1984-1992 4.0L 3F & 3F-E Engine Service & Repair Manual

TOYOTA. REPAIR MANUAL Dec.,1984 .. Pub .No .36253E

FOREWORD This repair manual has been prepared to provide information covering general service repairs for the 3F engine equipped on the TOVOTA LAND CRUISER (Heavy-Duty). Applicable models: FJ62 , 70. 73 and 75 series 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 notice. TOYOTA MOTOR CORPORATION

TOYOTA 3F ENGINE REPAIR MANUAL INTRODUCTION ED ENGINE MECHANICAL 1m FUEL SYSTEM liD COOLING SYSTEM D!J LUBRICATION SYSTEM 11m IGNITION SYSTEM .a STARTING SYSTEM EI CHARGING SYSTEM ED SERVICE SPECIFICATIONS .. STANDARD BOLT TORQUE SPECIFICATIONS SSTANDSSM .. © 1989 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 Corporat ion .

IN-1 INTRODUCTION HOW TO USE THIS MANUAL . Page IN-2 IDENTIFICATION INFORMATION . ABBREVIATIONS USED IN THIS MANUAL . IN -7 IN-4 GENERAL REPAIR INSTRUCTIONS . IN-4

IN-2 INTRODUCTION - How to Use This Manual HOW TO USE THIS MANUAL To assist in finding your way through this manual. the section title and major heading are given at the top of every page . An INDEX is provided on the 1st page of each section to guide you to the item to be repaired. At the beginning of each section, PRECAUTIONS are given that pertain to all repair operations contained in that section. Read these precautions before starting any repair task. TROUBLESHOOTING tables are included for each system to help you diagnose the system problem and find the cause. The repair for each possible cause is referenced in the remedy col- umn to quickly lead you to the solution. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together . Example : Oil • Gasket I r-- - - - - - - W ater Hose Oil Pressure Gauge Oil Filter Bracket _ J I or Sender Gauge r \--- - - - - -O il Cooler Relief valve - -- - - -' § I Spring Gasket • a -Ring '---- -- --- 1 650 147. 64) I Ikg-cm 1ft-lb. N.mll : Specified torque • : Non-reusable part LU0 2,O

INTRODUCTION - How to Use This Manual IN-3 //Ius tra tion : what to do and where The procedures are presented in a step-by-step format: • The illustration shows what to do and where to do it. • The task heading tells what to do . • The detailed text tells how to perform the task and gives other information, such as specifications and warnings. Example : Task heading : what to do INSTALL OIL COOLER BRACKET Install a new gasket and the oil filter bracket with the four bolts. Torque the bolts. --------- Detailed text : Torque: 185 kg-em (13 ft-Ib, 18 N'm) how to do task <. Torque Specification This format enables the experienced technician to have a FAST TRACK . He can read the task headings and only refer to the deta iled text when he needs it. Important spec ificat ions 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 go to. SPECIFICATIONS Specifications are presented in bold type throughout the text in the applicable step. You never have to leave the procedure to look up your specs. All specifications are also found in Appen- dix A, specifications for quick reference. WARNINGS, CAUTIONS, NOTES • WARNINGS are presented in bold type, and indicate there is a possibility of injury to you or other people. • CAUTIONS are also presented in bold type, and indicate there is a possibility of damage to the components being repaired. • NOTES are separated from the text but do not appear in bold. They provide additional information to help you perform the repair more efficiently.

IN-4 INTRODUCTION - Identification Information, General Repair Instructions IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the right side of the cylinder block . IN0 037 GENERAL REPAIR INSTRUCTIONS 1. Use fender, seat and floor covers to keep the vehicle clean and prevent damage. 2. During disassembly, keep parts in order to facilitate reassembly. 3. Observe the following : (a) Before performing electrical work, disconnect the cable from the battery terminal. (b) If it is necessary to disconnect the battery for inspec- tion or repair, always disconnect the cable from the negative (-) terminal which is grounded to the vehicle body . (c) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable straight up without twisting or prying it. (d) Clean the battery terminal posts and cable terminal with a shop rag. Do not scrape them with a file or such. (e) Install the cable terminal to the battery post with the nut loose and tighten the nut after installation. Do not use a hammer or such to tap the terminal onto the post. (f) Be sure the cover for the positive (+) terminal is properly in place. 4. Check all hose and wiring connectors to make sure they are securely and correctly connected. 5. Non-reusable Parts (a) Always replace cotter pins, gaskets, a-rings and oil seals, etc. with new ones. (b) Non-reusable parts are indicated in the component illustrations by the .. + .. symbol.

INTRODUCTION - General Repair Instructions IN-5 6. Precoated Parts Precoated parts are the bolts. nuts, etc. which are coated w ith a seal lock adheasive at the factory . (a) If a precoated part is tightened . loosened or caused to move in any way, it must be recoated with the specified adhesive. (b) Recoating of Precoated Parts (1) Clean off the old adhesive from the bolts, nut or installation part threads . IN0 0 3 6 (2) Dry with compressed air. (3) Apply the specified seal lock adhesive to the bolt or nut threads . (c) Precoated parts are indicated in the component illustrations by the "* .. symbol. 7. When necessary, use a sealer on gaskets to prevent leaks. 8. Carefully observe all specifications for bolt tightening tor- ques. Always use a torque wrench. 9. Use of special service tools (SST) and special service materials (SSM) may be required depending on the nature of the repa ir. Be sure to use SST and SSM where specified and follow the proper work procedure . A list of SST and SSM can be found at the back of th is manual. 10. When replacing fuses, be sure the new fuse is the correct amperage rat ing. DO NOT exceed the fuse amp rat ing or use one of a lower rating. 11 . Care must be taken when jacking up and supporting the veh icle. Be sure to lift and support the veh icle at the proper locations. (a) 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 . (b) After the veh icle is jacked up. be sure to support it on stands. It is extremely dangerous to do any work on the vehicle raised on one jack alone. even for a small job that can be finished quickly . WRONG CORRECT IN000 1 12 . Observe the following precautions to avoid damage to parts: (a) To d isconnect vacuum hoses. pull on the end. not the middle of the hose. (b) To pull apart electr ical connectors, pull on the connector itself. not the wires . (c) Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor . they should be replaced and not reused .

IN-6 INTRODUCTION - General Repair Instructions (d) When steam cleaning an engine, protect the distribu- tor , ignition coil, air filter, and VCV from water. (e) Never use an impact wrench to remove or install thermo switches or thermo sensors. (f) When checking cont inu ity at the wire connector, insert the tester probe carefully to prevent terminals from bending. (g) When using a vacuum gauge, never force the hose onto a connector that is too large . Use a step-down adapter instead. Once the hose has been stretched, it may leak. Example 13. Tag hoses before disconnecting them: (a) When disconnecting vacuum hoses, use tags to iden- t ify how they should be reconnected. (b) After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout. IN000 2

1984-1992 4.0L 3F & 3F-E Engine Service & Repair Manual

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