinder Liner
103
Check Cylinder Liner Ridge Protrusion
103
Boring of Cylinder Liners
104
Calculate Amount to Bore Cylinder Liner
104
Bore and Hone Cylinders to Calculated Dimensions
104
Inspection and Repair of Crankshaft
105
Inspect Crankshaft for Runout
105
Inspect Main Journals and Crank Pins
105
Inspection and Repair of Camshaft Bearing and Camshaft
106
Inspect Camshaft Oil Clearance
106
Replace Camshaft Bearings
106
Inspection of Valve Lifters and Valve Lifter Bores
107
Inspect Valve Lifter Oil Clearance
107
Replacement of Crankshaft Rear Oil Seal
108
Assembly of Piston and Connecting Rod Assemblies
109
Install Piston Rings
109
Install Bearings
110
Assembly of Cylinder Block
111
Install Main Bearings
111
Place Crankshaft on Cylinder Block
111
Install Main Bearing Caps and Lower Thrust Washers
111
Install Piston and Connecting Rod Assemblies
112
Install Connecting Rod Caps
112
Fuel System: Table of Contents
114
Replacement of Fuel Filter
115
Bleed Fuel Filter
116
Start Engine and Check for Fuel Leaks
116
Removal and Test of Injection Nozzles
117
Remove Injection Pipes
117
Remove Nozzle Leakage Pipe
117
Remove Injection Nozzles
118
Injection Pressure Test
118
Leakage Test
119
Spray Pattern Test
119
Disassembly, Cleaning and Test of Injection Nozzle
120
Sinking Test
121
Assembly of Injection Nozzles
122
Installation of Injection Nozzles
122
Removing Injection Nozzles
124
Disassembly Injection Nozzle
126
Nozzle Cleaning
126
Perform Pressure and Spray Pattern Test
128
Fuel Feed Pump
129
Removal and Test of Fuel Feed Pump
129
Disconnect Inlet and Outlet Pipes from Feed Pump
129
Remove Feed Pump from Injection Pump
129
Suction Test
130
Discharge Test
130
Disassembly of Fuel Feel Pump
131
Remove Priming Pump and Check Valves
131
Remove Feed Pump Piston
131
Remove Feed Pump Tappet
132
Insert Feed Pump Piston
132
Inspect Priming Pump
132
Install Feed Pump Tappet
132
Install Feed Pump Piston
133
Install Priming Pump and Check Valves
133
Installation of Fuel Feed Pump
133
Install Inlet and Outlet Fuel Pipes
133
Automatic Timer - Components
134
Removal of Automatic Timer
134
Disassembly of Automatic Timer
134
Remove Timer Bearing
134
Inspection of Automatic Timer
135
Inspect Timer Bearing
135
Inspect Timer Springs
135
Assembly of Automatic Timer
136
Install Timer Bearing
137
Adjustment of Automatic Timer
138
Adjust Advance Angle
138
Installation of Automatic Timer
139
Removal of Injection Pump
140
Remove Parts
141
Remove Injection Pump
142
Injection Pump - Components
143
Pump Body - Components
147
Disassembly of Injection Pump
148
Remove Governor Diaphragm Housing and Main Spring
148
Remove Governor Cover and Speed Control Spring
148
Remove Control Rack Levers
149
Remove Slider and Steel Balls
149
Remove Steel Ball Guide
149
Remove Adjusting and Stop Levers
149
Disassembly of Governor
150
Check Thrust Clearance of Full Stop Cam
150
Remove Boost Compensator
151
Remove Connecting Link of High Altitude Compensator
152
Remove Governor Cover Assembly
152
Check Thrust Clearance of Steering Lever
153
Check Thrust Clearance of Cam Plate
153
Disassemble Governor Cover Assembly
154
Remove Floating Lever Assembly
155
Check Thrust Clearance of Floating Arm
155
Disassembly Floating Lever Assembly
155
Remove Shackle and Control Rack Arm Assembly
155
Separate Shackle and Control Rack Arm
156
Check Fitting Dimensions of Sliding Weight Shaft
156
Check Thrust Clearance of Jointing Bolt
156
Remove Sliding Weight Shaft, Remove Guide Bushing
156
Remove Flyweight Assembly
157
Check Thrust Clearance of Flyweight
157
Remove Camshaft Bushing
158
Disassemble Flyweight Assembly
158
Check Thrust Clearance of Stopper Arm
158
Remove Stop Lever and Stopper Arm
159
Remove no 2 Full-Load Stopper Housing
159
Disassembly of Pump Body
160
Remove Pump Cove, Plate Plugs
160
Install SST to Tappet Service Holes
160
Remove Spline Shaft
160
Check Camshaft Thrust Clearance
161
Remove Pump Flange and Camshaft
161
Check Sliding Resistance of Control Rack
162
Remove Tappets, Plungers and Pinions
162
Remove Control Rack
163
Remove Delivery Valves and Pump Cylinders
164
Remove Governor Housing
165
Inspection of Injection Pump
166
Inspect Delivery Valves
166
Inspect Pump Plungers
166
Inspect Control Rack and Pinion
166
Inspect Springs
167
Inspect Tappets
167
Inspect High Altitude Compensator
167
Inspect Boost Compensator
168
Replacement of Bearings and Oil Seals
169
Replace Bearing of Speed Control Screw
170
Replace Oil Seal of Lever Shaft
170
Assembly of Injection Pump
171
Assembly of Pump Body
171
Mount Pump Housing to SST
171
Install Governor Housing
171
Install Control Rack and Pinions
172
Install Plungers and Tappets
173
Torque Delivery Valve Holders
174
Install Spline Shaft
175
Remove SST from Tappet Service Holes
175
Install Plate Plugs
175
Install Pump Cover
175
Adjusting of Pump Body
176
Pre-Test Check and Preparation
176
Adjust Injection Timing
178
Adjust Injection Volume
181
Assembly of Governor
183
Install Stop and Adjusting Levers
183
Install Steel Balls and Slider
183
Install Control Rack Levers
183
Install Speed Control Spring and Governor Cover
184
Install High Altitude Compensator
184
Install Governor Diaphragm
184
Adjustment of Governor
185
Check Air-Tight of Vacuum Chamber
186
Adjust Pneumatic Governor Section
186
Adjust Mechanical Governor Section
188
Adjust Speed Control Spring
188
Adjust Total Injection Volume
189
Seal Parts
190
Install Stopper Arm and Stop Lever
191
Install No2 Full Load Stopper Housing
191
Assembly Flyweight
192
Check Thrust Clearance of Damper
192
Install Dampers and Camshaft Bushing
193
Install Flyweight Assembly
193
Install Guide Bushing
193
Install Slide Weight Shaft
193
Assemble Shackle and Control Rack Arm
194
Install Shackle and Control Rack Arm Assembly
194
Assembly Floating Lever
194
Install Floating Lever Assembly
194
Install Slider and Supporting Levers
195
Assembly Governor Cover
195
Install Governor Cover Assembly
196
Install Connecting Link of High Altitude Compensator
197
Install Boost Compensator
197
Assemble Full Load Stopper Housing
197
Install Full-Load Stopper Housing Assembly
199
Install Idle up Actuator
199
Governor Characteristic Diagram
200
Install Angle Gauge to Adjusting Lever
203
Preset Idle Speed Control
203
Adjust Idle Speed Control
204
Preset Maximum Speed Control
205
Adjust Medium Speed Control
206
Adjust Maximum Speed Control
208
Adjust Boost Compensator
209
Check Stop Lever Operation
211
Install Injection Pump
212
Cooling System: Table of Contents
215
Cooling System - Troubleshooting
216
Check and Replacement of Engine Coolant
216
Check Engine Coolant Level at Reserve Tank
216
Check Engine Coolant Quality
216
Replace Engine Coolant
217
Removal of Water Pump
218
Remove Fan and Water Pump Pulley
219
Inspection of Water Pump Components
219
Inspect Water Pump
219
Inspect Fluid Coupling
219
Disassembly of Water Pump
220
Remove Pulley Seat
220
Remove Water Pump Bearing
221
Remove Water Pump Rotor and Bearing
221
Assembly of Water Pump
222
Install Water Pump Bearing
222
Install Seal
222
Install Rotor
223
Install Pulley Seat
223
Installation of Water Pump
224
Install Water Pump Pulley and Fan
224
Removal of Thermostat
224
Inspection of Thermostat
225
Installation of Thermostat
225
Cleaning of Radiator
226
Inspection of Radiator
226
Lubrication System: Table of Contents
227
Lubrication System: Troubleshooting
228
Oil Pressure Check
228
Check Engine Oil Quality
228
Replacement of Engine Oil and Oil Filter
229
Drain Engine Oil
229
Replace Oil Filter
229
Fill with Engine Oil
230
Removal of Oil Pump
231
Remove Camshaft Timing Gear
232
Remove Oil Pan
232
Remove Oil Strainer and Oil Pipe
233
Remove Oil Pump (Timing Gear Case)
233
Disassembly of Oil Pump
234
Remove Relief Valve
234
Remove Drive and Driven Gears or Rotors
234
Inspection of Oil Pump
235
Inspect Relief Valve
235
Inspect Drive and Driven Gears
235
Inspect Drive Spline
235
Inspect Drive and Driven Rotors
236
Inspect Drivve Spline
236
Replacement of Drive Spline
237
Remove Drive Spline
237
Install New Drive Spline
237
Assembly of Oil Pump
238
Install Relief Valve
238
Installation of Oil Pumps
239
Install Oil Strainer and Oil Pipe
239
Install Oil Pan
240
Install Camshaft Timing Gear
240
Oil Cooler and Relief Valve - Components
242
Removal of Oil Cooler and Relief Valve
243
Remove Oil Cooler Cover with Oil Cooler
244
Separate Oil Cooler and Oil Cooler Case
244
Inspection of Oil Cooler and Relief Valve
244
Installation of Oil Cooler and Relief Valve
245
Connect Alternator Oil Pipes
246
Oil Nozzles and Check Valve Components
247
Removal of Oil Nozzles and Check Valve
247
Inspection of Oil Nozzle and Check Valve
248
Inspect Oil Nozzles
248
Installation of Oil Nozzles and Check Valve
248
Starting System: Table of Contents
249
Pre-Heating System: System Circuit
250
Timer Characteristic Diagram
251
Pre-Heating Timer
251
Glow Plug Relays
252
Inspect Relay Continuity
252
Inspect Relay Operation
252
Glow Plug Current Sensor
253
Inspect Glow Plug Resistor
253
Inspect Glow Plug
253
Water Temperature Sensor
254
Inspect Water Temperature Sensor
254
Fixed Delay Type: System Circuit
255
Pre-Heating System (11B, 13B and 13B-T): System Circuit
257
Intake Heater Relay
259
No 1 and no 2 Intake Heater Relays (BU)
261
Starting System Troubleshooting
262
Starting System Circuit
262
Starter Components
263
Disassembly of Starter
263
Remove Field Frame and Armature Assembly
263
Remove Starter Housing, Clutch Assembly and Gear
264
Remove Brush Holder
264
Inspection of Starter
265
Armature Coil
265
Fiel Coil
266
Brushes
266
Brush Springs
266
Brush Holder
267
Clutch and Gears
267
Bearings
267
Magnetic Switch
268
Assembly of Starter
269
Performance Test of Starter
271
Perform Pull-In Test
271
Perform Hold-In Test
271
Perform No-Load Performance Test
271
Inspection of Starter Relay
272
Electrical Diesel Injection Control System
274
Inspect Lever Drive Position
274
Inspect Lever Operation
274
Inspect Oil Pressure Switch
275
Fuel Cut Diaphragm System Circuit
276
On-Vehicle Inspection
276
Inspection of Fuel Cut Diaphragm
277
Overinjection Magnet
278
Charging System: Table of Contents
279
Charging System: Precautions
280
Charging System: Troubleshooting
280
Charging System Circuit
281
Check Battery Specific Gravity
285
Check Battery Terminals, Fusible Links and Fuses
285
Inspect Drive Belt
285
Inspect Charge Warning Light Circuit
287
Check Charging Circuit Without Load
287
Check Charging Circuit with Load
288
Alternator Components
289
Disassembly of Alternator
290
Remove Drive End Frame and Rotor Assembly from Stator
291
Remove Rotor
291
Inspection of Alternator
292
Inspect Stator for Open Circuit
293
Inspect Stator for Ground
293
Inspect Exposed Brush Length
293
Inspect Positive Rectifier
294
Inspect Negative Rectifier
294
Inspect Front Bearing
294
Install Rectifier Holder to Stator
295
Install Rectifier End Frame to Rectifier Holder
295
Install Fan and Pulley
296
Assemble Drive End Frame and Rectifier End Frame
296
Install Brush Holder
297
Assemble Brush Holder and IC Regulator
297
Install Brush Holder and IC Regulator Assembly
297
Install Brush Holder Cover
298
Install Vacuum Pump
298
Inspection of Alternator Regulator
299
Inspect Point Surfaces for Seizure and Damage
299
Inspect Resistance between Terminals
299
Voltage Adjustment of Alternator Regulator
300
Adjust Voltage Regulator
300
Adjust Voltage Relay
300
Charge Light Relay
301
Inspection of Ignition Main Relay
304
Service Specifications: Table of Contents
305
Engine Mechanical Specifications
306
Torque Specifications
311
Fuel System Specifications
312
Injection Pump Adjustment (Pump Body)
316
Cooling System Specifications
324
Lubrication System Specifications
325
Starting System Specifications
326
Charging System Specifications
326
Standard Bolt Torque Specifications
327
How to Determine Bolt Strength
328
Specified Torque for Standard Bolts
329
SST and SSM
330
Special Service Tools
331

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Toyota 13B Repair Manual (339 pages)

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