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Manuals
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Toyota Manuals
Engine
2L-T
Repair manual
Toyota 2L-T Repair Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Repair Procedures
How to Use this Manual
Specifications
Engine Serial Number
Identification Information
General Repair Instructions
Abbreviations Used in this Manual
Table of Contents
Engine Mechanical
Description
Diesel Engine Diagnosis
Preliminary Checks
Troubleshooting
Engine Cranks Slowly - will Not Start
Engine will Not Crank
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 Key
Diesel Electrical System Diagnosis (2L-T Austria)
Engine Does Not Start Cold
Pre-Heating System (Super Glow Type)
Fuel Cut Solenoid Valve
Diesel Electrical System Diagnosis [2L-T Others
Engine Tune-Up
Inspection of Air Filter
Inspection of Engine Coolant
Inspection of Alternator Drive Belts
Adjust Valve Clearance
Adjustment of Valve Clearance
Adjusting Shim Selection Using Chart
Adjust Injection Timing
Check Injection Timing
Inspection and Adjustment of Injection Timing
Adjustment of Injection Timing
Install SST and Dial Indicator
Release ACSD Advance
Adjustment of Idle Speed and Maximum Speed
Adjustment of Air Conditioner Idle-Up Setting Speed
Check Throttle Valve (High Altitude Area)
Check Throttle Valve (Low Altitude Area)
INTAKE VENTURI SYSTEM (LN 2L-T Only
On-Vehicle Inspection
Check Throttle Valve
Inspect Venturi
Inspection of Intake Venturi System Components
Inspection VSV
Compression Check
Cylinder Head (2L-T) Components
Removal of Cylinder Head
Assembly of Cylinder Head
Inspect Camshafts and Bearings
Inspection, Cleaning and Repair of Cylinder Head Components
Installation of Cylinder Head
Cylinder Block
Install Cylinder Head
Install Cylinder Head Cover
Install Exhaust Manifold
Install Intake Manifold
Install No.2 Timing Belt Cover
Install Water Outlet and Outlet Housing Assembly
Inspect Cylinder Bore Diameter
Inspection of Cylinder Block
Inspection of Piston and Connecting Rod Assemblies
Inspect Clearance between Wall of Ring Groove and New Piston Ring
Inspect Connecting Rod
Boring of Cylinders
Assembly of Cylinder Block
Inspection and Repair of Crankshaft
Turbocharger System
Turbocharger System Description
Operation of Turbocharger
Waste Gate Valve
Turbocharger System Precautions
Insufficient Acceleration, Lack of Power or Excessive Fuel Consumption
Turbocharger System Troubleshooting
Abnormal Noise
Excessive Oil Consumption or White Exhaust
Turbocharger Electrical System Diagnosis
On-Vehicle Inspection of Turbocharger
Removal of Turbocharger
Inspect Axial Play of Impeller Wheel
Inspect Impeller Wheel Rotation
Inspection of Turbocharger
Inspect Actuator Operation
Inspect Radial Play of Turbine Shaft
Install Turbine Outlet Elbow
Installation of Turbocharger
Install Exhaust Manifold Stay
Install Turbo Oil Pipe
Install Turbo Water Pipe
Install Turbocharger to Exhaust Manifold
Fuel System
Fuel Heater System
Removal of Injection Pump
Disassembly of Injection Pump
Inspect Accumulator Assembly
Inspect Spring Length
Inspection of Injection Pump Components
Adjust Plunger Spring Shim
Assembly of Injection Pump
Assembly and Adjusting Pilot Injection (PIJ) Actuator
Check Plunger Stroke
Assemble Boost Compensator
Install Pilot Injection Actuator
Install Adjusting Lever
Install Adjusting Lever Shaft to Governor Shaft
Install Governor Cover
Install Dash Pot
Install Fuel Cut Solenoid
Install and Check Throttle Position Sensor
Install Idle-Up Lever
Install Thermo Wax
Adjustment of Injection Pump
Pre Test Check and Preparation
Pre-Set Full Load Injection Volume
Adjust Pump Inner Pressure
Pre-Set Maximum Speed
Pre-Setting of Load Sensing Timer
Adjust Timer
Check Overflow Volume
Release Cold-Starting System for Next Inspection
Adjust Full Load Injection Volume
Check Air Tightness of Boost Compensator
Adjust Maximum Speed
Check and Adjust Full Load Minimum Injection Volume
Adjust Boost Compensator Characteristic
Inspect and Adjust Boost Compensator Characteristic Tendency
Adjust Load Sensing Timer
Check Hysteresis
Check Injection Volume
Adjust Idle Speed
Adjust Fast Idle
Post Adjustment Check
Seal Parts
Installation of Injection Pump
Cooling System
Cooling System Description
Radiator
Radiator Cap
Reservoir Tank
Thermostat
Check and Replacement of Engine Coolant
Check Engine Coolant Quality
Cooling System Troubleshooting
Replace Engine Coolant
Inspection of Thermostat
Removal of Thermostat
Installation of Thermostat
Lubrication System
Lubrication System Description
Oil Filter
Oil Pressure Regulator (Relief Valve)
Oil Pump
Check Engine Oil Level
Check Engine Oil Quality
Oil Pressure Check
Drain Engine Oil
Replace Oil Filter
Replacement of Engine Oil and Oil Filter
Oil Cooler and Relief Valves Components
Removal of Oil Cooler and Relief Valves
Inspection of Oil Cooler and Relief Valves
Installation of Oil Cooler and Relief Valves
Install Relief Valves
Install Union
Install Union Bolt
Starting System
Pre-Heating System
Super Glow Type (2L-T)
Inspect Lighting Time of Glow Indicator Light
Inspection of Pre-Heating System
Inspect Pre-Heating Timer Circuit
Inspection of Components
Pre-Heating Timer
Inspect Relay Continuity
Inspect Relay Operation
Inspect Glow Plug
Inspect Glow Plug Resistor
Inspect Temperature Sensor
Water Temperature Sensor
Fixed Delay Type
Inspection of Starter Relay
Starter Relay (Lj
Charging System
Charging System Circuit
Charging System On-Vehicle Inspection
Inspect Battery Specific Gravity and Electrolyte Level
Check Battery Terminals, Fusible Links and Fuses
Inspect Drive Belts
Visually Check Alternator Wiring and Listen for Abnormal Noises
Inspect Discharge Warning Light Circuit
Inspect Charging Circuit Without Load
Inspect Charging Circuit with Load
Service Specifications
Engine Mechanical Specifications
Turbocharger System Specifications
Turbocharger System Torque Specifications
Fuel System Specifications
Injection Pump Adjustment
Cooling System Specifications
Cooling System Torque Specifications
Lubrication System Specifications
Lubrication System Torque Specifications
Standard Bolt Torque Specifications
How to Determine Bolt Strength
Specified Torque for Standard Bolts
SST and SSM
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Table of Contents
Troubleshooting
Troubleshooting
14
Turbocharger system troubleshooting
65
Cooling System Troubleshooting
125
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