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Manuals and User Guides for Toyota 2L-T. We have
1
Toyota 2L-T manual available for free PDF download: Repair Manual
Toyota 2L-T Repair Manual (175 pages)
Brand:
Toyota
| Category:
Engine
| Size: 5 MB
Table of Contents
Repair Procedures
5
How to Use this Manual
5
Specifications
6
Engine Serial Number
7
Identification Information
7
General Repair Instructions
7
Abbreviations Used in this Manual
10
Table of Contents
11
Engine Mechanical
11
Description
12
Diesel Engine Diagnosis
14
Preliminary Checks
14
Troubleshooting
14
Engine Cranks Slowly - will Not Start
15
Engine will Not Crank
15
Engine Cranks Normally but will Not Start
16
Rough Idle with Warm Engine
18
Engine Suddenly Stops
19
Lack of Power
19
Excessive Exhaust Smoke
20
Excessive Fuel Consumption
21
Engine Noise When Warm
22
Engine will Not Return to Idle
22
Engine will Not Shut off with Key
22
Diesel Electrical System Diagnosis (2L-T Austria)
23
Engine Does Not Start Cold
23
Pre-Heating System (Super Glow Type)
23
Fuel Cut Solenoid Valve
25
Diesel Electrical System Diagnosis [2L-T Others
26
Engine Tune-Up
28
Inspection of Air Filter
28
Inspection of Engine Coolant
28
Inspection of Alternator Drive Belts
29
Adjust Valve Clearance
30
Adjustment of Valve Clearance
30
Adjusting Shim Selection Using Chart
32
Adjust Injection Timing
34
Check Injection Timing
34
Inspection and Adjustment of Injection Timing
34
Adjustment of Injection Timing
35
Install SST and Dial Indicator
35
Release ACSD Advance
35
Adjustment of Idle Speed and Maximum Speed
37
Adjustment of Air Conditioner Idle-Up Setting Speed
39
Check Throttle Valve (High Altitude Area)
40
Check Throttle Valve (Low Altitude Area)
40
INTAKE VENTURI SYSTEM (LN 2L-T Only
40
On-Vehicle Inspection
40
Check Throttle Valve
41
Inspect Venturi
41
Inspection of Intake Venturi System Components
41
Inspection VSV
42
Compression Check
43
Cylinder Head (2L-T) Components
45
Removal of Cylinder Head
46
Assembly of Cylinder Head
49
Inspect Camshafts and Bearings
49
Inspection, Cleaning and Repair of Cylinder Head Components
49
Installation of Cylinder Head
50
Cylinder Block
52
Install Cylinder Head
52
Install Cylinder Head Cover
53
Install Exhaust Manifold
53
Install Intake Manifold
54
Install No.2 Timing Belt Cover
55
Install Water Outlet and Outlet Housing Assembly
55
Inspect Cylinder Bore Diameter
56
Inspection of Cylinder Block
56
Inspection of Piston and Connecting Rod Assemblies
56
Inspect Clearance between Wall of Ring Groove and New Piston Ring
57
Inspect Connecting Rod
58
Boring of Cylinders
59
Assembly of Cylinder Block
60
Inspection and Repair of Crankshaft
60
Turbocharger System
61
Turbocharger System Description
62
Operation of Turbocharger
63
Waste Gate Valve
63
Turbocharger System Precautions
64
Insufficient Acceleration, Lack of Power or Excessive Fuel Consumption
65
Turbocharger System Troubleshooting
65
Abnormal Noise
66
Excessive Oil Consumption or White Exhaust
66
Turbocharger Electrical System Diagnosis
67
On-Vehicle Inspection of Turbocharger
68
Removal of Turbocharger
70
Inspect Axial Play of Impeller Wheel
71
Inspect Impeller Wheel Rotation
71
Inspection of Turbocharger
71
Inspect Actuator Operation
72
Inspect Radial Play of Turbine Shaft
72
Install Turbine Outlet Elbow
72
Installation of Turbocharger
72
Install Exhaust Manifold Stay
73
Install Turbo Oil Pipe
73
Install Turbo Water Pipe
73
Install Turbocharger to Exhaust Manifold
73
Fuel System
75
Fuel Heater System
76
Removal of Injection Pump
77
Disassembly of Injection Pump
83
Inspect Accumulator Assembly
89
Inspect Spring Length
89
Inspection of Injection Pump Components
89
Adjust Plunger Spring Shim
90
Assembly of Injection Pump
90
Assembly and Adjusting Pilot Injection (PIJ) Actuator
91
Check Plunger Stroke
92
Assemble Boost Compensator
93
Install Pilot Injection Actuator
93
Install Adjusting Lever
97
Install Adjusting Lever Shaft to Governor Shaft
97
Install Governor Cover
97
Install Dash Pot
98
Install Fuel Cut Solenoid
98
Install and Check Throttle Position Sensor
99
Install Idle-Up Lever
99
Install Thermo Wax
99
Adjustment of Injection Pump
101
Pre Test Check and Preparation
101
Pre-Set Full Load Injection Volume
105
Adjust Pump Inner Pressure
106
Pre-Set Maximum Speed
106
Pre-Setting of Load Sensing Timer
106
Adjust Timer
107
Check Overflow Volume
107
Release Cold-Starting System for Next Inspection
107
Adjust Full Load Injection Volume
108
Check Air Tightness of Boost Compensator
108
Adjust Maximum Speed
109
Check and Adjust Full Load Minimum Injection Volume
110
Adjust Boost Compensator Characteristic
111
Inspect and Adjust Boost Compensator Characteristic Tendency
112
Adjust Load Sensing Timer
113
Check Hysteresis
113
Check Injection Volume
115
Adjust Idle Speed
116
Adjust Fast Idle
118
Post Adjustment Check
119
Seal Parts
119
Installation of Injection Pump
120
Cooling System
122
Cooling System Description
123
Radiator
124
Radiator Cap
124
Reservoir Tank
124
Thermostat
124
Check and Replacement of Engine Coolant
125
Check Engine Coolant Quality
125
Cooling System Troubleshooting
125
Replace Engine Coolant
125
Inspection of Thermostat
127
Removal of Thermostat
127
Installation of Thermostat
128
Lubrication System
129
Lubrication System Description
130
Oil Filter
131
Oil Pressure Regulator (Relief Valve)
131
Oil Pump
131
Check Engine Oil Level
132
Check Engine Oil Quality
132
Oil Pressure Check
132
Drain Engine Oil
133
Replace Oil Filter
133
Replacement of Engine Oil and Oil Filter
133
Oil Cooler and Relief Valves Components
135
Removal of Oil Cooler and Relief Valves
135
Inspection of Oil Cooler and Relief Valves
137
Installation of Oil Cooler and Relief Valves
137
Install Relief Valves
138
Install Union
138
Install Union Bolt
138
Starting System
140
Pre-Heating System
141
Super Glow Type (2L-T)
141
Inspect Lighting Time of Glow Indicator Light
142
Inspection of Pre-Heating System
142
Inspect Pre-Heating Timer Circuit
143
Inspection of Components
143
Pre-Heating Timer
143
Inspect Relay Continuity
144
Inspect Relay Operation
144
Inspect Glow Plug
145
Inspect Glow Plug Resistor
145
Inspect Temperature Sensor
146
Water Temperature Sensor
146
Fixed Delay Type
147
Inspection of Starter Relay
148
Starter Relay (Lj
148
Charging System
149
Charging System Circuit
150
Charging System On-Vehicle Inspection
151
Inspect Battery Specific Gravity and Electrolyte Level
151
Check Battery Terminals, Fusible Links and Fuses
151
Inspect Drive Belts
151
Visually Check Alternator Wiring and Listen for Abnormal Noises
152
Inspect Discharge Warning Light Circuit
152
Inspect Charging Circuit Without Load
152
Inspect Charging Circuit with Load
154
Service Specifications
155
Engine Mechanical Specifications
156
Turbocharger System Specifications
159
Turbocharger System Torque Specifications
159
Fuel System Specifications
160
Injection Pump Adjustment
162
Cooling System Specifications
167
Cooling System Torque Specifications
167
Lubrication System Specifications
168
Lubrication System Torque Specifications
168
Standard Bolt Torque Specifications
169
How to Determine Bolt Strength
170
Specified Torque for Standard Bolts
171
SST and SSM
172
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