Toyota 2H & 12H-T Diesel Engine Repair Manual – Land Cruiser HJ60 HJ61 HJ75

Description

Toyota 2H & 12H-T Diesel Engine Repair Manual — Land Cruiser HJ60, HJ61 and HJ75

This is the complete Toyota engine repair manual for the 2H and 12H-T diesel engines used in the Land Cruiser Heavy-Duty range. Published by Toyota Motor Corporation in November 1985, it covers engine mechanical service, fuel system repair, electrical diagnosis and turbocharger work for the HJ60, HJ61 and HJ75 series. Every procedure is written for the working technician — exploded illustrations show what fits where, task headings state what to do, and detailed text explains how to do it, including the specifications and warnings that apply.

File Details

• Manual type: Engine Repair Manual
• Brand / Manufacturer: Toyota Motor Corporation
• Models covered: Toyota Land Cruiser (Heavy-Duty) HJ60, 61, 75 series
• Engines covered: 2H, 12H-T diesel
• Language: English
• Page count: 338
• File format: PDF
• Publication date: November 1985

Chapters Covered

• Diesel Engine Diagnosis
• Diesel Electrical System Diagnosis [2H]
• Diesel Electrical System Diagnosis [12H-T]
• Turbocharger Diagnosis [12H-T]
• Turbocharger Electrical System Diagnosis [12H-T]
• Engine Tune-Up
• Compression Check [2H]
• Compression Check [12H-T]
• Turbocharger [12H-T]
• Cylinder Head
• Timing Gears and Camshaft
• Cylinder Block
• Fuel System (including Injection Nozzles, Feed Pump, Automatic Timer and Injection Pump)

Diesel Engine Diagnosis

The diagnosis chapter covers the full range of diesel engine complaints: engine will not crank, cranks slowly, cranks normally but will not start, rough idle with warm engine, engine suddenly stops, lack of power, excessive exhaust smoke, excessive fuel consumption, engine noise when warm, and engine will not return to idle. Each symptom is traced through possible causes, check procedures and correction methods. Injection timing (18° BTDC for 2H, 11° BTDC for 12H-T), nozzle opening pressures (2H: 105–125 kg/cm², 12H-T: 180–210 kg/cm²), idle speeds and maximum speeds are listed inline with the diagnostic steps.

Diesel Electrical System Diagnosis [2H & 12H-T]

Flow-chart based troubleshooting for the pre-heating systems. For the 2H the manual covers the Super Glow system: indicator light operation, pre-heating timer terminal voltage checks, glow plug current sensor testing, and glow plug resistance measurement. For the 12H-T it covers the intake heater system: power supply section inspection, control section inspection, pre-heating timer, intake heater relay and fusible link checks. The flow charts branch to the specific repair action depending on where the fault lies.

Turbocharger Diagnosis and Service [12H-T]

The 12H-T turbocharger gets its own diagnosis section and repair section. Diagnosis covers insufficient turbocharging pressure (0.39–0.53 kg/cm²), restricted or leaking intake and exhaust systems, and erratic turbocharger operation. The service chapter covers actuator and wastegate valve inspection with pressure limits, turbocharging pressure measurement at maximum speed, impeller wheel rotation and axial play checks (0.13 mm maximum), and complete removal and installation procedures with torque specifications for the turbine outlet elbow, oil pipe, turbocharger stay and heat insulators.

Engine Tune-Up and Compression Checks

The tune-up chapter walks through the checks and adjustments that keep the engine running correctly: coolant and oil inspection, battery specific gravity, air filter cleaning (paper and oil bath types), alternator drive belt tension, glow plug and intake heater inspection, injection nozzle opening pressure verification, valve clearance adjustment (intake 0.20 mm, exhaust 0.36 mm hot), injection timing adjustment using an inspection pipe on the No. 1 delivery valve holder, idle speed setting, maximum speed setting, and PS and A/C idle-up adjustments. Compression check procedures for both engines are included, with minimum pressure and cylinder-to-cylinder difference limits.

Cylinder Head

Complete cylinder head service for both engines. Removal sequences with bolt loosening order, disassembly including valve removal with SST and combustion chamber removal on the 2H, cleaning procedures, flatness inspection (0.20 mm maximum warpage), crack inspection with dye penetrant, valve stem and guide bushing measurement, valve grinding and seat resurfacing angles (44.5° face, 45°/30°/60°/75° cutters depending on position), valve spring testing, rocker arm and shaft clearance checks, push rod runout inspection, and full reassembly with torque sequences including the 26 cylinder head bolts at 1,150 kg-cm (83 ft-lb, 113 N·m).

Timing Gears and Camshaft

Service of the entire timing gear train: crankshaft pulley removal, timing gear cover removal, backlash measurement for the automatic timer drive gear, camshaft timing gear, and No. 1 and No. 2 idle gears, thrust clearance checks, camshaft inspection including circle runout, cam lobe height and journal diameter, idle gear and shaft clearance measurement, valve lifter inspection, and camshaft removal and installation. Timing gear cover oil seal replacement and proper gear meshing with timing marks are covered in detail.

Cylinder Block

The cylinder block chapter covers the bottom end and rotating assembly: connecting rod thrust clearance, connecting rod cap removal and bearing oil clearance measurement with Plastigage, piston and connecting rod removal, crankshaft thrust clearance, main bearing cap removal and oil clearance, crankshaft inspection (journal and crank pin diameters, taper and out-of-round), cylinder bore measurement and ridge removal, piston and connecting rod disassembly and inspection, piston ring end gap and groove clearance, connecting rod bushing replacement, and complete reassembly with main bearing cap torque at 1,390 kg-cm (100 ft-lb, 136 N·m) and connecting rod cap torque at 900 kg-cm (65 ft-lb, 88 N·m).

Fuel System

The fuel system section covers the components that deliver and meter fuel: replacement of the fuel filter with bleeding procedure, injection nozzle removal and testing for both engines (opening pressure, leakage, spray pattern, disassembly and cleaning), fuel feed pump removal and testing (suction, discharge pressure and volume), automatic timer removal and disassembly with advance angle adjustment, and injection pump removal and installation. Injection nozzle opening pressures, adjusting shim thicknesses, feed pump discharge pressure (1.8–2.2 kg/cm²) and volume specifications are listed in the relevant steps.

How the Manual Is Structured for Real Work

Toyota’s workshop format puts the illustration first: an exploded view identifies the components and shows how they fit together. The upper-case task heading tells you what to do at a glance. The detailed text below explains how to perform the task and includes the specifications, special service tools and warnings. Non-reusable parts — gaskets, O-rings, oil seals, cotter pins — are marked with a diamond symbol in the illustrations. Precoated bolts and nuts are marked with an asterisk and must be recoated with seal lock adhesive if disturbed. Torque values are given in kg-cm, ft-lb and N·m in the step where they apply.

The manual also includes the general repair instructions Toyota expects technicians to follow: battery disconnection sequence, handling of non-reusable and precoated parts, torque wrench use, SST and SSM identification, fuse rating checks, vehicle jacking safety, vacuum hose and electrical connector handling, and fuel system cleanliness after injection pump work. These are the same guidelines that apply across the HJ60, HJ61 and HJ75 platforms.

Get the Complete 2H and 12H-T Engine Repair Manual

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This Toyota 2H and 12H-T diesel engine repair manual gives you the complete factory service information for the Land Cruiser HJ60, HJ61 and HJ75 models in one PDF. From a routine valve clearance adjustment to a full cylinder head overhaul or turbocharger replacement, the procedures and specifications you need are in the same order a Toyota technician would use them. The PDF downloads instantly after payment — no shipping, no waiting, no missing pages. Open it on a laptop in the workshop, print the pages for the job at hand, or keep it on a tablet for quick reference. Every torque value, clearance, diagnostic flow chart and exploded illustration is there when you need it.