Repair of L-series engines of car Toyota Dyna (100/150)

Preliminary checks when adjusting the engine
Check the coolant level. Check the oil level. Check the density of the electrolyte in the battery. Standard value (fully charged battery at 20°C): 80 D26R — 1,27-1,29 others - 1.25 - 1.27 Check the condition of the glow...

Checking the air filter condition
Paper filter element 1. Visually check the filter element for contamination, integrity and oiliness. 2. Clean the element with compressed air. First, blow the filter thoroughly from the inside. Then blow the outside of...

Checking the tension of the alternator drive belt
Drive belt deflection under a 10 kg load: New - 7-10 mm Used - 10-15 mm Drive belt tension: New - 45-55 kg Used - 20-35 kg

Adjusting the clearances in the valve timing mechanism
Note: Perform work only on a cold engine. 1. Remove the intake pipe. 2. Remove the cylinder head protective cover (If installed). 3. Remove the cylinder head valve cover. 4. Set the piston of the first cylinder to TDC....

Checking and adjusting the injection advance angle
1. Install the special service tool and dial indicator. a) Remove the plug bolt from the fuel injection pump distributor head. b) Install special tool for service work (measuring instrument for determining plunger...

Adjusting idle speed and maximum speed
1. Before adjustment it is necessary: a) Set the gear shift lever to neutral position. b) Warm up the engine to operating temperature. c) Check: is an air purifier installed?, is all additional equipment turned off?,...

Adjusting the idle speed with the air conditioner on
1. Before adjustment it is necessary: a) Set the gear shift lever to neutral position. b) Warm up the engine to operating temperature. c) Check: is an air purifier installed?, are all vacuum lines connected correctly?,...

Checking the end of compression stroke pressure
Recommendation: If the engine lacks power, has excessive oil consumption or increased fuel consumption, check the end-of-compression pressure. 1. Warm up the engine, then stop it. 2. Disconnect the fuel shut-off...

Timing Belt — Design Description
1 - bolt M. 3. 167 Nm, 2 - plug, 3 - front timing belt cover, 4 - gasket, 5 - bolt M. 3. 33 Nm, 6 - bolt M.3. 44 Nm, 7 - tension pulley No.2, 8 - bolt M.3. 98 Nm, 9 - camshaft pulley, 10 - key, 11 - glow plug wire, 12 -...

Removal the timing belt
Recommendation: If the belt is replaced before the belt warning light comes on (the lamp turns on after one hundred thousand kilometers), then it is necessary to reset the belt counter readings, which is part of the...

Checking the condition of the timing belt
1. Inspect the timing belt. Warning: Do not bend, twist or turn the belt inside out. Do not allow the belt to come into contact with oil, water or steam. When installing or removing the camshaft pulley mounting bolt,...

Installing the timing belt
1. Install the crankshaft pulley. a) Place the pulley key into the crankshaft keyway. b) Using a hammer, lightly tap the pulley with the flange facing inward. 2. Install tension roller No.2. a) Install the spacer sleeve...

Cylinder head — design description
Engine cylinder head 2L, 3L. 1 - timing belt rear cover, 2 - camshaft oil seal housing, 3 - bolt M.3. 52 Nm, 4 - oil seal, 5, 8, 10, 13, 36 - gasket, 6 - cover, 7 - exhaust manifold, 9 - bolt M.3. 25 Nm, 11 - cylinder...

Removal the cylinder head
1. Drain the engine coolant (see the relevant section). 2. Remove the timing belt (see the relevant section). 3. Remove the injectors (see the relevant section). 4. Remove the camshaft pulley (see the relevant section)....

Disassembling the cylinder head
1. Remove the camshaft oil seal housing and gasket by unscrewing the four bolts. 2. Remove the camshaft. a) Turn the camshaft so that the camshaft keyway faces upward. b) Uniformly loosen and remove the ten bearing cap...

Condition monitoring, cleaning and repair of cylinder head components
1. Clean the piston bottom and the mating surface of the cylinder block. a) Turn the crankshaft and bring each piston to TDC in turn. Using a scraper, remove carbon deposits from the bottom of each piston. b) Remove all...

Replacing the camshaft seal
Note: There are two methods (A and B) to replace the oil seal, described below. A. If the camshaft oil seal retainer is removed: a) Using a screwdriver and a hammer, knock out the seal with light blows. b) Using a pipe...

Cylinder head assembly
Note: Thoroughly clean all parts to be assembled. Before installing parts, apply engine oil to all mating surfaces. Replace all gaskets and oil seals with new ones. 1. Install combustion chambers. a) Align the...

Installing the cylinder head
1. Check the piston protrusion and select the cylinder head gasket thickness. A. Check the protrusion of pistons No.1 and No.4. a) Align the TDC mark on the crankshaft pulley with the reference mark. b) Install the dial...

Cylinder Block — Design Description
1- front oil seal, 2 - bolt M. 3. 23 Nm, 3 - timing belt cover, 4 - gasket, 5 - cylinder block, 6 - nut - 54 Nm + 90°, 7 - connecting rod cover, 8 - connecting rod bearing shell, 9 - connecting rod, 10 - retaining ring,...

Disassembling the cylinder block
Preparing for disassembly 1. (Manual transmission) Remove the cover and clutch disc. 2. (Manual transmission) Remove the flywheel. 3. (Automatic transmission) Remove the drive disc. 4. Remove the rear end cover. Remove...

Cylinder block condition monitoring
1. Using a scraper, remove all gasket material from the cylinder block surface. 2. Clean the cylinder block using a soft brush and solvent. 3. Check the warping of the plane of the cylinder block joint with the cylinder...

Disassembling the piston and connecting rod
1. Check the fit of the piston and piston pin by rocking the piston on the piston pin. If any movement (play) is felt, replace the piston and pin as a set. 2. Remove the compression piston rings using an expander....

Assessment of the technical condition of connecting rods, pistons and piston rings
1. Clean the piston. a) Using a scraper, remove carbon deposits from the piston bottom. b) Using the broken ring, clean the piston ring grooves. c) Using solvent and a soft brush, thoroughly clean the piston. Warning:...

Cylinder boring
Note: Rebore all four cylinders to fit the oversized piston outside diameter. Replace piston rings with ones that match the oversized pistons. Oversized piston diameter (0.50): 2L Engines - 92.44-92.47 mm Engine 3L -...

Crankshaft condition monitoring and repair
1. Check the crankshaft runout. a) Place the shaft on the prisms. b) Using a dial indicator, measure the runout of the crankshaft at the middle journal. Maximum runout - 0.06 mm If the runout exceeds the maximum...

Replacing crankshaft seals
Note: There are two methods (A and B) for replacing oil seals. 1. Replace the front crankshaft oil seal. A. If the oil pump is removed from the cylinder block: a) Using a screwdriver and a hammer, remove the seal with...

Pistons and connecting rods — assembly
1. Assemble the piston and connecting rod. a) Install a new retaining ring into one of the piston bosses. b) Gradually heat the piston to a temperature of approximately 60°C. c) Align the front side marks located on the...

Cylinder block assembly
Note: Thoroughly clean all parts to be assembled. Before installing parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts. 1. Install oil jets and...

Final assembly of the cylinder block
1. Install the oil cooler (see section " Lubrication system "). 2. Install the oil pump and oil pan (see section " Lubrication system "). 3. Install the water pump (see section " Cooling system "). 4. Install the...

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