Cylinder Head Cross Section

Correct

MEASURE SPECIFIC GRAVITY

Specific gravity 1.25 •

at 20

If reading is less than 1.23, recharge the battery.

CHECK ELECTROLYTE LEVEL

If low, add distilled water (or purified water) up to the proper level.

Klucz 09228 44010

OIL FILTER

LJ REPLACEMENT [Cartridge Type]

1. Remove the oil filter by using SST[09228-44010].

To install, hand-tighten the oil filter. After starting the engine, check for oil leaks and recheck the oil level.

[Paper Element Type]

Refer to "LUBRICATION SYSTEM" section.

1. Use new gaskets. Assemble the filter body gasket with the rounded side facing upward (toward cap).

2. After starting the engine, check for oil leaks and recheck the oil level.

Cross Section Cylinder HeadCross Section Cylinder Head

ENGINE OIL

CHECK LEVEL

Oil level should be up to the "F" line on level gauge.

If low, add oil up to the "F" line. - Note -

Use API service CC-CD classification engine oil.

CHECK QUALITY

Pull out the oil level gauge and examine the oil' adhering on the graduated part. The oil should not be discolored or thin.

ENGINE TUNE-UP - Fuel Filter 2-9

FUEL FILTER

L+l REPLACEMENT [Cartridge Type]

1. Remove the fuel filter by using SST [09228-34010].

2. To install, hand-tighten the fuel filter.

Toyota Bleed Air

A3. Bleed the air from fuel filter by operating priming pump. 4. After starting the engine, check for fuel leaks.

[Feed Pump Filter]

Remove the inlet union, and clean the filter.

2—10 ENGINE TUNE-UP — Injection Pump, Compression Pressure

Cylinder Head Cross Section

INJECTION PUMP

LUBRICATE DIAPHRAGM HOUSING

Place 3 or 4 drops of diaphragm oil to diaphragm.

Toyota Land Cruiser Glow Plugs

COMPRESSION PRESSURE

1. Warm up engine.

2. Remove all glow plugs.

Make sure the load wire is not grounded.

3... Install SST [09992-00020] ■■ fro the glow plug mounting hole and insert a compression gauge.

^ [Without EDIC System]

4. Pull the stop button all the way out.

[With EDIC System]

4. Disconnect the connector of EDIC motor wires after turning the engine key to "LOCK" position.

5. Depress accelerator pedal all the way down.

6. Measure the compression pressure while cranking the engine with starter motor.

Keep pressure measuring time to a minimum.

Cranking speed 250 rpm Compression pressure

Limit 20.0 kg/cm2 (284 psi)

Variation limit between cylinders

Cross Section Cylinder Head
Cross Wire Section
Fig. 2-32

INJECTION NOZZLE

SPRAY TEST

1. Install nozzle to injection nozzle hand tester and bleed air from union nut.

2. Injection pressure.

(1) Pump the tester handle 50 - 60 times/minutes by hand.

(2) Read injection starting pressure.

Opening pressure New nozzle

115 — 125 kg/cm2 (1636-1778 psi) Reused nozzle

105-125 kg/cm2 (1493-1778 psi)

1. Proper nozzle operation can be determined by the sound of snarl.

2. Adjust the injection starting pressure to 110 - 125 kg/cm2 (1565 - 1778 psi), if the reused nozzle was overhauled.

Cross Section Cylinder Head

3. To adjust the injection pressure, change the shim on the top of pressure spring.

1. 20 shims are available, each varying in thickness by 0.05 mm (0.0020 in.) from 1.00 - 1.95 mm (0.0394 - 0.0768 in.).

2. Varying the adjusting shim thickness by 0.05 mm (0.0020 in.) changes the injection pressure by about 5 kg/cm2 (71 psi).

Cylinder Head Land Cruiser

4. Spray patterns

(1) Check the spray patterns when pumping the tester handle 50 — 60 times/minutes by hand.

Link Spring Tester

(2) Spray should spread evenly down the nozzle center line in 4° conical form.

(3) Place a white sheet of paper about 30 cm (12 in.) away from the nozzle to check if spray pattern is in circular form.

Danfoss Mmimyk

5. There should be no dripping after injection.

6. Leakage test.

Apply 90 kg/cm2 (1,280 psi) of fuel pressure, and check for leaks at nozzle valve seat and retaining nut.

t il

Nozzle Holder Washing

NOZZLE CLEANING

1. Refer to "FUEL SYSTEM" section and disassemble the nozzle holder.

2. To wash nozzle, use nozzle cleaning kit, and wash in clean diesel oil or light oil.

3. Remove the carbon adhering on nozzle needle tip, using a wooden stick.

v jf

v jf

Cross Section Cylinder Head

4. Clean the nozzle seat with a cleaning scraper.

4. Clean the nozzle seat with a cleaning scraper.

5. Clean the nozzle body orifice with a cleaning needle.

Fig. 2-43

6. Remove the carbon from the exterior of the nozzle body (except wrapping angle) with a brass brush.

7. Wash the nozzle in clean diesel fuel or light oil.

Pull out the needle about half way from the body and then release. Needle should sink into the body extremely smoothly by its own weight. Repeat this test rotating needle slightly after each test.

11.

Refer to "FUEL SYSTEM' assemble the nozzle holder. Perform spray test.

section and

INJECTION TIMING

INSPECTION & ADJUSTMENT

1. Set the No.1 cylinder piston to 10° BTDC/Compression.

A 2. Set the aligning mark on the injection pump flange against the index mark on the timing gear case.

3. Check the injection timing.

(1) Install the inspection pipe on the No.1 delivery valve holder.

The length of the inspection pipe should be kept as short as possible.

(2) Bleed air from the fuel filter by operating the priming pump.

(3) Bleed air from the injection pump by operating the priming pump.

(4) Rotate the crank pulley slightly to the left and right. Repeat this action until fuel surfaces from the inspection pipe.

(5) Slowly rotate the crank pulley.The fuel level in the inspection pipe should start to rise when the No.1 piston is at 10° BTDC/Compression.

4. Adjust the injection timing by tilting the injection pump body slightly.

5. Recheck the injection timing.

This operation should be repeated at least two or three times.

2-18 ENGINE TUNE-UP - Injection Timing, Valve Clearance

6. Remove the inspection pipe and install the No.1 injection pipe.

7. Bleed air from the injection pipe by activating the starter motor.

8. Start the engine and inspect all pipe lines for fuel leaks.

7. Bleed air from the injection pipe by activating the starter motor.

8. Start the engine and inspect all pipe lines for fuel leaks.

Toyota 1dz Engine Valve Clearance

VALVE CLEARANCE

ADJUSTMENT

1. Warm up the engine.

2. Remove the cylinder head cover.

3. Retighten the head bolts and rocker support bolts.

Torque, Cylinder head

4. Start the engine and run at idle speed.

5. Adjust valve clearance.

Valve clearance

ENGINE TUNE-UP - Idle Speed & Maximum Speed 2-19

Engine Tune

IDLE SPEED & MAXIMUM SPEED

INSPECTION & ADJUSTMENT

1. Warm up the engine.

2. Check the engine idle speed.

Idle speed 625 - 675 rpm

Cylinder Head Cross Sction

Adjust the idle speed by turning the stop plate adjusting screw, if it is not within specification.

Make sure that the throttle valve is fully open when the accelerator pedal is depressed all the way.

Make the full open adjustment through the full throttle adjusting bolt or accelerator pedal stop bolt.

2-20

ENGINE TUNE-UP - Idle Speed & Maximum Speed

Cylinder Engine Cross Section

Check the engine maximum speed when the accelerator pedal is depressed all the way.

Maximum speed 4050 — 4100 rpm

If the maximum speed is not within specification, adjust by turning the adjusting screw of the injection pump.

ENGINE SERVICE

Page

CROSS SECTIONAL VIEW 3-2

CYLINDER HEAD 3-4

TIMING GEAR 3-22

CYLINDER BLOCK 3-33

3-2 ENGINE SERVICE - Cross Sectional View

CROSS SECTIONAL VIEW

ENGINE SERVICE - Cross Sectional View 3-3

CYLINDER HEAD

DISASSEMBLY

Disassemble in numerical order.

How Fix Cylinder Head Toyota Rav4

17 18

17 18

1.

Glow Plug

10.

Heater Hose Union

2.

Injection Pipe

11.

Front Engine Hanger

3.

Leakage Pipe

12.

Exhaust Manifold

4.

Injection Nozzle Holder

13.

Cylinder Head Cover

5.

Rear Engine Hanger

14.

Valve Rocker Shaft Assembly

6.

Fuel Filter

15.

Valve Push Rod

7.

Intake Manifold

16.

Cylinder Head Assembly

8.

Warter Outlet Housing

17.

Valve & Compression Spring

9.

V Belt Adjusting Bar

18.

Combustion Chamber

Cross Section Cylinder Head

Remove injection nozzle holders with SST [09268-46011).

Keep the nozzle holders in correct order.

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