Toyota 2L-T, Repair Manual

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Page 2: ...ries For basic engine service repair refer to the following repair manual 2L 3L Engine Repair Manual Pub No RM123E Please note that the publications below have also been prepared as relevant service manuals to the components and systems in this engine All information contained in this manual is the most up to date a t the time of publication However specifications and proce dures are subject to ch...

Page 3: ...M COOLING SYSTEM LUBRICATION SYSTEM l a STARTING SYSTEM CHARGING SYSTEM SERVICE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS SST AND SSM 01994 TOYOTA MOTOR CORPORATION All rights reserved This book may not be reproduced or copied in whole or in part without the written permission of Toyota Motor Corporation ...

Page 4: ...INTRODUCTION Page HOW TO USE THIS MANUAL IN 2 IDENTIFICATIONINFORMATION IN 4 GENERAL REPAIR INSTRUCTIONS IN 4 ABBREVIATIONS USED IN THIS MANUAL IN 7 ...

Page 5: ...n that pertain to all repair operationscontained in that section Read theseprecautions before starting any repair task TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause The repair for each possible cause is referenced in the remedy column to quickly lead you to the solution REPAIR PROCEDURES Most repair operations begin with an overview illustr...

Page 6: ... case task head ing can be read at a glance when necessary and the text below it provides detailed information Important specifications and warnings always stand out in bold type REFERENCES References have been kept to a minimum However when they are required you are given the page to refer to SPECIFICATIONS Specifications are presented in bold type throughout the text where needed You never have ...

Page 7: ...s en the terminal nut and raise the cable straight up without twisting or prying it d Clean the battery terminal posts and cable terminals with a shop rag Do not scrape them with a file or other abrasive object e Install the cable terminal to the battery post with the nut loose and tighten the nut after installation Do not use a hammer to tap the terminal onto the post f Be sure the cover for the ...

Page 8: ...e sure the new fuse is the correct amperage DO NOT exceed the rating or use one of a lower rating 11 Care must be taken when jacking up and supporting the vehicle Be sure to lift and support the vehicle a t the proper locations a I f the vehicle is to be jacked up only at the front or rear end be sure to block the wheels in order to en sure safety b After the vehicle is jacked up be sure to suppor...

Page 9: ... in sert the tester probe carefully to prevent terminals from bending g When using a vacuum gauge never force the hose on to a connector that is too large Use a step down adapter instead Once the hose has been stretched it may leak 13 Tag hoses before disconnectingthem a When disconnecting vacuum hoses use tags to iden tify how they should be reconnected b After completing a job double check that ...

Page 10: ...EVRV Electronic Vacuum Regulating Valve EX Exhaust manifold valve Ex Except FlPG Formed in Place Gasket FL Fusible Link HAC High Altitude Compensation IN Intake manifold valve LH Left Hand 01s Oversized PIJ Pilot Injection Device RH Right Hand SSM Special Service Materials SST Special ServiceTools STD Standard TDC Top Dead Center UIS Undersize VSV Vacuum Switching Valve w With wlo Without ...

Page 11: ... the above listed manual DESCRIPTION TROUBLESHOOTING Diesel Engine Diagnosis Diesel Electrical System Diagnosis 2L T Austria Diesel Electrical System Diagnosis 2L T Others ENGINE TUNE4 JP INTAKE VENTURI SYSTEM LN 2L T only COMPRESSION CHECK CYLINDER HEAD 2L T CYLINDER BLOCK Page EM 2 EM 4 EM 4 EM 13 EM 16 EM 18 EM 30 EM 33 EM 35 EM 46 ...

Page 12: ...EM 2 ENGINE MECHANICAL Description DESCRIPTION The 2L T engine is an in line 4 cylinder 2 4 liter OHC engine The 3L engine is an in line 4 cylinder 2 8 liter OHC engine 2L T ...

Page 13: ...oval of the camshafts Pistons are made of highly temperature resistant aluminum alloy Piston pins are the full floating type with the pins fastened to neither the piston boss nor the connecting rods Instead snap rings are fitted on both ends of the pins preventing the pins from falling out The No 1 compression ring is made of steel and the No 2 compression ring is made of cast iron The oil ring is...

Page 14: ...sary first check the compression timing and major componentsor systems Check the air filter and clean or replace it if necessary Check that there is sufficient fuel in the tank Check if the fuel is contaminatedwith gasoline or other foreign elements Only good qualitydiesel fuel should be used Bleed air from the system by pumping the priming Check for water in the fuel filter and fuel tank and drai...

Page 15: ...essary repairs 1 2 DISCHARGED B A T ENGINE CRANKS SLOWLY WILL NOT START Check alternator output and drive belt If necessary repair See page CH 3 3 INOPERATIVE STARTER 1 HINT Minimum cranking speed Cold 100 rpm Hot 150rpm Check for battery voltage at starter terminals 30 and 50 If okay see STARTING SYSTEM for repair pro cedure Possible Cause Check Procedure and CorrectionMethod Check alternator out...

Page 16: ...lty and should be replaced If no voltage refer to ELECTRICAL DIAGNOSIS and make necessary repairs Disconnect inlet hoses from fuel filter and feed clean fuel from separate container directly into fuel pump HINT When feeding fuel tank directly into pump keep container a t same level as vehicle fuel tank If engine starts either fuel filter or line between fuel tank and filter is clogged and should b...

Page 17: ...4 2L T Others 0 54 0 66 mm 0 0213 0 0260 in 3L 0 84 0 96 mm 0 0331 0 0378 in If not as above injection pump is improperly adjusted Check injection pressure with a nozzle tester Opening pressure 145 155 kg cm2 2 062 2 205 psi 14 220 15 200 kPa If not as above nozzle adjustment is improper and pressure should be readjusted If pressure cannot be adjustedto specification replace injection nozzle 8 2L ...

Page 18: ...T If less than standard idling would normally be rough If not as above adjust with idle speed adjusting screw Check for leaks a t injection pump connections pump distributive head bolt injection nozzles and delivery valve holders Tighten any loose connectionsto specified torque or replace parts as necessary With engine idling loosen injection pipe to each cylinder in order and check if idle speed ...

Page 19: ... air cleaner is not clogged the engine overheating Not applicable if the customer desires an output power higher than specified for that vehicle For ac curacy adjust with a chassis dynamo Refer to step 3 of ENGINE CRANKS NORMALLY BUT WILL NOT START above PossibleCause Check Procedure and Correction Method If necessary adjust so that lever is in contact with screw or make other required repairs 1 I...

Page 20: ...be interchanged Refer to step 3 of ROUGH IDLE WITH WARM ENGINE 16 IMPROPER INJECTION TIMING I EXCESSIVE EXHAUST SMOKE Refer to step 7 of ENGINE CRANKS NORMALLY BUT WILL NOT START 7 FAULTY INJEC HINT Check that the air cleaner is not clogged Refer to step 9 of ENGINE CRANKS NORMALLY BUT WILL NOT START Check with the customer whether or not oil consumption has been excessive Possible Cause Check Pro...

Page 21: ...fficiently warming up engine check idle speed See page EM 27 Idle speed 2L T 700 800 rpm 3L 650 750 rpm If not as above adjust with idle speed adjusting screw Check maximum speed Seepage EM 27 Maximum speed 2L T 4 700 4 900 rpm 3L Hong Kong Singaporeand Malaysia 4 300 4 500 rpm 3L Others 4 500 4 700 rpm If not as above adjust bivith maximum speed adjust ing screw Refer to step 9 of ENGINE CRANKS N...

Page 22: ...step 9 of ENGINE CRANKS NORMALLY BUT WILL NOT START Operate adjusting lever on top of injection pump and check if engine returns to idle See page EM 27 If so accelerator cable is binding or improperly ad justed and should be repaired accordingly If engine does not return to idle injection pump is faulty and should be replaced ENGINE WlLL NOT SHUT OFF WITH KEY Possible Cause Check Procedure and Cor...

Page 23: ...if necessary I I I I I I Blown 1Fuse OK Check if indicator light lights up with starter switch ON Lighton 5 6 seconds Yes Check f u v A Check for short circuit I I Starter switch OFF I CONTINUED ON PAGE EM 14 Check for battery voltage to terminal 825 W or A4 LN of pre heatingtimer connector onwire harness side Check indicator light bulb Check for battery voltage to terminal A6 W or A3 LN of pre he...

Page 24: ...en starter switch is placed a t START No Voltage Place starter switch a t ON and check for voltage to glow plug a few seconds later Thereafter voltage should drop about 112 Voltage Remains t I Glow plug okay No Voltage Check for battery voltage to positive I side of glow plug resistor If okay replace the resistor If no voltage No 2 glow plug relay is faulty and should be replaced i Connect water t...

Page 25: ...ation noise clicking sound while repeatedly connecting and disconnectingfuel cut solenoid valve No Noise i 1Fuel cut solenoid valve okay Noise I Check fuse Check for short circuit and repair as necessary I Fuse OK Blown I No Noise I I I Replace fuel cut solenoid valve Apply battery voltage directly to solenoid and check for noise Check wire harness from fuse to fuel cut solenoid Noise ...

Page 26: ...ON Light on 6 7 seconds Check indicator Replace bulb No Good I I Bulb OK No Blown P Check fuse See page ST 2 i Starter switch OFF timer connector on wire harness side I f okay pre heatingtimer is faulty and should be replaced I after engine is started I Fuse t If faulty repair charging system as necessary i If okay timer is faulty and should be replaced Check that there is 1 V or less to terminal ...

Page 27: ...er switch is Voltage I Starter switch OFF Check for battery voltage at negative side of glow plug resistor If no voltage No 1 glow plug relay is faulty and should be replaced placestarter switch a t ON and 1 at All check for voltage to glow plug a few seconds later Thereafter voltage should drop about 112 Check for battery voltage to positive side of glow plug resistor If okay replace the resistor...

Page 28: ... C 68 F 1 27 1 29 80D26R 1 25 1 27 Others INSPECTION OF AIR FILTER Paper Filter Type 1 INSPECT AIR FILTER Visually check that the filter element is not excessively dirty damaged or oily 2 CLEAN AIR FILTER Clean the filter element with compressed air First blow from the inside thoroughly Then blow off the outside of the filter element Washable Type 1 INSPECT AIR FILTER Visually check that the filte...

Page 29: ...water by shaking the filter element or blowing with compressed air NOTICE Do not beat or drop filter element e Wipe off dust on the air cleaner case interior INSPECTION OF ALTERNATOR DRIVE BELTS See step 3 on page CH 3 Drive belt deflection New belt 7 10 mm 0 28 0 39 in Used belt 10 15 mm 0 39 0 59 in Drive belt tension Reference New belt 40 6 0 kg Used belt 20 35 kg INSPECTION OF GLOW PLUGS See p...

Page 30: ...lves indicated in the illustration Using a feeler gauge measure the clearance be tween the valve lifter and camshaft Record the valve clearance measurements which are out of specification They will be used later to determine the required replacement adjusting shim Valve clearance Cold Intake 0 20 0 30 mm 0 008 0 012 in Exhaust 0 40 0 50 mm 0 016 0 020 in b Turn the crankshaft one revolution 360 an...

Page 31: ... A Measuredvalve clearance N Thickness of new shim Intakeside N T A 0 25 mm 0 010 in Exhaustside N T A 0 45 mm 0 018 in Select a new shim with a thickness as close as pos sible to the calculated values HINT Shims are available in seventeen sizes in incre ments of 0 050 mm 0 0020 in from 2 500 mm 0 0984 in to 3 300 mm 0 1299 in f Install a new adjusting shim Place a new adjustingshim on the valve l...

Page 32: ...E New shim thickness rnrn in Shim Shim I No Thickness 1 1 Thickness I Intakevalve clearance Cold 0 20 0 30 mm 0 008 0 012 in EXAMPLE The 2 80 0 rnrn 0 1102 in shim is installed and the measured clearance is 0 350 rnrn 0 0138 in Replace the 2 800 rnrn 0 1102 in shim with a No 21 shim ...

Page 33: ...sting Shim Selection Using Chart EXHAUST Exhaustvalve clearance 0 40 0 50 rnm 0 016 0 020 in EXAMPLE The 2 800 mm 0 1102 in shim is installed and the measured clearance is 0 350 mm 0 0138 in Replace the 2 800 mm 0 1102 in shim with a No 11 shim ...

Page 34: ...ing injection pump to injection pump stay 2 Two nuts holding injection pump to timing belt case HINT Do not loosen the union nuts of injection pump more than 114 of a turn b Slightly tilt the injection pump body and align the belt case mark with the center mark on the pump flange to the correct overlap dimension c Tighten the following bolts and nuts 1 Two nuts holding injection pump to timing bel...

Page 35: ... from the timing pointer 2L T RELEASE ACSD ADVANCE a Using a screwdriver turn the cold starting lever counterclockwise approx 20 b Put a metal plate thickness of 8 5 10 mm 0 335 0 394 in between the cold starting lever and thermo wax plunger ADJUST INJECTION TIMING a Set the dial indicator at 0 mm 0 in b Recheck to see that the dial indicator remains at 0 mm 0 in while slightly rotating the cranks...

Page 36: ...ard the engine If the stroke is greater than specified tilt the pump away from the engine g Tighten the following bolts and nuts 1 Two nuts holding injection pump to timing belt case Torque 210 kg cm 15 ft lb 21 N m 8 Recheck the plunger stroke 2 Two bolts holding injection pump to injection pump stay Torque 185 kg cm 13 ft lb 18 N m 3 Four union nuts of injection pipes Torque 250 kg cm 18 ft lb 2...

Page 37: ...accelerator linkage b Start the engine c Check the idle speed Idle speed 2L T 700 800 rpm 3L 650 750 rpm d Adjust the idle speed Disconnectthe accelerator linkage Loosen the lock nut of the idle speed adjusting screw Adjust the idle speed by turning the IDLE SPEED ADJUSTING SCREW Idle speed 2L T 750 rpm 3L 700 rpm Securely tighten the lock nut and recheck the idle speed Reconnect the accelerator l...

Page 38: ...4020 W O HAC Loosen the lock nut of the maximum speed adjust ing screw Adjust the maximum speed by turning the MAXI MUM SPEED ADJUSTING SCREW Maximumspeed 2L T 4 800 rpm 3L Hong Kong Singapore and Malaysia 4 400 rprn 3L Others 4 600 rprn HINT Adjust at idle speed Then raise engine speed and recheck the maximum speed 2L Tand w HAC UsingSST securely tighten the lock nut SST 09275 54020 W O HAC Secur...

Page 39: ...ctly CONNECT TACHOMETER ADJUST AIR CONDITIONER IDLE UP SETTING SPEED a Start the engine b AICswitchesON c Disconnect the vacuum hose from the idle up actua tor d Apply vacuum to the idle upactuator e Race the engine to 2 500 rpm for a few seconds release the throttle and check the idle up setting speed A C idle upsetting speed 950 rprn f Adjust the idle up setting speed by turning the IDLE UP SETT...

Page 40: ...that vacuum operates on diaphragm chamber B so that the rods are pulled up Check that when the accelerator pedal is depressed atmospheric air operates on both diaphragm cham bers so that the rods return Check that when the starter switch is turned OFF engine stopped from idling condition vacuum operates on both diaphragm chambers so that the rods are pulled up Check that after the starter switch i...

Page 41: ...aphragm chamber so that the rods return c Check that after the starter switch is turned OFF the rods gradually return INSPECTION OF INTAKE VENTURI SYSTEM COMPONENTS 1 INSPECT VENTURI a Fully close the throttle valve and check that it re turns smoothly b Austria Using the hand help vacuum pump check that when vacuum is gradually applied to diaphragm chamber B of the actuator the throttle valve open...

Page 42: ...hmmeter check that there is continuity be tween the terminals Resistance Cold 37 44 2 If there is no continuity replace the VSV C Inspect VSV for ground Using an ohmmeter check that there is no continuity be tween each terminal and the body If there is continuity replace the VSV lnspect VSV operation a Check that air flows from pipes E to G b Apply battery voltage across the terminals c Check that...

Page 43: ...ow plug hole SST 09992 00024 09992 00121 b Connect SST compression gauge to SST attach ment SST 09992 00024 09992 00121 09992 00211 c Fully open the throttle valve d While cranking the engine measure the compression pressure HINT Always use a fully charged battery to obtain engine revolution of 250 rpm or more e Repeat steps a through d for each cylinder NOTICE This measurement must be done in as ...

Page 44: ... cylinder with lowcompression If adding oil helps the compression chances are that the piston rings and or cylinder bore are worn or damaged If pressure stays low a valve may be sticking or seating improperly or there may be leakage past the gasket REINSTALL GLOW PLUGS w Intake Pipe REINSTALL INTAKE PIPE REINSTALL AIR CLEANER RECONNECT INJECTION PUMP FUEL CUT SOLENOID CONNECTOR ...

Page 45: ... Heat Cover No 2 Heat Insulator e Valve Lifter Camshaft Bearing Cap Keeper Spring Retainer Camshaft Bearing valve Spring 8 Oil Seal Spring Seat EGR Valve and Pipe Combustion Chamber Belt Cover EGR Valve Adaptor 11 I kg cm ft lb m Specified torque Venturi Assembly Air Pipe Austria Non reusablepart EM92 ...

Page 46: ...MSHAFT TIMING PULLEY REMOVE NO 2 TIMING BELT COVER Remove the four bolts and belt cover REMOVE WATER OUTLET AND OUTLET HOUSING ASSEMBLY a Disconnect the water temperature switch connector b Disconnect the by pass hose from the thermo wax of the injection pump c Remove the three bolts water outlet outlet housing assembly and gasket REMOVE LH ENGINE HANGER LN REMOVE VENTURI ASSEMBLY a Disconnect the...

Page 47: ...gaskets b Disconnect the connectors from the VSV and EVRV c Remove the three bolts and EGR control valve assembly d Remove the two nuts EGR valve with the pipe and gasket REMOVE INTAKE MAN1FOLD a Remove the nut and insulator of the glow plug re sistor b Remove the six bolts two nuts intake manifold and gasket REMOVE EXHAUST MANIFOLD a Remove the four bolts nut and two heat insulators ...

Page 48: ...e eighteen cylinder head bolts in several passes in the sequence shown NOTICE Head warpage or cracking could result from removingbolts in incorrect order b Lift the cylinder head from the dowels on the cy linder block and place the head on wooden blocks on a bench HINT If the cylinder head is difficult to lift off pry with a screwdriver between the cylinder head and block NOTICE Be careful not to ...

Page 49: ...3L 54 290 54 310 mm 2 1374 2 1382 in Exhaust 54 990 55 010 mm 2 1650 2 1657 in Minimum cam lobe height lntake 2L T 52 95 mm 2 0846 in 3L 53 79 mm 2 1177 in Exhaust 54 49 mm 2 1453 in If the cam lobe height is smaller than the minimum replacethe camshaft ASSEMBLY OF CYLINDER HEAD See page EM 35 INSTALL HALF CIRCULAR PLUG a Remove any old packing FIPG material b Apply seal packing to the half circul...

Page 50: ...needle on the piston measuring point c Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclock wise d Set the dial indicator a t 0 mm 0in e Measure the piston protrusion from the cylinder block by sliding the dial indicator Protrusion 0 68 0 97 rnrn 0 0268 0 0382 in HINT For each piston measure the piston protrusion a t two measuring points When removi...

Page 51: ...0591 0 0630 in Mark F 1 60 1 70 mm 0 0630 0 0669 in When selecting a new cylinder head gasket use the largest value from the eight measurements made of the piston protrusion HINT There are 6 types of cylinder head gasket marks A to F installed a t the factory but only 3 types for sup ply parts mark B D and F so when replacing the gasket choose from one of the 3 types above SET NO 1 CYLINDER TO TDC...

Page 52: ...of engine oil on the threads and under the heads of the cylinder head bolts b First install and uniformly tighten the eighteen cy linder head bolts in several passes in the sequence shown Torque 800 kg cm 58 ft lb 78 N m HINT The bolt lengths for bolt types A and B shown in the illustration are A 107 mm 4 12 in B 127 mm 5 00 in If any one of the bolts does not meet the torque specifica tion replac...

Page 53: ...cover c Install the cylinder head cover with the eight bolts and two nuts Torque 50 kg cm 43in lb 4 9 N m INSTALL RH ENGINE HANGER Torque 380 kg cm 27 ft lb 37 N m INSTALL EXHAUST MANIFOLD a Install a new gasket in direction as shown in the illust ration b Install the exhaust manifold with the four nuts and four bolts Torque 530 kg cm 38 ft lb 52 N m c Install the two heat insulatorswith the four ...

Page 54: ... insulator and nut to the glow plug resistor HINT lnstall the insulator and engine wire terminals as shown in the illustration Austria INSTALL EGR VALVE PIPE VALVE ADAPTOR AND CONTROL VALVE ASSEMBLY a Place a new gasket in position on the intake manifold b lnstall the EGR valve and pipe with the two nuts Torque 130 kg cm 9 in lb 13 N m c lnstall the EGR control valve assembly with the three bolts ...

Page 55: ...orque 195kg cm 14ft lb 19N m b Connect the by pass hose to the thermo wax of the injection pump c Connect the water temperature switch connector 12 INSTALL NO 2 TIMING BELT COVER Install the timing belt cover with the four bolts Torque 185 kg cm 13 ft lb 18 N m 13 INSTALL CAMSHAFT TIMING PULLEY 14 INSTALL INJECTION NOZZLES 15 INSTALL INJECTION PUMP Seesteps 2 to 11on pages FU 46and 47 16 INSTALL T...

Page 56: ...TD mark 1 96 000 96 010 mm 3 7795 3 7799 in STD mark 2 96 010 96 020 mm 3 7799 3 7803 in STD mark 3 96 020 96 030 mm 3 7803 3 7807 in Maximum diameter 2L T STD 92 23 mm 3 6311 in 01s 0 50 92 73 mm 3 6508 in 3L STD 96 23 mm 3 7886 in 01s 0 50 96 73 mm 3 8083 in If the diameter is greater than maximum rebore all four cylinders If necessary replace the cylinder block INSPECTION OF PISTON AND CONNECTI...

Page 57: ...201 3 EM5482 EM568C Standard oil clearance 0 050 0 070 mm 0 0020 0 0028 in Maximum oil clearance 0 14 mm 0 0055 in If the oil clearance is greater than maximum replace all four pistons and rebore all four cylinders If necessary replacethe cylinder block HINT Use cylinder block subassembly When installing a standard piston install one with the same number mark as the standard bore diameter mark on ...

Page 58: ...TING ROD Inspect connecting rod alignment Using a rod aligner check the connecting rod alignment 0 Check for bending Maximum bending 0 05 mm 0 0020 in per 100 mm 3 94 in If bent is greater than maximum replace the connecting rod assembly Check for twist Maximum twist 0 15 mm 0 0059 in per 100 mm 3 94 in If twist is greater than maximum replace the connecting rod assembly lnspect connecting rod bol...

Page 59: ...r Replace the piston rings with ones to match the over sized pistons KEEP OVERSIZED PISTONS Oversized 01s 0 50 piston diameter 2L T 92 440 92 470 mm 3 6394 3 6405 in 3L 96 440 96 470 mm 3 7968 3 7980 in CALCULATE AMOUNT TO BORE CYLINDER a Using a micrometer measure the piston diameter a t right angles to the piston pin center line the indicat ed distance from the piston head Distance 2L T 58 27 58...

Page 60: ...ameter STD 54 988 55 000 mm 2 1649 2 1654 in U S 0 25 54 745 54 755 mm 2 1553 2 1557 in U S 0 50 54 495 54 505 mm 2 1455 2 1459 in If the diameter is not as specified check the oil clearance b Check each main journal and crank pin for taper and out of roundas shown Maximum taper and out of round 0 02 mm 0 0008 in If the taper or out of round is greater than maximum grind or replace the crankshaft ...

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Page 62: ... hence exhaust gas to turn the turbine or supercharger raises the potential power output type using the engine crankshaft etc to mechani In other words by installing a special turbo cally turn the pump etc For LAND CRUISER charger and providing a higher air than usual and 4 RUNNER 2L T engine the turbocharger engine output can be increased by increasing the type has been adopted average combustion...

Page 63: ...turbine wheel revolutions increase approx 20 000 115 000 rpm thus the turbocharged air pressure grows greater and engine output increases If the turbocharged air pressure exceeds the prescribed air pressure the flow of exhaust gas by passes the turbine controlling turbine wheel revolutions and turbocharged air pressure This by pass valve which controls the quantity of ex haust gas flowing to the t...

Page 64: ...ing or grasp it by easily deformed parts such as the actuator or rod when moving it Before removing the turbocharger plug the intake and exhaust ports and oil inlet to prevent entry of dirt or other foreign material If replacing the turbocharger check for accumulation of sludge particles in the oil pipes and if necessary replace the oil pipes Completely remove the gasket adhered to the lubrication...

Page 65: ...cm2 8 7 11 5 psi 60 79 kPa If the pressure is below specification begin diagnosis from item 2 Check intake air system and repair or replaceparts as necessary Seepage TC 8 3 LEAK IN IN Check intake air system and repair or replace parts as necessary See page TC 8 4 RESTRICTED EXHAUST SYSTEM Check exhaust system and repair or replace parts as necessary See page TC 8 5 LEAK IN EXHAUST SYSTEM Check ex...

Page 66: ...IL CONSUMPTION OR WHITE EXHAUST necessary Check for exhaust pipe deformation loose mounting Possible Cause Check Procedure and Correction Method bolts or a damaged gasket and repair or replace as I FAULTY TURBOCHARGER OIL SEAL Check for oil leakage in exhaust system Remove the turbine elbow from the turbocharger and check for excessive carbon deposits on the turbine wheel Excessive carbon deposits...

Page 67: ...re switch and tachometer switch Amber light comes on Check for open circuit in Faulty high pressure and tachometer and check for ground connectionof switch switch l YES t Does green indicator light come on when 0 14 kg cm2of 2 0 psi 13 7 kPa pressure is applied to both pressure switches Check for short circuit in wire harness between low pressure Faulty low pressure switch and tachometer switch YE...

Page 68: ...ts Check and replace CHECK TURBOCHARGING PRESSURE a Warm up the engine b Connect a 3 way union to the intake pipe pressure hose and install SST turbocharger pressure gauge to it SST 09992 00241 b Press in the clutch pedal then press the accelerator pedal down as far as it will go Measure the turbo charging pressure at 2 400 rpm or more Standard pressure 0 61 0 81 kg cm2 8 7 11 5 psi 60 79 kPa If t...

Page 69: ...i TURBOCHARGER SYSTEM Turbocharger TC 9 COMPONENTS Intake Pipe kg cm ft lb N m 1 Specified torque Non reusablepart ...

Page 70: ...Remove the three nuts intake pipe and gasket 3 DISCONNECT WATER BY PASS HOSES 4 REMOVE TURBO HEAT INSULATORS Removethe four bolts and three heat insulators 5 REMOVE EXHAUST MANIFOLD STAY Remove the two bolts two nuts and exhaust manifold stay 6 REMOVE TURBO OIL PlPE a Remove the union bolt and two gaskets holding the turbo oil pipe to the cylinder block b Disconnectthe turbo oil hose c Remove the ...

Page 71: ...PECTION OF TURBOCHARGER 1 INSPECT IMPELLER WHEEL ROTATION Grasp the edge of the turbine wheel and turn it Check that the impeller wheel turns smoothly If the impeller wheel does not turn or if it turns with a drag replacethe turbocharger assembly 2 INSPECT AXIAL PLAY OF IMPELLER WHEEL Insert a dial indicator into the intake side hold the turbine wheel edge by hand and check the axial play Axial pl...

Page 72: ...ATION a Disconnect the actuator hose b Using SST turbocharger pressure gauge apply ap prox 0 81 kg cm2 11 5 psi 79 kPa of pressure to the actuator and check that the rod moves SST 09992 00241 If the rod does not move replace the turbocharger assem bly NOTICE Never apply more than 0 95 kg cm2 13 5 psi 94 kPa of pressure to the actuator NOTICE After replacing the turbocharger assembly pour approx 20...

Page 73: ...b lnstall the turbocharger with the four nuts Torque 530 kg cm 38 ft lb 52 Nom 4 INSTALL TURBO OIL PlPE a lnstall a new gasket and the turbo oil pipe with the two nuts Torque 195 kg cm 14ft lb 19 N m b Connect the turbo oil hose c lnstall two new gaskets and the union bolt of the turbo oil pipe Torque 260 kgcm 19 ft lb 25 N m 5 INSTALL EXHAUST MANIFOLD STAY lnstall the exhaust manifold stay with t...

Page 74: ...120 kg cm 9 ft lb 12 N m 7 CONNECT WATER BY PASS HOSES 8 INSTALL INTAKE PIPE a Connect the air hose and install a new gasket and the intake pipe with the three nuts Torque 120 kg cm 9ft lb 12 Nsm b Connect boost compensatorvacuum hoses 9 FlLL ENGINE WITH COOLANT See page CO 5 10 START ENGINE AND CHECK FOR LEAKS 11 CHECK ENGINE OIL LEVEL ...

Page 75: ... FUEL SYSTEM REFER TO 2L 3L ENGINE REPAIR MANUAL Pub No RM123E NOTE The following pages contain only the points which differ from the above listed manual Page FUEL HEATER SYSTEM LJ FU 2 INJECTION PUMP FU 3 ...

Page 76: ...tch body Resistance Approx 0 7 L at 20 C 68 F If the resistance is not as specified replace the fuel heater and vacuum switch assembly Vacuum Switch INSPECT SWITCH CONTINUITY Using an ohmmeter check that there is no continuity be tween terminal 1 and the switch body If continuity is not as specified replace the fuel heater and vacuum switch assembly INSPECT SWITCH OPERATION a Apply a vacuum of 285...

Page 77: ...e 2L T I Thermo Wax Water By PassHose 2L T Fuel Hose I Fan 1 1 700 123 167 I clamp Crankshaft Pulley No 1 Timing Belt Cover Injection Pipe Accelerator Linkage Injection PumpStay Y O HAC Fuel Outlet Pipe I 250 18 25 Gasket Fuel lnlet Pipe kg cm ft lb N m 1 Specified torque Non reusablepart ...

Page 78: ...E UP VACUUM HOSE 12 2L T DISCONNECT WATER BY PASS HOSES FROM THERMO WAX 13 DISCONNECT INJECTION PUMP CONNECTOR S 14 DISCONNECT FUEL HOSES FROM INJECTION PUMP 15 REMOVE INJECTION PIPES a Loosen the union nuts of the injection pipes from the injection nozzles b Loosen the union nuts of the injection pipes from the injection pump c Remove the four clamps and injection pipes NOTICE On vehicles with PI...

Page 79: ...ot place new matchmarks for reinstallation the c Removethe two nuts and injection pump NOTICE Do not hold or carry the injection pump by the adjust ing lever Do not p i t the injection pump 2L T and w HAC at an angle more than 45 from the horizontal 17 REMOVE FUEL INLET AND OUTLET PIPES FROM INJECTION PUMP ...

Page 80: ...ring Austria Throttle Position Sensor Austria Adjusting Lever Push Rod Main Spring Maximum Speed Adjusting Screw Lever Return Spring Adjusting Lever Shaft F I Idle Speed Adjusting Screw Control Lever Support Pin 7 Ring Fuel Inlet Hollow Screw Gasket Regulator Valve Non reusablepart FU29i ...

Page 81: ... Gasket Rubber Cao Shim Push Rod Connecting Pin Control Lever Control Lever Support Pin Gasket Adjusting Lever L e v e r Return Spring Maximum Speed Adjusting Screw Governor Cover Idle Speed Adjusting Screw Adjusting Lever Shaft Speed Control Spring Non reusablepart Pump Body FU2922 ...

Page 82: ...or Piston Lift Gap I I Bearing IRetainer Fuel Cut Others I E Ring Solenoid Distributive Head Plug I Spring Distributive Head Plua Bolt No 2 Flyweight Washer Governor Link Ru bbe pace Lamplate 6 9 _ Drive Shaft Washer Distributive Head Feed Pump Cover Timer S rina Istopper Pin Timer Adjusting Screw I Slide Pin Timer Sub piston i m e r Piston O Ring d Non reusablepart LH i m e r Cover FU294 ...

Page 83: ...res from the connector b Remove the pickup sensor and O ring 2L T Austria REMOVE THROTTLE POSITION SENSOR Using a 5 mm hexagonal wrench remove the three bolts and throttle position sensor 2L T REMOVE IDLE UP LEVER Using a 5 mm hexagonal wrench remove the three bolts and idle up lever 2L T REMOVE THERMO WAX a Using a screwdriver turn the cold starting lever counterclockwise approx 20 b Put a metal ...

Page 84: ...LENOID a Using a 6 mm hexagonal wrench remove the bolt and connector bracket b Disconnect the lead wire connector from the bracket c Disconnect the dust cover from the fuel cut solenoid d Remove the nut lead wire and dust cover e Remove the fuel cut solenoid O ring spring valve strainer and wave washer REMOVE ADJUSTING LEVER Remove the bolt nut adjusting lever and return spring ...

Page 85: ...the speed control spring from the spring seat and remove the spring seat damper spring speed control spring governor cover adjusting lever shaft assembly and gasket 12 REMOVE GOVERNOR ADJUSTING LEVER SHAFT FROM GOVERNOR COVER Remove the following parts from the governor cover 1 Adjusting lever shaft O ring and washer assem bly 2 O ring 3 Washer 13 2L T DISASSEMBLE BOOST COMPENSATOR A Remove boost ...

Page 86: ...a only 2 Sub spring Austria only 3 Diaphragmand push rod 4 Main spring 5 Boost compensator shim A 1 1 I B Remove guide bushing C Remove control lever a Using a 4 mm hexagonal wrench remove the two bolts and gaskets b Using a small screwdriver push out the support pin and remove the control lever c Using a 4 mm hexagonal wrench remove the plug and gasket ...

Page 87: ...4 2L TAustria REMOVE PILOT INJECTION PIJ ACTUATOR Usingthe PIJ socket remove the PIJ actuator Part No 95096 10380 NIPPONDENSO 15 2L T Austria PIJ INJECTION PRESSURE TEST a Using the PIJ retaining socket remove the plug bolt and gasket Part No 95096 10390 NIPPONDENSO PIJ Connector Y b Using the PIJ socket install the PIJ actuator on the PIJ connector and torque Part No 95096 10380 and95096 10400 NI...

Page 88: ...ng pressure is not as specified disassemble the PIJ actuator and change the adjusting shim on the top of the pressure spring mm in I Adjustin 1 025 0 0404 1 300 0 0512 1 050 0 0413 1 PIJ RetainingSock PIJ Body Socket FU2949 himthickness 1 575 0 0620 1 SO0 0 0630 1 625 0 0640 1 650 0 0650 1 675 0 0659 1 700 0 0669 1 725 0 0679 1 750 0 0689 1 775 0 0699 1 800 0 0709 1 825 0 0719 HINT Varying the adj...

Page 89: ...upling spring 16 0 mm 0 630 in Pneumatic bellowsspring wl HAC 35 0 mm 1 378 in Boost compensator main spring 2L T Austria 24 1 mm 0 949 in 2L T Others 19 4 mm 0 764 in Boost compensator sub spring 2L TAustria 22 3 mm 0 878 in If the free length is not as specified replacethe spring s 2L T Austria INSPECT ACCUMULATOR ASSEMBLY a Wash the accumulator in clean diesel oil NOTICE Do not touch the accumu...

Page 90: ... T Others and 3L New plunger spring shim thickness 5 9 A A Measuredplunger position Plunger spring shim selection chart for 2L T Austria rnrn in Measured Shim Measured Shim clearance thickness clearance thickness More than 3 6 3 8 4 6 0 181 5 0 059 0 142 0 150 2 5 0 098 4 1 4 2 Less than 0 1 6 1 0 165 2 0 0 079 3 2 0 126 3 0 0 1 18 Plunger spring shim selection chart for 2L T Others and 3L More th...

Page 91: ...PIJ body socket and PIJ retaining socket install the retaining nut Part No 95096 10390and95096 10400 NIPPONDENSO Torque 675 kg cm 49 ft lb 66 N m c Placethe PIJ actuator and magnet stand on top of the surface place insert the measure attachment in the thread hole in the plug bolt and set the dial gauge Part No 95096 10420 NIPPONDENSO d Set the dial indicator scale to 0 mm 0 in on top of the measur...

Page 92: ...he plug bolt hole of distributive head plug SST 09275 5401 0 d Install the marking guide to the drive shaft align the plunger with lower dead center and set the dial indi cator a t 0 mm 0 in Part No 95096 10430 NIPPONDENSO e Rotate the drive shaft in the pump rotation direction and use a punch to engrave the flange when the plunger lift plunger stroke is a t maximum valve Part No 95096 10440 NIPPO...

Page 93: ...cm 65 ft lb 88 Nm NOTICE Check that the PIJ actuator and injection are clean and free of foreign material 2L T ASSEMBLE BOOST COMPENSATOR lnstall No 2 overflow screw Install the No 2 overflow screw and cover Install control lever a Insert the connecting pin into the governor cover b Using a 4 mrn hexagonalwrench install the plug with a new gasket c Using a small screwdriver install the control lev...

Page 94: ...ernor cover Part No 95096 10330 NlPPONDENSO b Measure the distance between the end surface of the control lever and the attachment measure 1 lnstall the shim and diaphragm HINT Do not assemble the spring 2 With the push rod against the surface flat part measure dimension L2 with vernier calipers as shown Dimension L2 Austria Approx 10 75 mm 0 4232 in Others Approx 10 39 mm 0 4091 in HINT Dimension...

Page 95: ...ness 1 1mm 0 043 in 1 3 mm 0 051 in 1 5 mm 0 059 in 1 7 mm 0 067 in 1 9 mm 0 075 in 2 1 mm 0 083 in 2 3 mm 0 090 in 2 5 mm 0 098 in 2 7 mm 0 106 in 2 9 mm 0 114 in 3 1 mm 0 122 in 3 3 mm 0 130 in 4 Removethe diaphragm and push rod c Insert 1 5 2 5 cc 0 09 0 15 cu in of engine oil into the bushing hole d Install the following parts 1 Boost compensator shim A 2 Main spring 3 Diaphragmand push rod 4 ...

Page 96: ...ute pressure to the boost compensator and measure dimension L5 with vernier calipers as shown Select shim B to adjust AL3 obtained as the difference between L5 and L2 measured in b Difference A L3 1 70 1 94 mm 0 0669 0 0764 in Adjustingshim thickness 12 90 mm 0 508 in 13 15 mm 0 518 in 13 40 mm 0 528 in 0thers Apply 0 27 kg cm2 3 8 psi 26 kPa of pressure to the boost compensator and measure dimens...

Page 97: ...usting lever shaft to the governor link and twist the shaft lightly c 3L Install the speed control spring to the adjusting lever shaft dl 3L lnstall the damper spring and spring seat and connect the speed control spring to the spring seat e Using a 5 mm hexagonal wrench install the governor cover with the four bolts Torque 85 kg cm 74 in lb 8 3 N m HINT Use the bolt which is 35 mm 1 38 in length f...

Page 98: ...EL CUT SOLENOID a lnstall a new O ringon the fuel cut solenoid b lnstall the strainer valve spring a new gasket and the fuel cut solenoid Torque 225 kg cm 16 ft lb 22 N m c lnstall the lead wire to the fuel cut solenoid with the nut d lnstall the dust cover to the fuel cut solenoid e lnstall the lead wire connector to bracket f Using a 6 rnm hexagonal wrench install the con nector bracket with the...

Page 99: ...lunger c Install a new O ring to the pump body dl Using a 5 mm hexagonal wrench install the thermo wax with the two bolts 12 2L T INSTALL IDLE UP LEVER Using a 5 mm hexagonal wrench install the idle up lever with the three bolts 13 2L TAustria INSTALL AND CHECK THROTTLE POSITIONSENSOR a Using a 5 mm hexagonal wrench install the throttle position sensor with the three bolts b Using an ohmmeter chec...

Page 100: ... I 2L T and w HAC 4 7 3 2 D FU2129 17 PERFORM AIR TIGHT TEST a Install a bolt to the overflow port 16 REMOVE INJECTION PUMP FROM SST STAND b Connect an air hose to the fuel inlet pipe and place the injection pump into diesel fuel NOTICE On vehicles with the throttle position sensor 2L T Austria be careful not to immerse sensor in diesel fuel c Apply 0 5 kg cm2 7 psi 49 kPa of pressure and con firm...

Page 101: ...200 kPa b Check the accuracy of the tachometer Allowable error 40 rpm c lnstall the angle gauge stand d Mount the injection pump body on the pump tester HINT Place a mark on the key groove portion of the coupling e Install an injection pipe with the following specifica tions Outer diameter 6 0 mm 0 236 in Inner diameter 2 0 mm 0 079 in Length 840 mm 33 07 in Minimum bendingradius 25 mm 0 98 in or ...

Page 102: ... a 5 mm hexagonal wrench remove the two bolts and RH timer cover j Install the inner pressure gauge with the timer measuringdevice Part No 950 10220and 95095 10231 NIPPONDENSO HINT Bleed air by the air bleed screw k 2L T Connect SST turbocharger pressure gauge to the boost compensator SST 09992 00241 Nozzle SST 2L T I only Overflow Port f 1 I I I Measuring Cylinder I Fuel Feed ...

Page 103: ...ould be 40 45 C 104 n Install an angle gauge to the stand and set it to the adjusting lever 0 Secure the adjusting lever fully on the maximum speed side p Check the installation direction of the camplate as follows 0 Disconnect the injection pipe from the position marked C on the distributive head 0 UsingSST removethe delivery valve holder SST 09260 54012 09269 54020 Check that fuel is flowing out...

Page 104: ...d the air from the injec tion pipes r Race the injection pump for 5 minutes at 2 000 rpm NOTICE Check that there is no fuel leakage or abnormal noise HINT 0 Measure the volume of each injection cylinder with a measuringcylinder Before measuring the injection volume first hold the cylinder tilted for a t least 30 seconds to discard all the fuel ...

Page 105: ...he boost compensator d Measurethe injection volume e Remove the collar seal as follows 0 Hold the full load set screw and release the collar seal from the spot weld by turning the lock nut counterclockwise 90 or more Item IPump rpm No of measuring strokes Using a screwdriver remove the collar seal Injection volume cc icu in 1 f Adjust by turning the full load set screw HINT The injection volume wi...

Page 106: ... kg cm2 9 0 psi 62 kPa of pressure to the boost compensator d Measure the injection volume Injectionvolume cc cu in 2L T Maximum Speed Adjusting Screw No of measuringstrokes Item I 3L e Cut off the seal wire f Adjust the injection volume with the maximum speed adjusting screw Pump rpm Austria Others 5 ADJUST PUMP INNER PRESSURE Hong Kong Singapore Malaysia Others a Measure the pump inner pressure ...

Page 107: ...g a screwdriver turn the cold starting lever counterclockwise approx 20 b Put a metal plate thicknessof 8 5 10mm 0 33 0 39 in between the cold starting lever and thermo wax plunger HINT Keep the cold starting system released until all measurements and adjustmentsare finished 8 ADJUST TIMER a Set the timer measuringdevice at zero b Measurethe piston stroke at the below listed rpm Piston stroke mrn ...

Page 108: ...INJECTION VOLUME a The adjusting lever angle for the adjustment below should be as shown in the illustration I Adjusting lever angle I I A Maximumspeed side I B Idle speed side I I Plus 23 5 33 5 I Minus 12 5 22 5 b 2L TAustria Apply 0 68 kg cm2 9 6 psi 66 kPa of pressure to the boost compensator c 2L TOthers Apply 0 63 kg cm2 9 0 psi 62 kPa of pressure to the boost compensator d Measure the full ...

Page 109: ...ssure to the boost compensator c Measure the injection volume at each pump rpm Adjusting No of Pump measuring lnjectionvolume lever angle Remarks rpm cc cu in position strokes 4 3 6 3 0 26 0 38 Plus 8 3 10 5 0 51 0 64 23 5 33 5 2 750 1 3 0 8 or less Plus 1 7 1 9 3 0 43 0 57 23 5 33 5O 2 750 1 3 0 8 or less 2 200 4 6 6 2 0 28 0 38 Adjust Plus 2 000 200 8 44 10 44 0 52 0 64 23 5 33 5 2 400 1 3 0 8 o...

Page 110: ...e plug 1 Stop ring 2 Bearing and two bearing retainers Measure the head thickness of the sleeve plug and select a new sleeve plug I Sleeve plug head thickness mrn in I HINT Lengthening the plug 0 1 mm 0 004 in will in crease injection volume by 0 6 cc 0 04 cu in Install the following parts to the new sleeve plug with a new E ring 1 Bearing and two retainers 2 Stop ring 2L T CHECK AND ADJUST FULL L...

Page 111: ... stopper Austria 2L T ADJUST BOOST COMPENSATOR CHARACTERISTIC Others a Apply pressureto the boost compensator b Measure the injection volume bushing 200 1 400 8 8 10 0 10 54 0 61 c Usinga screwdriver adjust the guide bushing HINT When the guide bushing is turned clockwise as seen from above the injection volume will increase Item Austria Others Pump rPm 500 1 200 Boost pressure kg cm2 psi Pa 0 0 0...

Page 112: ...t compensator injection volume characteristictendency c Adjust cold starting injection volume F U Z 67012 FU2973 68899 1 Austria I 500 1 0 41 5 9 40 1 200 1 14 6 15 4 0 89 0 93 1 I I I I Others 1 200 0 14 1 9 13 200 11 2 12 0 0 68 0 73 I Item la Sub Spring Boost pressure kg cm2 psi kPa Pump rpm c Austria If the injection volume is not as specified replace the sub spring of the boost compensator wi...

Page 113: ...int of the Austria Others load sensing timer Idle Speed Maximum Side Speed Side Adjusting Lever Position 2 3 1 7 FU0251 1 400 1 400 500 500 1 200 1 200 1 200 1 200 I f not within standard value check each sliding part of the boost compensator and check whether or not there is any oil 16 2L T and w o HAC ADJUST LOAD SENSING TIMER 0 74 10 5 73 0 68 9 6 66 0 41 5 9 40 O 0 0 0 74 10 5 73 0 63 9 0 62 0...

Page 114: ...surement again as specified HINT The injection volume will increase approx 3 cc 0 2 cu in with each 112 turn of the governor shaft h Check the end point injection volume by slowly mov ing the adjusting lever from the maximum speed side to the idle speed side and secure it at the point where the pump inner pressure stops dropping No of lnjection Pump measuring volume I I strokes 1 cc cu in 3L i Che...

Page 115: ...me limit Remarks cc cu in cc CU in 13 94 14 26 0 4 Basic full load 0 85 0 87 0 02 injectionvolume 13 60 18 40 1 2 Volume during 0 83 1 12 0 07 starting 13 70 15 10 0 5 0 84 0 92 0 03 12 30 13 70 0 5 0 75 0 84 0 03 11 60 12 80 0 5 0 7 1 0 78 0 03 13 94 14 26 0 4 Basic full load 0 85 0 87 0 02 injectionvolume 13 60 18 40 1 2 Volume during 0 83 1 12 0 07 starting 12 10 13 10 0 5 0 74 0 80 0 03 10 96 ...

Page 116: ...hers 3L Adjusting lever angle position Minus 12 5 22 5 1 200 Variation Injection volume limit Remark cc cu in cc cu in Pump rpm 200 200 Minus 13 5 21 5 Minus 13 5 21 5 q plus 0 5 0 03 or more q minus 1 1 2 1 0 07 0 13 No of measuring strokes 375 350 450 375 350 450 q plus 0 5 0 03 or more 1 1 q minus 0 7 1 7 0 04 0 10 1 1 1 8 2 8 0 11 0 17 1 0 34 0 02 1 Adjust 1 2 0 07 or less d Adjust by turning ...

Page 117: ...t by turning the idle speed adjusting screw Austria Others 600 600 h 2L T lnstall the dash pot cover Item 2L T ADJUST COLD STARTING SYSTEM a Remove the overflow screw and check the fuel tem perature in the fuel pump Fuel temperature 15 35 C 59 95 F b Set the set key of the pump drive shaft in a vertical or horizontal position c Set the scale of the timer measuringdevice to zero d Check the adjusti...

Page 118: ...3 in lb 4 9 N m and keep the lever tightened for about 10 seconds Then release the torque g Measurethe timer piston stroke 1 Item I Timer piston stroke Fuel temperature mm in h Adjust by turning the timer adjusting screw HINT Screw in for stroke decrease Austria Others 20 2L T ADJUST FAST IDLE a Measure the clearance between the adjusting lever and idle speed adjustingscrew 25 C 7 7 2 5 77 F 0 7 0...

Page 119: ... ADJUSTMENT CHECK a Check that injection stops when the fuel cut solenoid harness is removed Pump revolution 100 rpm b Check the adjusting lever movement Adjusting lever angle 2L T 41 51 3L 43 49 22 SEAL PARTS Seal the maximum speed adjusting screw and full load set screws with new lead seals ...

Page 120: ...wo nuts holding the injection pump to the timing belt case Torque 210 kg cm 15 ft lb 21 N m c Install the pump stay with the four bolts Torque 185 kg cm 13ft lb 18 N m CHECK INJECTION TIMING See page EM 24or 25 INSTALL INJECTION PIPES a Place the two lower clamps on the intake manifold b Install the four injection pipes Torque 250 kpcm 18 ft lb 25 N m NOTICE On vehicles with the PIJ 2L T Austria d...

Page 121: ...AGE INSTALL INJECTION PUMP DRIVE PULLEY Torque 650 kg cm 47 ft lb 64 N m SET NO 1 CYLINDER TO TDCICOMPRESSION INSTALL TIMING BELT CHECK VALVE TIMING INSTALL NO 1 TIMING BELT COVER INSTALL CRANKSHAFT PULLEY Torque 1 700 kg cm 123ft lb 167 N m INSTALL WATER PUMP PULLEY FLUID COUPLING AND FAN 2L T INSTALL TURBO WATER HOSE 2L T FILL WITH ENGINE COOLANT Seepage CO 5 START ENGINE AND CHECK FOR FUEL LEAK...

Page 122: ...NGINE REPAIR MANUAL Pub No RM123E NOTE The following pages contain only the points which differ from the above listed manual Page DESCRIPTION CO 2 TROUBLESHOOTING CO 4 CHECK AND REPLACEMENT OF ENGINE COOLANT CO 4 THERMOSTAT 2L T CO 6 ...

Page 123: ...LING SYSTEM Description DESCRIPTION This engine utilizes a pressurized water forced circulation cooling system which includesa thermostat equip ped with a by passvalve mounted on the inlet side 2L T From Heater ...

Page 124: ...0 C 212 F A relief valve pressurization valve and a vacuum valve negative pressure valve are built into the radiator cap When the pressure generated inside the cooling system exceeds the limit coolant tem perature 110 120 C 230 248 F pressure 0 3 1 0 kg cm2 4 3 14 2 psi 29 4 98 1 kPa the relief valve is opened by the pressure and lets steam escape through the overflow pipe The vacuum valve opens t...

Page 125: ...the thermostat would have an adverse effect causing a lowering of cooling efficiency Do not remove the thermostat even if the engine tends to overheat Radia Drain CHEC ENGlF K AND REPLACEMENT OF IE COOLANT CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The coolant level should be between the LOW and FU LL lines If low check for leaks and add coolant up to the FULL line CHECK ENGINE COOLANT QUALITY T...

Page 126: ... coolant should be mixed with demineralized water or distilled water Capacity w o Heater LJ 10 0 liters 10 6 USqts 8 8 Imp qts LN 2L T 8 2 liters 8 7 US qts 7 2 Imp qts 3L 8 1 liters 8 6 USqts 7 1 Imp qts Capacity w Heater LJ 10 9 liters 11 5 USqts 9 6 Imp qts LN 2L T 9 1 liters 9 6 US qts 8 8 Imp qts 3L 9 0 liters 9 5 US qts 7 9 Imp qts Capacity w Front and rear heaters LJ 2L T 11 5 liters 12 2 U...

Page 127: ... numbered with the valve open ing temperature a Immerse the thermostat in water and gradually heat the water b Check the valve opening temperature Valve opening temperature 86 90 C 187 194 F If the valve opening temperature is not as specified replace the thermostat c Check the valve lift Valve lift 8 mm 0 31 in or more at 100 C 212 F If the valve lift is not as specified replace the thermostat d ...

Page 128: ...HOUSING a Install a new gasket to the thermostat b Install the thermostat with the jiggle valve upward 2 INSTALL WATER OUTLET TO WATER OUTLET HOUSING Install the water outlet with the three bolts Torque 195kg cm 14ft lb 19N m 3 FILL WITH ENGINE COOLANT See page CO 5 4 START ENGINE AND CHECK FOR LEAKS ...

Page 129: ...EPAIR MANUAL Pub No RM123E NOTE The following pages contain only the points which differ from the above listed manual Page DESCRIPTION LU 2 OIL PRESSURE CHECK LU 4 REPLACEMENT OF ENGINE OIL AND OIL FILTER LU 5 OIL COOLER AND RELIEF VALVES 2L T LU 7 ...

Page 130: ...this engine 2L T I 1 I VALVE LIFTERS I I I C I I I CRANK JOURNALS CAMSHAFT OIL HOLE 4 I I I I OIL NOZZLE CAMSHAFT JOURNAL I I t 1 I No 3 I I CHECK VALVE t I I CYLINDER HEAD 1 I I I I I I I MAIN OIL HOLE 1 I I r I I TURBOCHARGER I 2L T only I OIL FILTER VACUUM PUMP I I I I I L I I I I I I I I OIL STRAINER I 3 t t I I OIL PAN ...

Page 131: ...wn in when the space widens and is discharged I when the space becomes narrow II OIL PRESSURE REGULATOR RELIEF VALVE A t high engine speeds the oil pump supplies more oil to each part that is necessary For this reason an oil pressure regulator which works to prevent oversupply of oil is installed on the oil pump During normal oil supply a coil spring and valve keep the by pass closed but when too ...

Page 132: ...E OIL LEVEL The oil level should be between the L and F marks on the dipstick If low check for leakage and add oil up to F mark NOTICE Do not fill with engine oil above the F mark REMOVE OIL PRESSURE SWITCH OR SENDER GAUGE HINT wlSender gauge Use SST SST 09027 12140 INSTALL OIL PRESSURE GAUGE WARM UP ENGINE Allow the engine to reach normal operating temperature CHECK OIL PRESSURE Oil pressure At i...

Page 133: ... the frequency and length of time your skin is exposed to used engine oil Protective clothing and gloves that cannot be penetrated by oil should be worn The skin should be thoroughly washed with soap and water or use waterless hand cleaner to remove any used engine oil Do not use gasoline thinners or solvents In order to preserve the environment used oil and used oil filters must be disposed of on...

Page 134: ...T 09228 10001 wl By passelement type 09228 44011 Full flow type LU0944 3 FILL WITH ENGINE OIL a Clean and install the oil drain plug with a new gasket Torque 400 kg cm 29 ft lb 39 N m b Fill with new engine oil API grade CC 3L only CD or better and recommended viscosity oil Capacity liters US qts Imp qts c Reinstall the oil filler cap 4 START ENGINE AND CHECK FOR LEAKS 5 RECHECK ENGINE OIL LEVEL S...

Page 135: ... prevent oil from flowing to main oil hole Non reusablepart Precoated part L U W REMOVAL OF OIL COOLER AND RELIEF VALVES DRAIN ENGINE COOLANT See page CO 4 REMOVE TURBOCHARGER See steps 2 to 7 on pages TC 10and 11 CONTROL VALVE ASSEMBLY See step 11on page EM 37 REMOVE EXHAUST MANIFOLD Seestep 13 on page EM 38 REMOVE ALTERNATOR LJ REMOVE UNION BOLT REMOVE OIL FILTER See page Austria REMOVE EGR VALV...

Page 136: ...valve Remove the two relief valves Front Rear HINT Arrange the spring and relief valves in correct order 10 REMOVE OIL COOLER AND OIL FILTER BRACKET ASSEMBLY Remove the nine bolts LN or ten bolts LJ two nuts the oil cooler filter bracket assembly and gasket 11 SEPARATE OIL COOLER AND OIL FILTER BRACKET Remove the four nuts the oil cooler and two gaskets from the filter bracket ...

Page 137: ...ssary replace the oil cooler INSTALLATION OF OIL COOLER AND RELIEF VALVES See page LU 7 ASSEMBLE OIL COOLER AND OIL FILTER BRACKET Install new gaskets and the oil cooler to the filter bracket with the four nuts Torque 145 kg cm 10 ft lb 14 N m INSTALL OIL COOLER AND OIL FILTER BRACKET ASSEMBLY Install a new gasket the oil cooler and filter bracket assembly with the nine bolts LN or ten bolts LJ an...

Page 138: ... side of the union Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent b UsingSST install and torque the union SST 09326 20011 Torque 430 kg crn 31ft lb 42 Nm HINT Use a torque wrench with a fulcrum length of 300 mm 11 81 in INSTALL OIL FILTER See page LU 5 LJ INSTALL UNION BOLT a Apply adhesive to two or three threads of the union bolt Adhesive Part No 08833 00070 THREE BOND 1324 or equiva...

Page 139: ... INSPECT DRIVE BELTS See step 3 on page CH 3 9 INSTALL EXHAUST MANIFOLD See step 6 on page EM 43 10 Austria INSTALL EGR VALVE PIPE VALVE ADAPTOR AND CONTROLVALVE ASSEMBLY See step 8 on page EM 44 11 INSTALL TURBOCHARGER Seesteps 3 to 8 on pagesTC 13and 14 12 FILL WITH ENGINE COOLANT Seepage CO 5 13 START ENGINE AND CHECK FOR LEAKS 14 CHECK ENGINE OIL LEVEL See page LU 4 ...

Page 140: ... 3L ENGINE REPAIR MANUAL Pub NO RMl23E NOTE The following pages contain only the points which differ from the above listed manual Page PRE HEATING SYSTEM ST 2 Super Glow Type 2L TI ST 2 Fixed Delay Type 3Ll ST 8 STARTER RELAY LJ ST 9 ...

Page 141: ... TI SYSTEM CIRCUIT LJ Austria W Others Starter Switch Resistor I Pre Heating Timer Emission Control ECU mWater Temperature Sensor AM1 GLOW F L 1 1 1 i p Battery Plug No Relay CilOw Plug No 1 Relay Glow E Resistor FL Pre Heating Timer 9Glow Plug d 9 To Alternator 7 Terminal L Water Temperature Sensor ...

Page 142: ...ay Pre Heating Timer Emission Control Water Temperature Sensor B9 INSPECTION OF PRE HEATING SYSTEM HINT Refer to Diesel Electrical System Diagnosis for inspection procedures See page EM 13 INSPECT LIGHTING TIME OF GLOW INDICATOR LIGHT Turn the starter switch ON measure the light lightingtime Light lightingtime Refer to chart Watei Temperature O C O F ST0910 ...

Page 143: ...k for Condition Specified value LJ LN Continuity B12 A1 Ground Continuity Voltage A2 A7 Ground Battery voltage Voltage 814 812 Ground I l l Turn starter switch OFF No voltage Turn starter switch ON Battery voltage Voltage Turn starter switch OFF No voltage 1A 1A 1 round Turn starter switch ON Battery voltage Continuity I B23 A5 I Ground I I Continuity I Continuity 1 815 B11 I Ground I I Continuity...

Page 144: ...as specified replace the relay INSPECT RELAY OPERATION a Apply battery voltage across terminals E and g b Using an ohmmeter check that there is continuity between terminals B and G If operation is not as specified replace the relay No 2 Glow Plug Relay LJ LOCATION In the engine compartment on the left side INSPECT RELAY CONTINUITY a Using an ohmmeter check that there is continuity between terminal...

Page 145: ...there is no continuity replace the glow plug HINT Be careful not to damage the glow plug pipes as it could cause an open circuit or shorten life of the plugs Avoid getting oil and gasoline on the glow plug when cleaning During inspection be sure to wipe any oil off the glow plug terminal and bakelite washer with a dry cloth Be careful to apply more than 11 volts to the glow plug as it could cause ...

Page 146: ... TI ST 7 Water Temperature Sensor d INSPECT TEMPERATURE SENSOR Using an ohmmeter measure the resistance between the sensor terminals Resistance Refer to chart I f the resistance is not as specified replace the sensor WATER TEMP SENSOR TEMPERATURE O C O F ...

Page 147: ...y Type 3L SYSTEM CIRCUIT Starter Switch 1 T Glow Plug Relay AM1 GLOW FL GLOW 7 5A Pre Heating Timer INSPECTION OF PRE HEATING SYSTEM INSPECT LIGHTING TIME OF GLOW INDICATOR LIGHT Turn the starter switch GLOW measure the light lighting time Light lightingtime Approx 6 seconds ...

Page 148: ... there is no continuity between terminals B and Mg If continuity is not as specified replacethe relay ST0813 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals E and ST b Using an ohmmeter check that there is continuity between terminals B and Mg If operation is not as specified replacethe relay STARTER RELAY LJ a LOCATION In the engine compartment on the left side ...

Page 149: ... SYSTEM REFER TO 2L 3L ENGINE REPAIR MANUAL Pub No RM123E NOTE The following pages contain only the points which differ from the above listed manual Page CHARGING SYSTEM CIRCUIT CH 2 ON VEHICLE INSPECTION CH 3 ...

Page 150: ...GING SYSTEM CIRCUIT LJ w Hi Speed Compact Type Alternator w IC Regulator w Tachometer W OTachometer Alternator LN w Conventional Type Alternator w o IC Regulator I Starter Switch 1 I 1 Europe 2 Others 55A Type I I I I Alternator Regulator Alternator 1 ...

Page 151: ...S a Visually check each belt for cracks oiliness or wear Check that the belt does not touch the bottom of the pulley groove If one belt has any of the above defects replace both belts b Check the drive belt deflection by pressing on the belt at the points indicated in the illustration with 10 kg 22 0 Ib 98 N of pressure Drive belt deflection New belt 7 10 mm 0 28 0 39 in Used belt 10 15 mm 0 39 0 ...

Page 152: ...o ON Check that the discharge warning light is lit d Start the engine Check that the light goes out If the light does not operate as specified troubleshoot the discharge light circuit 6 INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT If a batterylalternator tester is available connect the tester to the charging circuit as per manufacturer s instructions a If a tester is not available connect a voltmete...

Page 153: ...he regula tor If necessary replace regulator wl IC Regulator Standard amperage 10 A or less Standardvoltage 13 9 15 1 V at 25 C 77 F 13 5 14 3 V at 115 C 239 F If the voltmeter reading is greater than standard voltage replacethe IC regulator If the voltmeter reading is less than standard voltage check the IC regulator and alternator as follows With terminal F grounded start the engine and check th...

Page 154: ...pm turn on the high beam headlights and place the heater blower switch a t HI b Check the reading on the ammeter Standard amperage 30 A or more If the ammeter reading is less than standard amperage repair the alternator HINT With the battery fully charged the indication will sometimes be less than standard amperage ...

Page 155: ...L Pub No RM123E NOTE The following pages contain only the points which differ form the above listed manual Page ENGINE MECHANICAL A 2 TURBOCHARGER SYSTEM A 5 FUEL SYSTEM A 6 COOLING SYSTEM A 13 LUBRICATION SYSTEM A 14 STARTING SYSTEM A 14 CHARGING SYSTEM A 14 ...

Page 156: ...g pressure New nozzle Reused nozzle Valve clearance Intake Exhaust 10 0 liters 8 2 liters 8 1 liters 10 9 liters 9 1 liters 9 0 liters 11 5 liters 9 4 liters 9 3 liters 6 7 liters 5 7 liters 7 4 liters 6 7 liters 5 7 liters 7 4 liters 6 8 liters 5 8 liters 7 5 liters 5 8 liters 4 8 liters 6 5 liters CD or better 10 6 US qts 8 7 US qts 8 6 US qts 11 5 US qts 9 6 US qts 9 5 US qts 12 2 US qts 9 9 US...

Page 157: ... 80 mm 2 85 mm 2 90 mrn 2 95 mm 3 00 mm 3 05 mm 3 10 mrn 3 15 mm 3 20 mm 3 25 mm 3 30 mm 0 0984 in 0 1004 in 0 1024 in 0 1043 in 0 1063 in 0 1083 in 0 1102 in 0 1 122 in 0 1 142 in 0 1161 in 0 1181 in 0 1201 in 0 1220 in 0 1240 in 0 1260 in 0 1280 in 0 1299 in Within the marks of belt case and pump flange See page EM 24 0 54 0 66 mm 0 0213 0 0260 in 0 84 0 96 rnm 0 0331 0 0378 in 750 rpm 700 rpm 4...

Page 158: ... 030 mrn 92 23 rnm 92 73 mm 96 000 96 010 mm 96 010 96 020 mm 96 020 96 030 rnm 92 23 mm 92 73 mm 96 23 mm 96 73 mm 3 6220 3 6224 in 3 6224 3 6228 in 3 6228 3 6232 in 3 631 1 in 3 6508 in 3 7795 3 7799 in 3 7799 3 7803 in 3 7803 3 7807 in 3 6311 in 3 6508 in 3 7886 in 3 8083 in 0 0268 0 0382 in 0 028 0 077 mm 0 070 0 1 15 mrn 0 030 0 070 mm 0 20 mm 0 028 0 077 mm 0 060 0 105 mm 0 030 0 070 mm 0 20...

Page 159: ...g belt cover x Cylinder head Connecting rod cap x Connectingrod 1st 2nd TURBOCHARGER SYSTEM Specifications kg cm ft lb N m 255 185 800 90 turns 90 turns 50 380 530 120 240 130 195 380 195 185 350 120 turns Turbocharger Turbine outlet elbow x Turbocharger Turbo water pipe x Turbocharger Turbocharger x Exhaust manifold Turbo oil pipe x Turbocharger Turbo oil pipe x Cylinder block Exhaust manifold st...

Page 160: ... 127 kg cm2 1 749 1 806 psi 12 054 12 446 kPa 0 500 mm 0 0197 in 0 550 mm 0 0217 in 0 600 mm 0 0236 in 0 650 mm 0 0256 in 0 700 mm 0 0276 in 0 750 mm 0 0295 in 0 800 mm 0 0315 in 0 850 mm 0 0335 in 0 900 mm 0 0354 in 0 950 mm 0 0374 in 1 000 mm 0 0394 in 1 025 mm 0 0404 in 1 050 mm 0 0413 in 1 075 mm 0 0423 in 1 I00 mm 0 0433 in 1 125 mm 0 0443 in 1 150 mm 0 0453 in 1 175 mm 0 0463 in 1 200 mm 0 0...

Page 161: ...nrn 2 000 rnrn 2 050 rnrn 2 100 rnrn 2 150 r n r n 2 200 rnrn 2 250 rnrn 2 300 mrn 2 350 rnrn 2 400 rnrn 2 450 mrn 2 500 mm 24 4 rnrn 30 0 mrn 16 0 mrn 35 0 rnrn 22 3 rnrn 24 1 rnm 19 4 rnrn 0 175 0 475 rnrn 0 60 0 80 rnrn 1 1 rnrn 1 3 rnrn 1 5 rnrn 1 7 mrn 1 9 rnrn 2 1 rnrn 2 3 mrn 2 5 rnrn 2 7 rnrn 2 9 rnrn 3 1 mrn 3 3 rnrn 12 90 rnrn 13 15 mrn 13 40rnrn 1 2 kg crn2 1 4 kg crn2 0 0709 in 0 0719 ...

Page 162: ...2L T Maximum Others speed side Hong Kong Singapore Maximum speed side Others speed side ltem Adjusting lever position Maximum speed side 2L T Maximum speed side Others 3L Maximum speed side DN12SD12 145 155 kg cm2 2 062 2 205 psi 14 220 15 200 kPa Hong Kong Singapore Malaysia 6 0 mm 0 236 in 2 0 mm 0 079 in 840 mm 33 07 in 25 mm 0 98 in or more 40 4 5 0 2 kg cm2 2 8 psi 20 kPa 6 V Maximum speed si...

Page 163: ...Hong Kong Singapore Plus Malaysia 23 5 33 5 1 1 200 1 200 110 96 1 1 28 0 67 0 69 Others Maximum speed ltem Adjusting lever angle position Austria Pump rpm Plus 23 5 33 5 Plus 23 5 33 5 2L T Others No of measuring strokes 2 450 2 250 2 750 2 400 2 250 2 750 Hong Kong Singapore Plus 8 44 10 44 0 52 0 64 Malaysia 23 5 33 5 lnjection volume cc CU in I 1 1 3 0 8 or less 200 200 Others 4 3 6 3 0 26 0 3...

Page 164: ...iation limit cc cu in Injection volume Adjusting lever angle position Austria 2L T 3L Plus 23 5 33 5O Others Hong Kong Singapore Malaysia Plus 23 5 33 5 Others Plus 23 5 33 5O 10 19 11 09 0 1 18 in 0 122 in 0 126 in 0 130 in Governor sleeve plug head thickness 0 134 in 0 138 in 0 142 in 0 146 in 0 150 in 0 154 in 0 158 in 0 161 in 0 165 in ...

Page 165: ...73 0 63 9 0 62 0 41 5 9 40 0 14 2 0 14 Injection volume cc cu in No of measuring strokes 2L T 3L Remark 200 200 200 200 Pump No of measuring I rpm I strokes 2L T 1 200 1 200 1 8 10 8 50 0 49 0 52 1 10 8 11 6 0 65 0 71 12 9 13 5 0 79 0 82 Injection volume cc cu in 1 200 1 200 Injectionvolume cc cu in Hysterises cc CU in 13 84 14 36 0 84 0 88 13 94 14 26 0 85 0 87 14 60 15 40 0 89 0 94 10 80 11 60 0...

Page 166: ...e I Minus 13 5 21 5 Others Adjust q minus 0 7 1 7 0 04 0 10 1 8 2 8 0 11 0 17 1 8 2 8 0 11 0 17 Adjust 0 34 0 02 0 34 0 02 Minus 12 5 22 5 Remarks Dash pot ltem Pump rpm Austria No of measuring strokes 2L T lnjection volume cc CU in Lever set q plus 0 2 0 4 0 01 0 02 Adjust Lever set Others q plus 0 2 0 4 0 01 0 02 Adjust Cold start system ltem Fuel temp O C O F 25 77 Austria 2L T Others Timer pis...

Page 167: ... Pump stay x lnjection pump Pump stay x Cylinder block lnjection pipe x lnjection nozzle lnjection pipe x lnjection pump lnjection pump drive pulley x lnjection pump Crankshaft timing pulley x Crankshaft COOLING SYSTEM Specifications kg cm ft lb N m Torque Specifications See page A 2 0 75 1 05 kg cm2 10 7 14 9 psi 74 103 kPa 0 6 kg cm2 8 5 psi 59 kPa 86 90 c 187 1 9 4 8 mm 0 31 in or more Engine c...

Page 168: ... 14 mm head bolt Alternator x Fan belt adjustingbar 12 mm head bolt Oil pressure STARTING SYSTEM at idling at 3000 rpm Pre heating system kgcm ft lb N m 400 29 39 145 10 14 195 14 19 210 15 21 370 27 36 500 36 49 200 14 20 510 37 50 130 9 12 Light lighting time Supper glow type Fixed delay type Water temp sensor resistance at 2 0 4 F at 0 C 32 F at 20 C 68 F at 40 C 104 F at 60 C 140 F at 80 C 176...

Page 169: ...STANDARD BOLT TORQUE SPECIFICATIONS Page STANDARD BOLT TORQUE SPECIFICATIONS 6 2 ...

Page 170: ...ICATIONS HOW TO DETERMINE BOLT STRENGTH Hexagon head bolt Hexagon flange bolt W washer hexagon bolt Hexagon head bolt Hexagon flange bolt W washer hexagon bolt Hexagon head bolt Hexagon head bolt Mark I class Bolt 6 Stud bolt 0iz ruding lines Welded bolt 6T Mark Class ...

Page 171: ...RQUE SPECIFICATIONS B 3 SPECIFIED TORQUE FOR STANDARD BOLTS Diameter mm Pitch mm Hexagon head bolt kg an ft ib N m 55 48 in lb 5 130 9 12 5 260 19 26 480 35 47 760 55 74 1 150 83 115 Hexaaon flange bolt kg an ft lb N m ...

Page 172: ...M REFER TO 2L 3L ENGINE REPAIR MANUAL Pub No RM123E NOTE The following pages contain only the points which differ from the above listed manual Page SST SPECIAL SERVICE TOOLS C 2 SSM SPECIAL SERVICE MATERIALS C 2 ...

Page 173: ... Tension Gauge Belt Tension Gauge Cable N By pass element type Oil Filter Wrench FUII flow type Oil Filter Wrench Water Pump Overhaul Tool Set Shaft C Sovernor sleeve plug lnjectionPump Stand Set Injection Pump Stand Arm Valve Clearance Adjusting Tool Injection Pump Tool Set Distributor Head Plug Wrench Socket 14 mm Plunger Stroke MeasuringTool ...

Page 174: ...Nut Wrench Cylinder Compression Check Gauge Set No 4 Attachment Gauge Assy Turbocharger PressureGauge SSM SPECIAL SERVICE MATERIALS Use etc Seal packing or equivalent Sac Part Name Cylinder head cover Half circulator plug Part No Adhesive 1324 Three bond 1324 or equivalent Union Union bolt Adhesive 1344 Three bond 1344 Loctite 242 or equivalent Oil pressureswitch or sender gauge ...