Timing Gear Land Cruiser 1992

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REPAIR MANUAL

©TOYOTA MOTOR SALES CO., LTD.

FOREWORD

This repair manual has been prepared to provide information covering normal service repair for the new B and 2B engine equipped on the TOYOTA DYNA, COASTER and LAND CRUISER.

Applicable models:

BU20, 30 series BB10 series

BJ40, 43 series (From F. No. BJ40-013531 and BJ43-001392)

All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without previous notice.

TOYOTA MOTOR SALES CO., LTD.

CONTENTS

TITLE

SECTION 1

GENERAL

1

ENGINE TUNE-UP

2

ENGINE SERVICE

3

LUBRICATION SYSTEM

4

COOLING SYSTEM

5

FUEL SYSTEM

6

EDIC SYSTEM

7

STARTING SYSTEM

8

CHARGING SYSTEM

9

SST & SERVICE SPECIFICATIONS

Page

GENERAL REPAIR INSTRUCTIONS 1 -2

ABBREVIATIONS USED IN THIS MANUAL 1 -3

HOW TO USE THIS MANUAL 1 -4

SYMBOL MARKS 1-6

GENERAL REPAIR INSTRUCTIONS

1. Use fender, seat, and floor covers to keep the car clean and prevent damage.

2. During disassembly, keep parts in order for reassembly.

3. Before performing electrical work, disconnect the cable to the positive (+) battery terminal.

4. Always replace gaskets and O-ring with new ones.

5. Always use sealer on gaskets to prevent leaks.

6. Carefully observe all specifications for bolt torques. Always use a torque wrench.

7. Use genuine Toyota parts.

8. If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels in order to ensure safety.

9. After the vehicle is jacked up, do not fail to support it on stands. It is extremely dangerous to do any work on the vehicle raised on jack alone, even for a small job that can be finished quickly.

10. Use of a special service tool (SST) may be required, depending on the nature of the repair. Be sure to use SST where specified and follow the proper work procedure. A list of the SST is found at the back of this manual.

ABBREVIATIONS USED IN THIS MANUAL

For convenience, the following codes are used in this manual.

Abbreviation

Term

Definition

BDC

Bottom Dead Center

BTDC

Before Top Dead Center

EX.

Exhaust

IN.

Intake

MP

Multipurpose

Use in the case of MP grease.

O/S

Oversize

Sizes larger than STD are indicated as O/S.

SST

Special Service Tool

This term designates tools that have been manufactured specially for the servicing of this vehicle. Their part numbers are shown in the text enclosed by [ ].

STD

Standard

This term refers to the dimension of the part when originally manufactured.

TDC

Top Dead Center

U/S

Undersize

Sizes smaller than STD are indicated as U/S.

HOW TO USE THIS MANUAL

1. OVERVIEW ILLUSTRATION

Many service operations begin with an overview illustration as a general guide.

3-22 ENGINE SERVICE -Timing Gear

TIMING GEAR

DISASSEMBLY

Disassemble in numerical order.

DISASSEMBLY

Disassemble in numerical order.

Land Cruiser 1992 Motor
Fig. 3-64

1.

Oil Pan

7.

Crankshaft Pulley

2.

Push Rod Cover

8.

Timing Gear Cover

3.

Valve Lifter

9.

Automatic Timer

4.

Cooling Fan

10.

Idle Gear & Shaft

5.

Fan Pulley

11.

Camshaft & Timing Gear

6.

V Belt

12.

Crankshaft Timing Gear

(§) : The bold numerals show the order in which the components should be assembled. (R): The figure numbers refer to more detailed instructions, and specifications.

2. ILLUSTRATED INSTRUCTIONS

All important steps in every service job are illustrated, but obvious steps are omitted to save space. Experienced technicians may only need to glance at the overview illustration and/or specifications.

60°C--

li WMHWHfflfflmWWWfflUW

ms\r

l/mmmmmtNtttm \\

Jffln-<r

A Remove the automatic timer from the timing gear cover after heating the cover to about 60°C (140°F).

For disassembly and assembly of the automatic timer, refer to "FUEL SYSTEM" section.

Install the automatic timer to the injection pump spline shaft, and measure the timing gear backlashes. Back lash

Camshaft, Timer to idle gear

(0.0024 - 0.0035 in.) Crankshaft to idle gear

@: The picture gives basic information on what to do in the step. @: A symbol is often used to explain the action required. The text explains how to do the step. : Specifications, Notes, and Cautions are given in bold type so you won't miss them.

SYMBOL MARKS

The following symbols have been adapted for simplicity and for easy comprehension.

REMOVE or DISASSEMBLE

INSTALL or ASSEMBLE

INSPECT

MEASURE

TIGHTEN

*E*I CLEAN

IMPORTANT

FRONT CAB TILT PROCEDURE

When it is necessary to tilt the cab to perform major maintenance procedures, either of the following two methods may be used.

Insure working safety at all times.

HOIST METHOD

1. Remove the cab mounting bolts.

2. Install the hoist to the cab.

3. Insuring that the hoist is kept perpendicular, tilt the cab by slowly pushing the vehicle backwards.

Be careful not to damage any wiring or hoses.

Fig. 1-4

4. Insure that there is no interference between the front grill and bumper.

Always keep the cab supported by the hoist during work.

5. To lower the cab, slowly push the vehicle forward.

6. Install the mounting bolts after the cab has fully returned to its original position.

LOCKING STAY METHOD

1. In advance, prepare a locking stay as shown in the figure.

o Thickness 10 mm o Length 1060 mm o Clip (clutch release bearing clip) part no. 31232-30010 o Weld two stoppers positioned 900

mm apart, o Drill a 2 mm hole at each end.

2. Remove the cab mounting bolts.

3. With 2 persons on both the left and right side, lift the upward.

Be careful not to damage any wiring or hoses.

4. Insuring that there is no interference between the front bumper and grill, install the locking stay in the mounting bolt holes.

Be careful that the cab does not overturn.

5. After necessary work is completed, the cab should be lowered slowly by four persons.

6. Install the mounting bolts after the cab has been fully lowered to its original position.

ENGINE TUNE-UP

Page

ENGINE TUNE-UP ITEMS 2-2

COOLING SYSTEM 2-4

DRIVE BELT 2-5

AIR CLEANER 2-5

BATTERY 2-6

OIL FILTER 2-7

ENGINE OIL 2-8

FUEL FILTER 2-9

INJECTION PUMP 2-10

COMPRESSION PRESSURE 2-10

INJECTION NOZZLE 2-12

INJECTION TIMING 2-16

VALVE CLEARANCE 2-18

IDLE SPEED & MAXIMUM SPEED 2-19

ENGINE TUNE-UP ITEMS

ITEM

SPECIFICATION

1

COOLING SYSTEM

Coolant level Coolant quality Leakage

Radiator cap valve opening pressure

Coolant capacity (w/Heater) B Engine

Limit 0.6 kg/cm2 8.5 psi STD 0.75-1.05 kg/cm 2 10.7 — 14.9 psi

13.0 liter 13.7 USqt

11.4 Imp.qt 14.0 liter 14.8 USqt 12.3 Imp.qt

2

DRIVE BELT

Deflection at 10 kg (22 lb) force B Engine 2B Engine

10- 13 mm 0.4 - 0.5 in. 8-11 mm 0.3-0.4 in.

3

Oil capacity (Oil bath type)

Indicated level

4

BATTERY

Specific gravity Electrolyte level

1.25- 1.27 at 20°C (68°F)

5

ENGINE OIL

Oil level Oil quality Replenishment Oil capacity Total

API service CC-CD classification

7.3 liter 7.7 USqt

6.4 Imp.qt

5.4 liter 5.7 USqt f 4.8 Imp.qt

6

INJECTION PUMP

Lubricate diaphragm housing

3 or 4 drops of diaphragm oil

7

COMPRESSION PRESSURE

Variation limit between cylinders

STD 30.0 kg/cm2 427 psi Limit 20.0 kg/cm2 284 psi 2.0 kg/cm2 28 psi

ITEM

SPECIFICATION

8

INJECTION NOZZLE Injection starting pressure

New nozzle

115 — 125 kg/cm2 1636 - 1778 psi

Reused nozzle

105-125 kg/cm2 1493 - 1778 psi

Spray condition

4° conical form

Leakage test

At 90 kg/cm2 1280 psi

Cleaning

AIR BLEEDING Fuel filter

Injection pump High pressure pipe

10° BTDC

Exhaust

0.20 mm 0.008 in. 0.36 mm 0.014 in.

11

IDLE SPEED

625 - 675 rpm

12

MAXIMUM SPEED (NO LOAD)

4050 - 4100 rpm

13

PREHEATING SYSTEM Glow time at 0°C (32°F)

12V type

About 20 seconds

24V type

About 15 seconds

Load current

12V type

7.7 — 10.3 A

24V type

Fig. 2-2

COOLING SYSTEM

CHECK COOLANT LEVEL

If coolant level is low, fill to "FULL" line of reservoir tank.

CHECK COOLANT

Check for evidences of oil in coolant and deposit of rust or scales.

INSPECT COOLING SYSTEM

Radiator Cap Tester

Radiator Cap

Radiator Cap Tester

Radiator Cap

Install the radiator cap tester to the radiator, apply pressure and check for leakage in the cooling system under normal operating temperature.

Applicable pressure

2. Check pressure sealing and vacuum relief valve operation.

Valve opening pressure

Limit 0.6 kg/cm2 (8.5 psi) STD 0.75-1.05 kg/cm2 (10.7-14.9 psi)

3. If readings are not within acceptable limits, replace the radiator cap.

DRIVE BELT

VISUAL CHECK

Check belt for the following defects.

1. Cracks, deterioration or stretches.

2. Adherence of oil or grease.

DRIVE BELT

VISUAL CHECK

Check belt for the following defects.

1. Cracks, deterioration or stretches.

2. Adherence of oil or grease.

Clearance

Clearance

3. Improper contacting between belt and pulley.

CHECK & ADJUST TENSION

When the belt is depressed with a force of 10 kg (22 lb), it should sag a specified amount.

Deflection at 10 kg (22 lb) force

B engine 10-13 mm (0.4 - 0.5 in.) 2B engine 8-11 mm (0.3 - 0.4 in.)

AIR CLEANER

CLEAN ELEMENT [Cyclone Type]

1. In removing the air cleaner or the element, use care not to drop dirt or dust down into the air horn.

2. In cleaning the element, blow air from the inner side.

3. In case the element is damaged or excessively dirty, replace with new one.

4. Replace the air cleaner gasket if it is badly worn or damaged.

[Oil Bath Type]

1. Wash the element and the case with kerosene, and dry them thoroughly.

[Oil Bath Type]

1. Wash the element and the case with kerosene, and dry them thoroughly.

2. Refill the case up to the indicated level with clean engine oil.

3. Saturate the element with clean engine oil. ¿Ja 4. Install the case and element.

BATTERY

VISUAL CHECK

If the top of the battery is dirty, clean before checking. There should be no defects such as listed below:

1. Damage or leakage in battery.

2. Loose connection, rusting, deterioration or corrosion of battery terminals.

If reading is less than 1.23, recharge the battery.

TRANSLUCENT BATTERY

TRANSLUCENT BATTERY

„Upper Level "Lower Level

BLACK BATTERY Top View

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  • tom schroeder
    How to remove an 89 Toyota land cruiser timing gears?
    11 days ago

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