Toyota 2H Manuals

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Toyota 2H Repair Manual

Toyota 2H Repair Manual (336 pages)

Brand: Toyota | Category: Engine | Size: 12.95 MB

Table of Contents

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 Return to Idle
18
Engine will Not Shut off with Stop Button or Key
19
Diesel Electrical System Diagnosis
20
Pre-Heating System (Super Glow Type)
20
Pre-Heating System: Inspect Power Supply Section
22
Inspect Control Section
23
Turbocharger Diagnosis
26
Insufficient Acceleration, Lack of Power or Excessive Fuel Consumption
26
Abnormal Noise
27
Excessive Oil Consumption or White Exhaust
27
Turbocharger Electrical System Diagnosis
28
Troubleshooting of Turbocharger Indicator Light and Warning Light Operation
28
Engine Tune up
29
Cleaning of Air Filter
29
Inspection of Alternater Drive Belt
30
Inspection of Injection Nozzles
30
Adjustment of Valve Clearances
31
Adjustment of Injection Timing
32
Adjustment of Idle Speed and Maximum Speed
35
Adjustment of Idle Speed and Maximum Speed (2H A/T and 12H-T)
37
Adjustment of Power Steering Idle-Up Setting Speed
39
Adjustment of Air Conditioner Idle-Up Setting Speed (2H M/T)
40
Adjustment of Air Conditioner Idle-Up Setting Speed (2H A/T and 12H-T)
41
Inspection of Intake Shutter (2H A/T)
42
Inspection of Intake Shutter (2H-T)
43
Compression Check (2H)
44
Compression Check (12H-T)
45
Turbocharger (12H-T)
46
On-Vehicle Inspection of Turbocharger
47
Inspect Intake Air System
47
Inspect Exhaust System
47
Inspect Turbocharger Pressure
47
Removal of Turbocharger
49
Remove PCV Pipe
49
Remove Intake Air Connector
49
Remove Intake Pipe
49
Remove Heat Insulators
50
Remove Oil Pipe
51
Remove Turbine Outlet Elbow
51
Inspection of Turbocharger
52
Inspect Impeller Wheel Rotation
52
Inspect Axial Play of Impeller Wheel
52
Installation of Turbocharger
52
Install Turbocharger
53
Install Turbocharger Stay
54
Install Intake Pipe
54
Install Intake Air Connector
55
Install PCV Pipe
55
Cylinder Head: Components
56
Removal of Cylinder Head (2H)
58
Remove Glow Plugs
58
Remove Fuel Filter Assembly
58
Remove Intake Manifold
59
Remove Exhaust Manifolds
59
Separate Exhaust Manifolds
60
Remove Water Outlet Assembly
60
Remove Cylinder Head Cover
60
Remove Valve Rocker Shaft Assembly
60
Remove Push Rods
61
Remove Cylinder Head
61
Removal of Cylinder Head (12H-T)
62
Disassembly of Cylinder Head
65
Remove Valves
65
Remove Combustion Chambers (2H)
65
Inspection, Cleaning and Repair of Cylinder Head Components
66
Clean Top of Piston and Top of Block
66
Remove Gasket Material
66
Clean Combustion Chambers
66
Inspect Cylinder Head for Flatness
67
Inspect Cylinder Head for Cracks
67
Clean Valves
68
Inspect Valve Stem and Valve Guide Bushing
68
Inspect and Grind Valves
69
Inspect and Clean Valve Seats
70
Inspect Valve Springs
71
Inspect Rocker Arm and Shaft
72
Inspect Push Rods
74
Inspect Intake and Exhaust Manifolds
74
Assembly of Cylinder Head
75
Install Combustion Chambers
75
Install Valves
75
Installation of Cylinder Head (2H)
77
Install Edic Motor
80
Installation of Cylinder Head (12H-T)
82
Timing Gears and Camshaft: Components
86
Removal of Timing Gears and Camshaft
87
Remove Crankshaft Pulley
88
Remove Oil Pipe (12H-T)
88
Remove Timing Gear Cover
88
Check Backlash of Automatic Timer Drive Gear and Camshaft Timing Gear
89
Remove Automatic Timer
89
Remove Camshaft Timing Gear and Camshaft Assembly
90
Remove Crankshaft Timing Gear
91
Inspection of Timing Gears and Camshaft
92
Inspect Camshaft
92
Inspect Idle Gears
93
Inspect Valve Lifters
93
Replacement of Camshaft (or Camshaft Timing Gear)
94
Remove Camshaft
94
Install New Camshaft
94
Replacement of Automatic Timer Drive Gear (12H-T)
95
Remove Drive Gear
95
Install New Drive Gear
95
Replacement of Crankshaft Front Oil Seal
96
Installation of Timing Gears and Camshaft
97
Install Timing Gear Cover
100
Cylinder Block: Components
101
Disassembly of Cylinder Block
102
Check Connecting Rod Thrust Clearance
102
Remove Connecting Rod Caps and Check Oil Clearance
103
Remove Piston and Connecting Rod Assemblies
104
Check Crankshaft Thrust Clearance
105
Remove Main Bearing Caps and Check Oil Clearance
105
Remove Crankshaft
106
Inspection of Cylinder Block
107
Inspect Cylinder Bore Diameter
107
Remove Cylinder Ridge
108
Disassembly of Piston and Connecting Rod Assemblies
108
Inspection of Piston and Connecting Rod Assemblies
109
Clean Piston
109
Inspect Piston Diameter and Oil Clearance
110
Inspect Clearance between Wall of Piston Ring Groove and New Piston Ring
110
Inspect Piston Ring End Gap
111
Check Piston Pin Fit
111
Inspect Connecting Rods
111
Replacement of Connecting Rod Bushings
112
Remove Connecting Rod Bushings
112
Install New Connecting Rod Bushing
113
Hone Connecting Rod Bushing and Check Piston Pin Fit in Connecting Rod
113
Boring of Cylinders
114
Keep Oversized Piston
114
Calculate Amount to Bore Cylinder
114
Bore and Hone Cylinders to Calculated Dimensions
114
Inspection and Repair of Crankshaft
115
Inspect Crankshaft for Runout
115
Inspect Main Journals and Crank Pins
115
Inspection and Repair of Camshaft Bearing and Camshaft
116
Inspect Camshaft Oil Clearance
116
Replace Camshaft Bearings
117
Inspect Valve Lifter Oil Clearance
118
Inspection of Valve Lifter Bores
118
Replacement of Crankshaft Rear Oil Seal
119
Assembly of Piston and Connecting Rod Assemblies
120
Install Bearings
121
Assembly of Cylinder Block
122
Install Main Bearings
122
Install Main Bearing Caps and Lower Thrust Washers
122
Install Piston and Connecting Rod Assemblies
123
Install Connecting Rod Caps
123
Install Rear Oil Seal Retainer
124
Install Rear End Plate
124
Install Flywheel
125
Fuel System: Table of Contents
126
Replacement of Fuel Filter
127
Injection Nozzles (2H)
128
Removal and Test of Injection Nozzles
128
Remove Injection Pipes
128
Remove Nozzle Leakage Pipe
128
Remove Injection Nozzles
129
Injection Pressure Test
129
Leakage Test
130
Spray Pattern Test
130
Injection Nozzles: Components
131
Disassembly, Cleaning and Test of Injection Nozzle
131
Nozzle Cleaning
131
Sinking Test
132
Assembly of Injection Nozzles
133
Installation of Injection Nozzles
133
Remove Injection Pipes/Remove Injection Nozzles
135
Leakage Test/Spray Pattern Test
136
Injection Nozzles (12H-T): Components
137
Assembly of Injection Nozzles/Installation of Injection Nozzles
139
Fuel Feed Pump
141
Removal and Test of Fuel Feed Pump
141
Disconnect Inlet and Outlet Pipes from Feed Pump
141
Remove Feed Pump from Injection Pump
141
Suction Test
142
Discharge Test
142
Fuel Feed Pump: Components
143
Disassembly of Fuel Feed Pump
143
Remove Priming Pump and Check Valves
143
Remove Feed Pump Piston
143
Remove Feed Pump Tappet
144
Inspection of Fuel Feed Pump
144
Inspect Priming Pump
144
Install Feed Pump Piston
145
Install Priming Pump and Check Valves
145
Installation of Fuel Feed Pump
145
Install Inlet and Outlet Fuel Pipes
145
Removal of Automatic Timer
146
Automatic Timer Components
148
Disassembly of Automatic Timer
149
Check Thrush Clearance of Driver Gear
149
Disassemble Automatic Timer
149
Inspection of Automatic Timer
150
Inspect Timer Springs
150
Assembly of Automatic Timer
150
Check Thrust Clearance of Drive Gear
151
Adjustment of Automatic Timer
152
Installation of Automatic Timer
153
Removal of Injection Pump
154
Remove Injection Pump
156
Injection Pump Components
157
Disassembly of Injection Pump
162
Check Thrust Clearance of Full Stop Cam
165
Disassembly Full Load Stopper Housing Assembly
165
Remove Governor Cover Assembly
166
Check Thrust Clearance of Steering Lever
168
Check Thrust Clearance of Cam Plate
168
Disassemble Governor Cover Assembly
168
Remove Supporting Levers and Slider
169
Remote Floating Lever Assembly
169
Check Thrust Clearance of Floating Arm
169
Disassemble Floating Lever Assembly
170
Remove Shackle and Stopper Arm Assembly
170
Check Fitting Dimensions of Sliding Weight Shaft
170
Remove Sliding Weight Shaft
171
Remove Guide Bushings
171
Check Thrust Clearance of Flyweight
171
Disassemble Flyweight Assembly
172
Check Thrust Clearance of Stopper Arm
173
Remove Stop Lever and Stopper Arm
173
Disassembly of Pump Body
174
Remove Pump Cover
174
Install SST to Tappet Service Holes
174
Check Thrust Clearance of Camshaft
174
Remove Plate Plugs
175
Remove Camshaft and Governor Housing
175
Check Sliding Resistance of Control Rack
177
Remove Tappets, Plungers and Pinions
177
Remove Control Rack
178
Remove Delivery Valves and Pump Cylinders
178
Inspection Injection Pump
180
Inspect Delivery Valves
180
Inspect Pump Plungers
180
Inspect Control Rack and Pinion
181
Inspect Springs
181
Inspect Tappets
181
Inspect High Altitude Compensator
181
Inspect Boost Compensator
182
Replacement of Bearings and Oil Seals
183
Replace Bearing of Speed Control Screw
184
Replace Oil Seal of Lever Shaft
184
Assembly of Injection Pump
185
Assembly of Pump Body
185
Install Pump Cylinders and Delivery Valves
185
Install Control Rack and Pinions
186
Install Plungers and Tappets
186
Install Governor Housing and Camshaft
188
Install Plate Plugs
189
Remove SST from Tappet Service Holes
190
Install Pump Cover
190
Adjustment of Pump Body
191
Pre-Test Check and Preparation
191
Adjust Injection Volume
196
Assembly of Governor
198
Install Stop and Adjusting Levers
198
Install Steel Ball Guide
198
Install Steel Balls and Slider
198
Install Speed Control Spring and Governor Cover
199
Install Governor Diaphragm
199
Install Governor Main Spring and Governor Diaphragm Housing
199
Adjustment of Governor (2H M/T)
200
Check Air-Tight of Vacuum Chamber
201
Adjust Pneumatic Governor Section
201
Adjust Mechanical Governor Section
202
Adjust Speed Control Spring
202
Adjust Total Injection Volume
203
Install and Seal Parts
204
Install Stopper Arm and Stop Lever
205
Check Thrust Clearance of Damper
206
Assemble Shackle and Stopper Arm
207
Install Shackle and Stopper Arm Assembly
207
Assemble Floating Lever
207
Install Floating Lever Assembly
208
Install Slider and Supporting Levers
208
Assembly Governor Cover
208
Install Governor Cover Assembly
209
Assemble Full-Load Stopper Housing
210
Assemble Full Load Stopper Housing
212
Assembly and Boost Compensator
212
Install Idle-Up Actuator
213
Adjustment of Governor (2H A/T and 12H-T)
214
Governor Characteristic Diagram
214
Preset Idle Speed Control
215
Adjust Idle Speed Control
216
Preset Maximum Speed Control
217
Adjust Medium Speed Control
218
Adjust Maximum Speed Control
219
Adjust Boost Compesator
220
Check Stop Lever Operation
222
Install Cap Nut and Cover Plate of Full Load Stopper Housing
222
Installation of Injection Pump
223
Install Injection Pump Retainer
223
Cooling System: Table of Contents
225
Cooling System: Troubleshooting
226
Check and Replacement of Engine Coolant
227
Check Engine Coolant Level at Reserve Tank
227
Check Engine Coolant Quality
227
Replace Engine Coolant
227
Removal of Water Pump
228
Remove Fan and Water Pump Pulley
229
Disconnect Hoses from Water Pump
229
Remove Water Pump
229
Inspection of Water Pump Components
229
Water Pump Components
230
Disassembly of Water Pump
230
Remove Water Pump Body
230
Remove Pulley Seat
230
Remove Rotor
231
Remove Water Pump Bearing
231
Assembly of Water Pump
232
Install Water Pump Bearing
232
Install Pulley Seat
233
Install Water Pump Body
233
Installation of Water Pump
234
Removal of Thermostat
235
Inspection of Thermostat
235
Installation of Thermostat
236
Cleaning of Radiator
236
Inspection of Radiator
236
Inspect Radiator Cap
236
Lubrication System: Table of Contents
237
Lubrication System: Troubleshooting
238
Oil Pressure Check
239
Check Engine Oil Quality
239
Check Engine Oil Level
239
Check Oil Pressure
239
Replacement of Engine Oil and Oil Filter
240
Removal of Oil Pump
241
Remove Camshaft Timing Gear
242
Remove Oil Pan
242
Remove Oil Strainer and Oil Pipe
243
Oil Pump Components
244
Remove Relief Valve
244
Remove Drive and Driven Rotors
244
Inspection of Oil Pump
245
Replacement of Drive Spline
246
Remove Drive Spline
246
Assembly of Oil Pump
247
Install Drive and Driven Rotors
247
Installation of Oil Pump
247
Install Stiffening Plate
248
Install Oil Strainer and Oil Pipe
248
Install Oil Pan
249
Install Camshaft Timing Gear
249
Install Crankshaft Timing Gear
249
Oil Cooler and Relief Valve: Components
251
Removal of Oil Cooler and Relief Valve
252
Inspection of Oil Cooler and Relief Valve
253
Installation of Oil Cooler and Relief Valve
254
Oil Nozzles and Check Valves (12H-T) - Components
256
Removal of Oil Nozzles and Check Valves
257
Inspection of Oil Nozzle and Check Valves
257
Installation of Oil Nozzles and Check Valves
258
Starting System: Table of Contents
259
Pre-Heating System (2H) - System Circuit
260
Pre-Heating Timer
261
Timer Characteristic Diagram
261
Inspect Glow Plug
263
Glow Plug Current Sensor
263
Glow Plug Resistors
263
Inspect Water Temperature Sensor
264
Ignition Main Relay
264
Fixed Delay Type - System Circuit
265
Pre-Heating System (12H-T) - System Circuit
266
Inspect Intake Heater
267
Inspect Intake Heater - Troubleshooting
268
Starting System Circuit
268
Starter - Components
269
Disassembly Field Frame and Armature Assembly
269
Remove Starter Housing, Clutch Assembly and Gear
270
Remove Steel Ball
270
Remove Brush Holder
270
Inspection of Starter
271
Armature Coil
271
Field Coil (Field Frame)
272
Brush Springs
272
Inspect Brush Spring Load
272
Brush Holder
273
Clutch and Gears
273
Bearings
273
Magnetic Switch
274
Preform Pull-In Coil Open Circuit Test
274
Preform Hold-In Coil Open Circuit Test
274
Assembly of Starter
275
Install Brush Holder
275
Install Clutch Assembly and Gear
275
Install Field Frame and Armature Assembly
276
Performance Test of Starter
277
Starter Relay
278
Inspection of Starter Relay
278
Electrical Diesel Injection Control (EDIC) System - Circuit
279
Inspect Connecting Rod Length
279
Inspect Lever Operation
279
Inspect EDIC Motor
280
Oil Pressure Switch
280
Inspect Connecting Wire Length
281
Charging System: Table of Contents
282
Charging System: Precautions
283
Charging System: Troubleshooting
283
Charging System Circuit
284
On-Vehicle Inspection
287
Check Battery Specific Gravity
287
Inspect Drive Belt
287
Inspect Charge Warning Light Circuit
288
Check Charging Circuit Without Load
289
Check Charging Circuit with Load
290
Alternator Components
291
Disassembly of Alternator
292
Remove Brush Holder and IC Regulator
293
Remove Drive End Frame and Rotor Assembly from Stator
293
Remove Pulley and Fan
294
Inspection of Alternator
295
Inspect Rotor for Open Circuit
295
Inspect Rotor for Ground
295
Inspect Stator for Open Circuit
295
Inspect Exposed Brush Length
296
Inspect Positive Rectifier
296
Inspect Negative Rectifier
296
Inspect Front Bearing
297
Install Rectifier Holder to Stator
297
Install Rectifier End Frame to Rectifier Holder
297
Install Rotor
298
Install Fan and Pulley
298
Assemble Drive End Frame and Rectifier End Frame
299
Assemble Brush Holder and IC Regulator
300
Install Brush Holder Cover
301
Install Vacuum Pump
301
Inspection of Alternator Regulator
302
Voltage Adjustment of Alternator Regulator
303
Charge Light Relay
304
Inspect Relay Continuity
304
Inspect Relay Operation
304
Inspection of Charge Light Relay
305
Inspect Relay Continuity/Operation
305
Service Specifications: Table of Contents
307
Engine Mechanical Specifications
308
Torque Specifications
313
Fuel System Specifications
314
Injection Pump Adjustment Specifications
318
Injection Pump Adjustment (Governor 2H M/T)
320
Injection Pump Adjustment (Governor 2H A/T and 12H-T)
321
Cooling System Specification
323
Lubrication System Specifications
324
Starting System Specifications
325
Charging System Specifications
325
Standard Bolt Torque Specifications
326
SST and SSM: Table of Contents
329
Special Service Tools
330

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Toyota 2H Repair Manual

Toyota 2H Repair Manual (338 pages)

Brand: Toyota | Category: Engine | Size: 32.56 MB

Table of Contents

How to Use this Manual
5
Repair Procedures
5
Specifications
6
Warnings, Cautions, Notes
6
Identification Information
7
Engine Serial Number
7
Ge N E R a L R Epa I R I N S Tr U C Tio N S
7
Abbreviations Used in this Manual
10
Engine M Echanical
11
Preliminary Checks
12
Fuel LEAKAGE
15
Improper Operation
16
Lack of Power
17
Exc E S S I V E Fuel C O N Sum Ption
18
Operation
20
Diesel Electrical Sy Ste M Diag N Osi S
21
Tu R Bo C H a R G E R E L E C T R I C a L System D Ia G N O S I S
29
I N S Pe C T I O N O F B Attery
30
Clean I N G O F Ai R F I Lter
30
A D J U St M E N T O F Valve C L E a R a N C E S
32
I N I T I a L C O N Ditions
40
Engine Mechani Cal
41
Adj Usting Screw
41
C O M P R E S S I O N C H E C K
46
I N Sta Llat I O N O F T U R B Och a R G E R
53
Cylinder Head
57
Drain Engine C O O L a N T
59
Remove Glow P L U G S
59
R E M O V a L of Cyli N D E R H E a D
63
E N G I N E Mechanical
75
Install V a L V E S
76
I N St a L Lati O N of C y L I N D E R H E a D
78
I N Stall PUSH R O D S
78
T I M I N G G E a R S
87
Remove Piston R I N G S
111
C L E a N Piston
112
A S S E M B L E Piston a N D C O N N Ecti N G Rod
123
I N Stall C O N N E C T I N G Rod Caps
126
Fuel System
129
R E P L Ac E M E N T O F F U E L F I Lt E R
130
Replace F U E L F I L T E R
130
I N J Ecti O N N O Z Z L es
131
Leakage Test
133
Nozzle C L E a N I N G
134
S P R a Ypattern T E S T
139
F U E L Feed P U M P
144
Discharge Test
145
Automatic Timer
149
R E M O V E Drive B E Lt
150
Fuel System
172
Fuel System
192
Cooling System
228
Troubleshooting
229
Check E N G I N E Coolant Q U a Lity
230
R E M O V a L O F Water P U M P
231
Remove Water P U M P
232
I N Sta L L a T I O N O F Water P U M P
237
R E M O V a L O F T H E R M Ostat
238
Remove T H E R M Ostat
238
I N S P E C T I O N O F T H E R M Ostat
238
Lubrication System
240
Oil Pump
244
Relief Valve
257
O I L N O Z Z L E S a N D C H E C K V a L V E S
259
Starting System
262
Starter Relay
262
I Ns P E C T I O N O F C O M Po N Ents
264
Troubleshooting
271
Sta Rt I N G S y S T E M C I Rc U I T
271
C H a Rg I N G Syste M C I Rc U I T
287
O N - Ve H I C L E I N S P E Ct I O N
290
Charging System
296
I N S Pecti O N O F Alte R N a T O R
298
A Lternator Regulator
305
I G N I T I O N M a I N R E la y
309
Service Specifications
310
E N G I N E M E C H a N Ical
311
Lubrication System
327
S Ta N D a R D B O Lt to R Q U E S P E C I F I C at I O N S
329

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