Toyota 3L Manuals

Manuals and User Guides for Toyota 3L. We have 1 Toyota 3L manual available for free PDF download: Repair Manual

Toyota 3L Repair Manual

Toyota 3L 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
- Diesel Electrical System Diagnosis [2L-T Others
  26
- 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 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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