Toyota 3R-B 1969 Repair Manual Download Page 142 | Manualshive

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C H A R G I N G S Y S T E M - Tr ou b le Shooting. Al ternator & Regulator

8-3

e . Regulator voltage adjusted too high

f. Opened o r p oor connection of

w irin g between alternator " N "

terminal and regulator " N "
terminal

Adjust regulator

R ep air o r re p la ce w iring

3. Defective actuation of charge warning light o r defective ammeter operation,

a . L o o s e fan belt

b . L o o s e w irin g connections

c . Defective regulator operation

4. A ltern a tor noisy

a . Defective bearing/s
b . Malfunction of rectifier/s

c . Grounded o r shorted stator coil

A L T E R N A T O R & R E G U L A T O R

Construction

Adjust fan belt tension

Tighten o r rep a ir connections

Adjust o r replace regulator

Replace  bearing/s
R eplace  rectifier/s
Replace  stator

F i g . 8-2

C r o s s Sectional V ie w of A ltern a to r

Y5 118

T h e   components  and  the  specification  of  the  alternator  fo r   R S ,   R T   and  R K
s e r ie s   a re  slightly  different,  but  the  construction  and  operation  a re   sam e.
T h e   main  components  of  the  alternator  a r e   composed  of the  ro to r ,  stator,  recti

fie r s and the fr a m e s .

T h e ro tor consists of two s ix - fin g e r e d , cup-shaped h a lv e s , which when a ss e m

bled become a 12-pole ro to r .

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Summary of Contents for 3R-B 1969

Page 1: ......

Page 2: ...5R 3R B 3R C ENGINE REPAIR MANUAL TOYOTA MOTOR SALES CO LTD EXPORT TECHNICAL DIVISION ...

Page 3: ...uickly locate any desired section A t the beginning of each section is a title page which lists each main subjects in the section The service procedures on these engines are almost similar how ever there are some major or minor differences between each model engines In this manual every repair process is detailed respectively to cover the models thoroughly If the service procedures are the sam e t...

Page 4: ...SECTION INDEX GROUP INDEX SECT GENERAL INFORMATION ENGINE TUNE UP A ENGINE E EXHAUST SYSTEM A FUEL SYSTEM E LUBRICATING SYSTEM i COOLING SYSTEM 1 CHARGING SYSTEM E STARTING SYSTEM K IGNITION SYSTEM B ...

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Page 6: ...G E N E R A L IN F O R M A T IO N G E N E R A L 1 1 G E N E R A L S P E C IF IC A T IO N 1 5 R E C O M M E N D E D S S T 1 9 M EM ORANDUM 1 10 ...

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Page 8: ... the cylinder block front at the right side to lubricate the valve rocker arm mechanism The pistons are of a low expansion type which is of aluminum silicone alloy with excentric finished slightly larger at the right angle to the piston pin b o re M ore over these pistons are cast in with a steel ringunder the oil ring groove to minimize the heat expansion of the piston The piston rings are of two...

Page 9: ...1 2 G E N E R A L IN F O R M A T IO N General Y6177 Fiq 1 1 Cross Sectional View o f 5 R Model Engine Y5973 ...

Page 10: ...G E N E R A L IN F O R M A T IO N General 1 3 G3422 Fig 1 2 Cross Sectional View of 3R C Model Engine G3423 ...

Page 11: ... with the diameter of 9 mm 0 31 and both ends of the pipe are welded tothe steel balls by butt welding Precauition Whenever any work is performed on the car special care should be taken to prevent scratching the body fenders or spoiling the seats To perform a satis factory w ork fender covers or seat covers must be used during the operation The use of S ervice Special Tools must be emphasized as t...

Page 12: ... L s X ON 0 0 ON O Du i i oo LO 00 1 100 LO LO o LO LO E a L o o o LO ro LO ON oo s 2 s 3 a a r a u M O O r r O Q Q Q Q O O to o H r r O O O n O O r r E E 1 p h DQ DQ h c c t o o O u u a _ w D Q C Q C r o L O 0 fO s 0 o lo O o o o o CO ro LO lo COr o r o r o r o ON t CO CO LO LO T l o o q q h CQ a E i o L OC O LO I 3 C OT ro f U u 03 O I 0 J5n g c r 1 to t H s 0 0 E I e 0 LO Id Q lo to a o _c 0 C ...

Page 13: ...J 0 0 u u t u C D C L s p to S 3 U 0 1 tu S t 0 0 5 5 4 3 L 0 3 4 3 c c 0 0 2 W rH 0 0 0 1 C O 3 5 0 1 a E 0 1 T N 0 l m rn _Ci H r H a d i5S 0 0 0 4 S L 3 in 2 t o a _c s o o 33 o a 3 L 0 Lu h CL tf Z o cr CO g j 3 E a C N LO 00 0 0 1 O S3 o 0 _Q 3 4 3 2 C _ 0 T J 0 J 0 0 1 9 4 0 01 3 3 C h 0 t o J 2 o S F CO g 3 5 C T sL0 r vo LO O 00 t o O 4 o o o CM CM CM o y a a 0 o a 2 S 0 0 3 3 Cl Cl to S 3...

Page 14: ... a O a u o O a 7 3 0 c 0 0 _ o o 2 XON 0 0 7 O 1 GO O 00 O O a a a ro ro JC vo in 4 5 6 4 5 6 10 0 0 0 r 0 T I O O O M CL 0 0 00 H O ro LO X iH t H S h VO 4 5 4 5 01 4 5 O a ro 0 Z J 10 0 H iO 10 LO C4 i H T r H 04 CQ CQ 3 0 0 0 C ro PO n 04 in vO H s Q 00 0 tH h 0 0 CQ in 0 0 1 m m m m a n u 1 0 ro VO m 04 0 in m csj 1 0 0 0 00 1 0 0 O 1 0 0 3 s i 0 a id 0 C L Q o _c Si 3 Ui o x o b ffi 0 0 a a o...

Page 15: ... LD CM LO 0 0 CO CO CM CM T r I 3 3 3 p P P 3 3 3 3 P TJ P a p a 8 C o c frt c 0 o 0 0 J 0 0 X C D p D X C D CL CQ d CQ d CQ 8 p P 5 C D C D C D I d 5 _ f3 8 rO 5 5 JD 4 3 4 3 P C D 4 3 3 h 0 1 3 P P _C D di h 2 1 3 r 8 O 01 CQ D a 01 LO 00 3 LO oo C I 3 5 a to o to 4 3 cr cr 2 co ft f a 3 i 3ri f H a c o a 3 r f 0 0 d I d T3 D O p 0 c 0 8 g 3 P Jb 1 o c CO ft D I LO o to oo 0 3 d fQ ol 5 y d co M...

Page 16: ...er Connecting Rod Bushing Rem over Replacer Timing Gear Tool Set Camshaft Bearing Rem over Replacer Differential Side Bearing Replacer Crankshaft Pulley Gear Replacer Imput Shaft Front Bearing Replacer Clutch Guide Tool Carburetor 09860 11010 Carburetor S crew d river Set 09240 44010 Carburetor Adjust Kit for R S R T series 09240 40021 Carburetor Adjust Kit for R K series Water Pump 09239 40010 Wa...

Page 17: ...1 10 o M EM O RAN D U M MEMO 4 ...

Page 18: ... J U S T M E N T 2 1 B a tte ry 2 1 Engine Oil 2 1 Coolant 2 1 Pan Belt 2 1 Fuel Filter 2 2 A ir Cleaner 2 2 Distributor 2 2 Spark Plug 2 2 Ignition Timing 2 3 Octane S e le c to r 2 3 Valve Clearance 2 4 Carburetor 2 4 Compression T e s t 2 5 M EM O RAND U M 2 6 ...

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Page 20: ...tween each cell is above 0 025 the battery should be charged by disconnecting the battery ground cable If the difference exceeds 0 025 after fully charging the battery the battery should be inspected at a battery service station 3 Clean the terminals and top of the battery 4 Check the battery terminals and tighten them if necessary Check the battery case for cracks or other damages Apply grease on...

Page 21: ...not return readily the distributor must be disassem bled and the cause of the trouble should be corrected 4 Check the vacuum advancer me chanism by pushing in the octane selector then release the selector to see if the selector returns to its retarded position Any stiffness in the operation of the vacuum advancer mechanism will affect the ignition timing Correct any interference or bind ing 5 Clea...

Page 22: ...lector must be set at zero advance Ignition timing 5R 8 550 rpm B T D C 3 R B 12 400 rpm B T D C 3 R C 5 650 rpm B T D C Fig 2 3 Ignition Timing B0264 Marks 2 T o adjust loosen the distributor clamp attaching bolt and then turn the distributor housing in the direc tion required to align the timing marks T o advance the timing turn the distributor housing coun terclockwise and to retard the timing ...

Page 23: ...el level If the level is not satisfactory ad just the float level 2 The adjustment of the engine idling should be performed with the air cleaner installed a Remove the intake manifold suction hole plug then install the adapter to connect the vacuum gauge Connect the vacuum gauge hose to the adapter b Connect the tachometer onto the ignition coil c Turn the throttle adjusting screw until the engine...

Page 24: ... to cut off the secondary circuit 3 Install the compression gauge into the spark plug hole open the throt tle valve fully and measure the compression of each cylinder N O T E Alw ays use a fully charged battery to obtain the engine revo lution more than 250 rpm 4 The specified compression p res sure should be more than 11 0 kg cm2 153 psi at 250 rpm on the 5R 3R B and 3 R C engines The limit is 9 ...

Page 25: ...2 6 M EM O RAND UM MEMO ...

Page 26: ...3 12 Valve lifter 3 13 Push r o d 3 14 Cylinder block 3 14 Cylinder bore 3 14 Cylinder boring 3 15 Cylinder sleeve 3 17 Piston piston pin 3 18 Piston ring 3 18 Connecting r o d 3 19 Connecting rod bearing 3 20 Crankshaft 3 21 Crankshaft bearing 3 22 Crankshaft timing g e a r 3 23 Flywheel 3 23 Camshaft 3 24 Camshaft b ea rin g 3 25 Camshaft timing gear 3 26 Intake exhaust manifolds 3 27 A s s e m ...

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Page 28: ...ly f Clogged fuel filter element 4 Insufficient carburetor air intake a Restricted air cleaner b Choke valve partially closed 5 Overheating a Insufficient coolant b Loose fan belt c Fan belt worn or damaged d Inoperative thermostat e Inoperative water pump f Clogged or leaky cooling system g Incorrect ignition timing h Incorrect ignition system Adjust valve clearance Lap valves and seats Replace v...

Page 29: ...inder worn excessively f Valve stem O ring damaged g Valve and guide bushing worn Hard Starting 1 Slow cranking a Improper oil viscosity b Discharged battery c Defective battery d P o or battery connections e Defective starter motor 2 Defective ignition system a Burnt distributor points Adjust brakes Adjust valve clearance Clean or replace exhaust system Replace with correct oil Overhaul or adjust...

Page 30: ...iming d Incorrect heat range plugs 2 Air fuel mixture a Lean combustion mixture b Fuel pipe dirty or restricted c A ir leak at carburetor or intake manifold 3 Valves a Incorrect valve clearance b Valves sticky Adjust points Adjust spark plug gap Tighten or replace spark plug w ires Replace ignition coil Tighten connections Replace condenser Repair or replace valves Tighten manifold bolts or replac...

Page 31: ... head gasket Engine Misses at Acceleration 1 Carburetor a Clogged accelerating system b Lean fuel mixture 2 Ignition system a Defective spark plugs b Defective ignition w ires c Incorrectly adjusted distributor points d Defective ignition coil 3 Engine a Burnt or incorrectly adjusted valves Replace springs Remove carbon Clean or replace water tube Replace gasket Adjust idling Clean and adjust or r...

Page 32: ...earings and check lubricat ing system 2 Connecting rod connecting rod bearings a Worn connecting rod bearings b Worn crankpin journals c Bent connecting rod d Melted bearings e Worn connecting rod bushing 3 Piston piston pin piston rings a Excessive cylinder w ear b Worn piston or piston pin c Burnt piston d Defective piston rings 4 Other components a Excessive camshaft thrust clearance b Worn cra...

Page 33: ... unit lead w ir e s 4 Jack up the car and support with stands Drain the engine oil and remove the propeller shaft T o prevent the oil leak from the transmission rear insert any a vailable universal joint sleeve yoke 5 Remove or disconnect the following parts a Transmission cover on R K b Transmission control links or ro d s c Speedometer cable d Parking brake cable e Front exhaust pipe support bra...

Page 34: ...racket oil cooler tubes and the clamps on car equipped with the Toyoglide Automatic 2 Remove the starter motor and the transmission 3 Stamp mating marks onto the clutch cover and the flywheel to relocate the original positions upon assem bly and remove the clutch cover and the clutch disc 4 Remove the torque converter as sembly on car equipped with the Toyoglide Automatic 5 If necessary remove the...

Page 35: ...nged in the order of the cylinder numbers 21 Turn the engine and position the bottom side up then remove the oil pan 22 Remove the oil pump outlet pipe from the cylinder block and re move the oil pump assembly with the strainer 23 Using the Crankshaft Pulley and Gear Puller 09213 60013 re move the pulley Fig 3 3 Crankshaft Pulley V4667 Removal 24 Remove the timing gear cover and remove the oil noz...

Page 36: ...he top of the pistons combustion cham bers in the cylinder head and also remove from the valves without dam aging the parts Do not mix the mated parts with the others Cylinder Head 1 Check the cylinder head for crack and inspect the gasket surface for burr and nicks Replace the cylinder head if de fective 2 Check for water leak from the cylinder head by applying water pressure of 5 kg cm2 70 p si ...

Page 37: ... upper with 75 cutter to obtain proper width 7 After cutting the valve should contact the valve seat exactly at the center To check apply a thin coat of red lead on the seat and insert the valve Apply a light pressure on the valve to check the contact If the seating is too high use the 15 cutter and 45 cutter and if too low use the 75 cutter and 45 cutter 8 Lap the valve and the seat with a lappin...

Page 38: ...uide Bushing Valve 1 Check the valve faces and the edge of the valve head for pits grooves scores and defects 2 Check the valve stem for bent and grooves at the neck of the valve stem 3 Check the valve head for burrs warpage crack and corrosion Replace it if excessively worn or damaged 4 If the valve head edge is worn and is less than 0 8 mm 0 031 for the intake and 1 0 mm or 0 039 for the exhaust...

Page 39: ...spring against the square edge and ro tate the spring slowly The space between the top coil of the spring and the square edge should be within the limit If it ex ceeds the limit replace the spring Limit Inner 1 6mn 0 063 O u ter 1 9mm 0 074 F ig 3 15 Checking Spring Squareness G0832 Valve spring specification F re e length Inner Outer F ree length limit Inner Outer Installed height 45 1 mm 1 781 5...

Page 40: ... install the bushing apply oil between the valve rocker arm and the bushing and install the bush ing from the front with a press F r o n t F ig 3 17 Bushing Section G1710 After installing finish the bushing with an adjustable reamer to ob tain proper clearance of 0 01 to 0 04 mm 0 000 4 0 0016 be tween the rocker shaft and the rocker arm bushing If the valve rocker arm shows excessive w ear at the...

Page 41: ...B0272 Block Flatness Cylinder B ore 1 Check the cylinder bore for out of round and taper with a cylinder bore gauge Measure the diameter of each cylinder bore at the top middle and bottom with the gauge placed at right angle and parallel to the center line of the engine Fig 3 20 Measuring Points G0833 of Cylinder Bore Fig 3 21 Measuring B0273 Cylinder Bore 2 Refinish the cylinders scored badly bur...

Page 42: ... O S 020 Mark 88 475 Piston diameter 88 468 88 478 mm 3 4830 3 4834 Mark 88 485 Piston diameter 88 478 88 488 mm 3 4834 3 4838 Mark 88 495 Piston diameter 88 488 88 498 mm 3 4838 3 4842 O S 030 Mark 88 725 Piston diameter 88 722 88 732 mm 2 4930 3 4934 Mark 88 735 Piston diameter 88 732 88 742 mm 3 4934 3 4938 Mark 88 745 Piston diameter 88 742 88 752 mm 3 4938 3 4942 C S 040 Mark 88 980 Piston di...

Page 43: ...8 730 mm 3 4956 3 4960 Mark 88 735 Piston diameter 88 730 88 740 mm 3 4960 3 5964 O S l 00 Mark 88 965 Piston diameter 88 960 88 970 mm 3 5050 3 5054 Mark 88 975 Piston diameter 88 970 88 980 mm 3 5054 3 5058 Mark 88 985 Piston diameter 88 980 88 990 mm 3 5058 3 5062 O S l 25 Mark 88 215 Piston diameter 88 210 89 220 mm 3 4755 3 5153 Mark 88 225 Piston diameter 89 220 89 230 mm 3 5153 3 5157 Mark ...

Page 44: ...d only when the cylinder bore is worn excessively and oversize 060 for th e 3 R B 3 R C and 1 50 for the 5R pistons Can not be utilized O S 160 Sleeve outer diameter 92 151 92 186 mm 3 6279 3 6293 Bore diameter 92 060 92 095 mm 3 6244 3 6257 O S 180 Sleeve outer diameter 92 661 92 696 mm 3 6490 3 6494 B ore diameter 92 570 92 605 mm 3 6444 3 6458 O S 200 Sleeve outer diameter 93 171 93 206 mm 3 66...

Page 45: ... to 50 to 60 C 122 140 F If the fitness is loose replace both the pin and the piston F ig 3 26 Piston Marks on B0274 Head Piston Ring 1 Check the rings for w ea r and other defects If the pistons are replaced the rings should be re placed at the same time The ring size must be selected to correspond the size of the piston The rings are provided with the marks and these marks should be faced upward...

Page 46: ...plate evenly or replace the connecting ro d 3 Install the connecting rod onto the crankshaft and check the thrust play The thrust play should be 0 17 to 0 28 mm 0 0067 0 0 110 The limit of thrust play is 0 4 mm 0 0 157 Fig 3 29 Checking Piston V4679 Ring Clearance Connecting Rod 1 Check the connecting rods for damage at the thrust surfaces on both sides If necessary replace the connecting rod If r...

Page 47: ...ull width of the bearing and parallel to the crankshaft avoiding the hole in the journal F i g 3 33 Placing Plastigage V4684 4 Installing the connecting rod bear ing and cap tighten the nuts to specified torque Do not turn the crankshaft while the Plastigage is in place Specified torque 6 0 7 0 m kg 43 51ft lbs 5 Remove the cap and check the width of the Plastigage with the Plastigage cover scale ...

Page 48: ...pin finished diameter 54 480 54 490 mm 2 1465 I 2 1469 U S 0 75 Bearing thickness 1 875 1 885 mm 0 0739 0 0743 Crank pin finished diameter 54 230 54 240 mm 2 1367 2 1371 U S 1 00 Bearing thickness 2 000 2 010 mm 0 0788 0 0792 Crank pin finished diameter 53 980 53 990 mm 2 1268 2 1272 7 If a new crankshaft is utilized al ways use a standard size bear ings When the bearing clearance ex ceeds the lim...

Page 49: ...o wards the crankshaft thrust sur face Crankshaft Bearing The crankshaft bearings are also of the insert type and selective fit with micro precision finished Therefore the same procedures of inspection and oil clearance check should be performed as the connecting rod bear ings 1 Check the bearing for poor con tact worn thin partially melted or heavily scored If necessary replace the bearings 2 Che...

Page 50: ...kshaft timing gear should be only removed when it is to be r e placed and the timing gear can be replaced on the car using the Timing Gear Too Set 09210 31010 1 Check the crankshaft timing gear for wear dam age and chipped teeth If defective replace the timing gear T o remove the timing gear use the Timing Gear Tool 09210 31010 2 T o assemble install the gear onto the crankshaft using the Timing G...

Page 51: ...he camshaft If the cam lobes are pitted or scored slightly and the pitting or scoring is not detrimental to the operation of the camshaft the lobes may be dressed with an oil stone Cam lobe height Intake 38 39 38 49 mm 1 511 1 516 Exhaust 38 29 38 39 mm 1 506 1 511 3 Check the distributor drive gear for score and w ear If necessary replace the camshaft 4 Check the camshaft end play and if the play...

Page 52: ...r The clearance should be 0 025 to 0 066 mm 0 0010 0 0025 If the clearance exceeds the limit of 0 1 mm 0 0 0 4 replace the bearings 3 Remove the expansion plug instal led at the rear of the camshaft rear bearing PI ace the Camshaft Bearing Rem over Replacer 09215 40010 and fit a wrench into the slot of the Shaft to prevent the shaft from turning and tighten the Nut with an another wrench and then ...

Page 53: ...h between the crankshaft timing gear and the camshaft timing gear with a dial gauge or a feeler gauge Th e backlash should be between 0 08 0 15 mm or 0 0031 to 0 0059 If the backlash exceeds 0 3 mm 0 0 1 2 replace the camshaft timing gear and or the crankshaft timing gear 4 T o remove the camshaft timing gear remove the gear retaining bolt and washers then remove the timing gear using the Timing G...

Page 54: ...on of the cylinder w a lls pistons bearings gears and etc It is recommended that all gaskets packings and seals be replaced with new ones T o prevent oil leak use liquid sealer on bolts packings and the gaskets if necessary Recheck the oil clearance backlash and thrust clearance upon assembly 1 Install the compression springs rocker arms rocker supports tension springs and the lock springs onto th...

Page 55: ...e in order from the piston head side 5 Clean the bearing fitting portion of the connecting rod and the bearings Install the bearings and the caps then tighten the nuts lightly 6 Fit the oil seal into the groove located at the re ar end of the cyl inder block and the rear bearing cap using a cylindrical tool and cut the protruding portion of the seal ends from the cylinder block surface F ro n t ma...

Page 56: ... using the piston ring com pressor facing the piston front mark towards the front of the cyl inder block When installing the piston it is advisable to insert vinyl tubes onto each of the connecting rod cap bolts to prevent scoring the cyl inder wall and the crankshaft pin Make sure that the end gap of each ring is not directed to the thrust face of the piston and also that each ring is not coinsid...

Page 57: ...que Fig 3 60 Installing Crank V4698 shaft Pulley 19 Install the oil pump assembly with the oil pump outlet pipe Tighten the securing bolt to 1 5 to 2 0 m kg 11 15 ft lb torque 20 Install the oil pan with the gasket and tighten the attaching bolts to 0 4 0 6 m kg 2 5 4 0 ft lb torque 25 Turn the engine and position the top side up and install the cyl inder head with the gasket Tighten the cylinder ...

Page 58: ...Install the distributor clamp and the distributor T o install the distributor refer to the Installation of the Distributor in the Ignition System 32 Install the spark plugs fuel pump carburetor fuel pipe and the va cuum pipe 33 Install the engine mounting front R H oil level gauge and the cyl inder head cover 34 Install the air pump air control valve air injection manifold and the hoses on the 3R ...

Page 59: ...sion fluid if equipped Engine oil capacities with the oil filter On R S 5 0 56 R T 4 3 L 52L RK171 176 series 4 8 liters 5 1 U S qts 4 3 Imp qts On R K 44 101 series 5 3 liters 5 6 US qts 4 8 Imp qts Coolant capacities On R S 5 0 56 series 7 5 liters 7 9 U S qts 6 6 Imp qts On R T 4 3 L 52L series 8 5 liters 9 0 U S qts 7 5 Imp qts On R K 4 4 101 series 9 1 liters 9 6 U S qts 8 0 Imp qts On RK171 ...

Page 60: ...E X H A U S T S Y S T E M D E S C R I P T I O N 4 1 E X H A U S T P I P E 4 4 R em oval 4 4 Inspection 4 5 Installation 4 5 M EM O RAND UM 4 6 ...

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Page 62: ... 4 1 D E S C R IP T IO N M ain m uffler P re m u ffler E x h au st P ip e F ro n t Tail P ip e F ig 4 1 Exhaust System on RS50 Series Y5847 E x h au st P ip e F ro n t S ilen cer Tail P ip e K F ig 4 2 Exhaust System on RS56 S eries Y6007 ...

Page 63: ...4 2 E X H A U S T S Y S T E M Description E x h au st P ip e C en ter No 2 m F ig 4 3 Exhaust System on R T 4 3 L R T 5 2 L Series G3120 F ig 4 4 Exhaust System on RK44 Series G3121 ...

Page 64: ...E X H A U S T S Y S T E M Description 4 3 F ig 4 6 Exhaust System on RK171 Series G3123 ...

Page 65: ...ont cen ter and the rear and the different exhaust systems on the various series are illustrated through figures 4 1 to 4 7 E X H A U S T P IP E Removal On R S S eries 1 Jack up the car and support the car with stands 2 Disconnect the main muffler on the RS50 series and the tail pipe on the RS56 series from the exhaust pipe support 3 Disconnect the main muffler from the exhaust pipe center on the ...

Page 66: ...ries 1 Disconnect the tail pipe from the supports and loosen the exhaust pipe clamp then remove the tail pipe from the muffler 2 Loosen the exhaust pipe clamp and remove the muffler 3 Loosen the exhaust pipe clamp and remove the exhaust pipe center from the exhaust pipe front on RK44 101 series 4 Remove the nuts retaining the flange onto the exhaust manifold and disconnect the exhaust pipe front f...

Page 67: ... 6 M EM O RAND UM MEMO ...

Page 68: ...r hone 5 17 Main body i 5 17 Flange 5 17 A s s e m b ly 5 17 Automatic c h o k e 5 18 A ir hone 5 19 Flange 5 19 Main body 5 20 Adjustment 5 21 Float le v e l 5 21 Secondary throttle valve initial opening a n g le 5 22 High speed valve stopper lever 5 22 Fast idle 5 23 Unloader 5 23 Automatic c h o k e 5 23 Idle adjusting screw 5 24 Installation 5 24 C A R B U R E T O R On R K series 5 25 Descript...

Page 69: ... adjusting screw 5 34 Installation 5 34 F U E L F I L T E R 5 35 Description 5 35 R em o v a l 5 35 Disassembly 5 35 Inspection 5 35 A s s e m b ly 5 36 Installation 5 36 F U E L P U M P 5 36 Description 5 36 R e m o v a l 5 38 Disassembly 5 38 Inspection 5 38 A s s e m b ly 5 38 Installation 5 39 T e s tin g 5 39 F U E L T A N K F U E L P I P E 5 40 R e m o v a l 5 43 Inspection 5 43 Installation...

Page 70: ...es is provided at the right side frame The fuel in the fuel tank is drawn into the fuel pump by the suction of the fuel pump through the pipe and is delivered into the fuel filter The fuel passes the filter element from the outside to theinside of the element and the fuelis filtered to remove dirt or water if contained within the fuel The fuel pump produces a constant controlled fuel pressure and ...

Page 71: ...an jet e Improper low speed jet seating Tighten jet or replace f Worn throttle shaft Replace shaft 9 Loose vacuum pipe union Tighten union h Plugged economizer jet Clean jet i Improper low speed jet passage seal Tighten plug or replace seal j Defective body flange gasket Replace gasket Excessive fuel consumption a Float level too high Adjust float level b Plugged air bleeder Clean or replace air b...

Page 72: ...r Fuel Pump Symptoms Probable Causes 1 Fuel leaks from fuel pump a Loose pump cover screw s b Defective or deteriorated diaphragm c Defective threads of union fitting or cracked fitting 2 Oil leaks from fuel pump a Loose fitting of rocker arm pin b Loose fuel pump mounting 3 Insufficient fuel delivery a Loose fuel pipe connections b Defective diaphragm c Defective valves d Cracked or broken fuel p...

Page 73: ...ating choke system and the thermostatic valve systems which enable to supply the air fuel mixture for normal operation When the throttle valve is opened wide for full load or for acceleration the secondary system also operates to supply the air fuel mixture together with the primary system The throttle valves of both the primary and the secondary systems are operated with linkage and are inter loc...

Page 74: ...d a r y b o r e 2 S e c o n d a r y m a in a i r b l e e d e r 1 4 S l o w a i r b l e e d e r N o l 2 6 P r i m a r y b o r e 3 S e c o n d a r y m a in n o z z l e 1 5 S l o w j e t 2 7 P r i m a r y th r o t t le v a l v e 4 A i r v e n t 1 6 P o w e r p is t o n 2 8 Id le p o r t 5 S e c o n d a r y s m a ll v e n t u r i 1 7 S t r a i n e r 2 9 S l o w p o r t 6 P u m p je t 1 8 S e c o n d a...

Page 75: ...eedle valve and a seat If the fuel enters into the float chamber faster than it is withdrawn into the engine the float 1 rises lifting the needle valve 2 causing to seat firmly against the needle valve seat 3 If the fuel withdrawn is quite fast opposite operation will take place to compensate to balance the fuel level height These items are very important to obtain proper performances of the carbu...

Page 76: ...the main air bleeder 2 and flows up the main nozzle H ere the mixture is atomized through the air horn F ig 5 5 Prim ary High Speed System G1736 and is mixed with the air stream flowing 4 Secondary high speed system The more the engine power is de sired the more of air fuel mix ture is required The secondary high speed system is so deviced to meet this requirement and con sists of the secondary ma...

Page 77: ...this rich mixture and the full engine pow er an additional device is in corporated in this carburetor 3 2 Fig 5 8 P o w e r System Y6715 A t light load when the manifold va cuum is high the manifold vacuum pulls up the power piston 1 to close the power valve 2 A s the primary throttle valve is opened fully the manifold vacuum drops and the power pis ton is pushed down by the spring tension which o...

Page 78: ...cessary for acceleration When the throttle is closed the pump plunger is pulled upward so that the pump cylinder becomes refilled with fuel ready for the next acceleration period Also when the accelerator pedal is fully depressed the power valve opens and the fuel is also supplied from the power system 7 Automatic choke system The automatic choke system ope rates by the exhaust manifold temp eratu...

Page 79: ...celeration of the engine d Fast idle When the carburetor is in choked position the fast idle cam follower 2 of the sliding rod 1 con nected to the throttle contacts a gainst the fast idle cam 3 and the throttle valve is opened slightly F o r this reason the idling revo lution becomes slightly higher Even though the engine warm s up and the choke valve is fully opened the fast idling is still in op...

Page 80: ...g a s k e t 16 5 C o il h o u s in g p la te 17 6 C h o k e shaft 18 7 T h e r m o s t a t c a s e 19 8 F a s t id le c a m 20 9 C a s e g a s k e t 21 10 P u m p l e v e r 22 1 1 C h o k e v a l v e 23 1 2 A i r h o r n 24 P u m p a r m s e c u r i n g s c r e w P u m p c o n n e c t i n g link U n io n fitting S t r a i n e r S li d i n g r o d B o o t C o n n e c t i n g link P i s t o n pin F ...

Page 81: ...e 25 S econ d ary throttle return 42 Pump discharge weight 10 O ring spring 43 Steel ball 11 Therm ostatic valve 26 P rim a ry throttle shaft arm 44 S econ d ary main jet 12 Therm ostatic valve c o v e r 27 Throttle le v e r collar 45 P rim a ry main jet 13 O ring 28 Fast idle le v er 46 Main passage plug 14 High speed valve shaft 29 F ast idle adjusting spring 47 Body flange gasket 15 High speed ...

Page 82: ...ed with clean gasoline or carburetor cleaning i 1 I I I I j 0 9 2 4 0 4 4 0 10 0 9 8 6 0 1 10 101 Fig 5 17 Carburetor Adjust B0347 Kit S crew drive Set I I I solvent These removal parts should be kept in a clean container to facilitate the assembly 1 Remove the connecting link 1 2 Disconnect the connection of the pump connecting link 2 and the pump lever 3 then remove the pump connecting link 3 Re...

Page 83: ...60 11010 10 Remove the power jet from the power valve 11 Remove the thermostatic valve cover and remove the thermo static valve 1 and the 1 1 0 1 1ring Do not disassemble the thermo static valve Fig 5 22 Removing B0352 Thermostatic Valve 12 Remove the three flange retaining screw s and separate the body from the flange One retaining screw is installed from the flange lower side 13 Remove the prima...

Page 84: ... shaft A s the throttle valve securing screw s are calked remove them after filing the calked portions of the screw s with a file 23 Remove the secondary throttle lev er retaining nut and remove the secondary throttle lever Remove the secondary throttle valve and the shaft in the same manner as the primary side Fig 5 24 Removing High B0354 Speed Valve B0355 Shaft 18 Remove the level gauge clamp le...

Page 85: ...e cam follower 1 and the sliding rod 2 Fig 5 29 Removing Choke V4772 Shaft 30 Remove the fast idle cam with the spring from the choke shaft 31 Take out the vacuum piston with the piston connector 32 Pull out the piston pin and dis assemble the vacuum piston and the connector 33 Remove the thermostat case re taining screw s and remove the case and the gasket from the air horn Inspection Wash all th...

Page 86: ...ective tab and also check for w ear or deformation of the float lever pin hole bracket and the lever pin 6 Check the needle valve and valve seat for proper seating 7 Check the strainer for clog and rust Main Body 1 Check the body for cracks dam age on the fitting surfaces defec tive threads and jet fitting surfaces 2 Check the jets for defective threads and slot 3 Check the power valve for proper ...

Page 87: ...haft 4 Install the choke valve onto the choke shaft and after checking for proper operation calk the securing screw ends 5 Assemble the piston connector onto the choke shaft with the connector retaining s c re w 6 Install the sliding rod into the ther mostat c a s e and assemble the fast idle cam follower F ig 5 34 Assembling V4773 Thermostat Case Related Parts 7 Assemble the coil housing plate ga...

Page 88: ...eck the throttle valve for proper operation then calk the throttle valve retaining screw ends The secondary throttle valve is thicker than the primary throttle valve The secondary throttle valve r e taining screw s are longer than that of the primary throttle valve F ig 5 37 Assembling V4775 Secondary Throttle Shaft 14 Assemble the primary throttle shaft onto the flange and check the shaft thrust ...

Page 89: ...ottle valve is opened to 60 F ig 5 40 Secondary Throttle G1740 Valve Adjustment 19 Install the throttle adjusting screw 20 Install the idle adjusting screw with the spring and screw in the screw clockwise until it is slightly seated with the fingers then screw it out counterclockwise three turns Do not screw in the idle adjusting screw securely Fig 5 41 Assembling Flange B0356 Related Parts Main B...

Page 90: ...stall it into the float chamber 30 Install the slow jet then install the slow passage plug with the pack ing 31 Install the primary and the secon dary small venturies and secure them with both the primary and the secondary main air bleeders 32 Insert the steel ball and the pump discharge weight then install the pump jet with the packings 33 Install the pump damping spring plunger and the plunger g...

Page 91: ...ning Angle Hold the primary throttle valve 1 at 30 before full opened position us ing the Angle Gauge At this time check if the throttle shaft link 2 touches the extreme end of the groove of the throttle shaft arm 3 as shown in figure 5 48 and if necessary bend the throttle shaft link 2 The secondary throttle valve 4 should not open when this checking is performed After adjusting the link check th...

Page 92: ...ened position Gauge onto the choke valve Adjust the opening angle of the choke valve 1 so that it will open at 20 from the closed position choke valve is at 50 before fully opened angle by bending the fast idle cam follower 2 or the choke shaft lip 3 Automatic Choke The automatic choke should be ad justed to supply adequate fuel and air mixture for engine starting in accord ance with the climatic ...

Page 93: ...apered end of the idle adju sting screw is damaged a smooth idling operation and the vacuum are not ob tainable Installation 1 Follow the removal procedures in the reverse order 2 After the eng ne is warmed up check the float level and for fuel leak then perform the idle adju st ment referring to Engine Tune Up section 3 If the car is equipped with the Toyoglide Automatic adjust the throttle link ...

Page 94: ...e is fully closed the primary throttle valve is mechanically opened to 12 from the closed position by the starting connecting link By this operation the engine can be warmed up adequately without stalling 1 Needle valve 13 Prim ary air bleeder 2 Float 14 Slow jet 3 P o w er valve 15 P o w e r piston 4 Prim ary main jet 16 Secondary small venturi 5 Idle adjusting screw 17 Secondary main nozzle 6 Pr...

Page 95: ...8 0 946 0 394 1 103 0 394 1 261 1 379 0 043 0 057 0 065 0 018 0 039 0 071 0 020 0 016 0 02 0 0 024 0 022 0 110 0 110 0 057 0 020 0 024 0 016 0 024 mmHg 0 173 from body surface on R K 4 4 101 series on RK171 series on R K 4 4 101 series on RK 171 series 10 pcs 4 p c s 4 pcs 8 p cs 3 15 3 94 inHg 0 8 cc Removal 1 Lift the engine cover with the as sistant driver s seat and support it with the hook be...

Page 96: ...r jet 5 Pump arm link 17 Pump weight 29 Main air bleeder jet 6 Wire clamp 18 Steel ball 30 Small venturi 7 Union bolt 19 Strainer clip 31 Venturi gasket 8 Union 20 Pump strainer 32 Main body 9 Strainer 21 Level gauge packing 33 Prim ary main jet 0 Needle valve seat 22 Level glass 34 Main jet plug 1 Needle seat shim 23 Level gauge clamp 2 Dust cover 24 Gauge glass gasket F ig 5 54 Carburetor Compon...

Page 97: ...arm 13 Lock washer 14 Throttle lever retaining nut 15 Pump connecting link washer 16 Pump connecting link spring 17 Throttle lever 18 E snap ring 19 Flange gasket 20 Insulator 21 Starting connecting link 22 Idle adjusting screw 23 Flange 24 Idle acfjusting screw spring 25 Slow passage gasket 26 Slow passage plug 27 Throttle adjusting screw 28 Throttle adjusting screw spring 29 Starting throttle le...

Page 98: ... ring retaining the pump arm 3 then remove the pump arm with the connecting link air horn and the cable holder on the RK101 series and the spring hanger on the RK171 series Main Body 3 Remove the pump plunger by pull ing out upward and then remove the strainer clip 1 pump strain er 2 and the steel ball 3 us ing a screw driver Fig 5 58 Removing Steel V5269 Ball Remove the primary main air bleeder 1...

Page 99: ...pin collar and the float 8 Remove the power jet valve using the Grooved S crew d river then remove the power jet from the power valve 9 Remove the main jet plug 1 and remove the primary main jet 2 and also remove the secon dary main jet 3 F ig 5 61 R emoving N eedle V5262 Valve Related Parts 6 Remove the union bolt 8 with the gasket union fitting 7 strainer 6 and the needle seat 5 then remove the ...

Page 100: ...econ dary throttle shaft arm and the r e turn spring and remove the throt tle valve retaining screw s then remove the secondary throttle valve and the shaft A ir Horn 16 Remove the vacuum piston by pull ing out straight forward using a pliers F ig 5 66 Removing Vacuum V5270 Piston 17 If necessary remove the choke valve retaining screw s and then remove the choke valve shaft and the spring Inspecti...

Page 101: ...shaft for proper operation and for ex cessive play and also check the related links arms and the springs for w ear and deformation 12 Check the idle adjusting screw for damage of the threads and the tapered end Assembly Follow the disassembly procedures in the reverse ord er Special care should be taken on the following items upon assembly and adjustment 1 A lw ays replace the gaskets or packings ...

Page 102: ...el in the float chamber with the level gauge line alignment by adding or decreasing the needle seat gasket shims The fuel level will vary about 0 7 mm Secondary Throttle Valve Initial Opening Angle Position the primary throttle valve at 30 before fully opened position using the Angle Gauge A t this time check if the throttle shaft link end a touches the extreme end of the groove b as shown in figu...

Page 103: ...obtain the clearance between the valve and the bore to be 0 6 mm 0 0 2 4 using the Wire Gauge by loosening the high speed valve retain ing screw s A fter adjusting the valve check if the operation of the valve is smooth then calk the retaining screw ends The idle adjusting screw should be correctly adjusted after the carburetor is installed onto the engine but as pre adjustment screw in the idle a...

Page 104: ...cles of dirt If the fuel is full in the fuel filter it is an indication that the element is being clogged therefore if the element is allowed to clog the engine performances will be impaired At frequent intervals disassemble and remove the element then clean with clean gasoline Removal 1 Disconnect the inlet and outlet hoses from the union fitting of the filter 2 Remove the fuel filter assembly fr...

Page 105: ...r R o ck er Arm Fig 5 76 C ross Sectional View of Fuel Pump G1774 Description The fuel pump is of a diaphragm type and is composed of the inlet and outlet valves diaphragm rocker arm upper and lower bodies The rotational motion of the camshaft actuates the rocker arm which m turn con verts into the reciprocation of the diaphragm This diaphragm movement draws the fuel into the pump and also deliver...

Page 106: ... 84 4 27 psi 400 mmHg 15 7 inHg 1 Fuel pump cover 2 Fuel pump cover gasket 3 Pump upper body 4 Fitting 5 Valve packing 6 Valve 7 Valve retainer 8 Diaphragm 9 Diaphragm spring 10 Oil seal spring retainer 11 Oil seal packing 12 Oil seal packing retainer 13 Pump lower body 14 Rocker arm spring 15 Rocker arm 16 Rocker arm pin 17 Rocker arm link 18 Insulator Fig 5 77 Fuel Pump Components on 5R Y6711 ...

Page 107: ...ow the passage with com pressed air Check the following items and if de fective replace as necessary 1 Check the cover and the body for c ra c k s defective threads and worn pin holes 3 Check the valves for proper ope ration 4 Check the spring for weakness and corrosion 5 Check the rocker arm link and the pin for w ear A ssembly A lw ays replace the gaskets with the new gaskets upon assembly 1 Pla...

Page 108: ...Installation Follow the removal procedures in the reverse order Alw ays replace the gaskets with the new gaskets After installation operate the engine and check for fuel and oil leaks T e sting 1 Remove the carburetor fuel pipe and connect a pressure gauge onto the pump outlet fitting Fig 5 79 Testing Delivery V4769 P ressu re 2 Operate the engine and measure the pump delivery pressure If the pres...

Page 109: ...ts on RS50 S eries G3125 Fuel hose Fuel pipe Fuel tank set packing 2 Fig 5 81 Fuel Tank Fuel Pipe Components on RS56 Series Y7291 1 2 3 4 5 6 7 8 9 1 0 11 1 2 Fuel hose Fuel pipe Fuel sender gauge Breather tube Tank vent chamber Fuel tank Drain plug Tank silencer pad Tank set packing Inlet joint hose Inlet upper pipe Fuel tank cap ...

Page 110: ... gauge 6 Drain plug 7 Fuel tank 8 Cap chain 9 Fuel tank cap Fig 5 82 Fuel Tank 3 4 5 6 1 Fuel hose 6 Fuel sender gauge 2 Tank bracket 7 Drain plug 3 Union bolt 8 Fuel tank 4 Fuel tank cap 9 Tank bracket 5 Breather hose Y 7292 Fuel Pipe Components on R T 4 3 L R T 5 2 L S eires F i g 5 83 Fuel Tank Pipe Components on RK101 G3126 ...

Page 111: ...move the fuel tank bands then remove the fuel tank assembly On RS56 S eries 1 Remove the rear body inside cov er L H and disconnect the inlet joint hose from the fuel suction pipe Tank Components on RK171 Y7293 2 Remove the spare tire 3 Remove the fuel tank drain plug and drain the fuel then remove the inlet joint hose retaining plate 4 Remove the fuel sender gauge cover and disconnect the gauge w...

Page 112: ...g from the tank and drain the fuel 2 Remove the fuel hose union bolt with the gaskets and disconnect the sender gauge w ire from the gauge 3 Remove the fuel tank band retain ing bolts and remove the fuel tank assembly Inspection 1 Inspect the fuel tank for cracks corrosion and leak If any defect is present repair or replace as necessary 2 Check the fuel hose or pipe and unions and if defective rep...

Page 113: ...eplaced at regular intervals The air cleaner should be cleaned at every 5 000 kilos or 3 000 miles on all models and the element should be replaced at every 30 000 kilos or 18 000 miles on the felt element type and 20 000 kilos or 12 000 miles on the paper element type The construction of these air cleaners are as shown in the following illustrations Disassembly of the air cleaner is self explanat...

Page 114: ... A ir cleaner case 8 Case gasket 9 Clamp 10 Clamp bolt Fig 5 85 A ir Cleaner Components on R S Series G3127 1 Wing nut 2 Seal washer 3 A ir cleaner cap 4 Element gasket 5 Cap gasket 6 A ir cleaner element 7 A ir cleaner case 8 Case gasket 9 Clamp 10 Clamp bolt 9 1 0 F ig 5 86 A ir Cleaner Components on R T 4 3 L R T 5 2 L S eries G3128 ...

Page 115: ... ir cleaner element 10 A ir cleaner case Fig 5 87 A ir Cleaner Components on RK101 S eries G3129 1 Connector Gasket 2 Clamp 3 Clamp bolt 4 Intake air connector 5 A ir cleaner hose 6 A ir cleaner cap 7 Cap gasket 8 A ir cleaner element 9 Element gasket 10 A ir cleaner case 11 Cleaner hose N o 2 12 Cleaner inlet No 2 F i g 5 88 A i r Cleaner Components on RK171 S eries G3130 ...

Page 116: ... P 6 2 Description 6 2 R em oval 6 3 Disassembly 6 4 Inspection R e p a ir 6 4 A s s e m b ly 6 5 Installation 6 5 OIL F I L T E R 6 5 Description 6 6 R em oval j 6 7 Disassembly 6 7 Inspection 6 7 A s s e m b ly 6 7 Installation 6 7 Oil Filter Element R eplacem ent 6 8 ...

Page 117: ......

Page 118: ...the oil flows separately into two ways again for lubricating the crankshaft bearings and the camshaft bearings The oil reaching the crankshaft lubricates the crankshaft journals and after lu bricating the crankshaft pins through the oil holes in the crankshaft this oil flow sprays onto the cylinder walls and the piston pins from the hole located at the connecting rod bearing end But on the connect...

Page 119: ... which is engaged with the camshaft Therefore the delivery quantity of the oil pump will increase in proportion to the engine revolution When the engine is running at high revolution the oil pressure will increase above the specified pressure F o r this reason the oil pump is provided witfK a relief valve in the oil pump cover to regulate the oil pressure F ig 6 3 Relief Valve Operation G1705 ...

Page 120: ...3 2 kg cm2 40 50 psi Testing oil S A E 30 Relief valve operating pressure at oil temperature 100 C 212 F at 2 500 rpm T rochoid More than 2 liters 2 1 US qts or 1 7 Imp qts per minute at 300 rpm More than 22 liters 23 3 US qts or 19 4 Imp qts per minute at 2 500 rpm Starts to open at 3 7 4 3 kg cm2 52 8 61 4 p si Delivery quantity zero at 5 5 6 5 kg cm2 78 1 92 3 psi 1 Plane washer 2 Oil pump body...

Page 121: ...tor and or the c o v e r F ig 6 5 Disassembling Oil V4657 Pump Inspection Repair Wash all parts in cleaning solvent and check the following items 1 Check the oil pump shaft for ex cessive w ear and scores If necessary replace the shaft 2 Check the drive rotor and the driven rotor for excessive w ear and sco res If defective replace the rotors as a set D rive rotor diameter is 29 70 to 29 74 mm 1 1...

Page 122: ...s for cracks and damages and check the strainer for clog and damage Replace if defective Assembly Follow the disassembly procedures in the reverse o r d e r Installation 1 Installthe oil pump into the cyl inder block and tighten the bolt to 1 5 2 0 m kg 11 0 15 0 ft lb torque 2 Connect the outlet pipe and tighten the union nut securely 3 Installthe oil pan with the new gasket and tighten the bolts...

Page 123: ...by pass In this manner the oil from the pump is de livered to the hole within the cylinder block directly without filtering the oil and without decreasing the oil line pressure S pecification Type Case capacity Filtering area Lifter valve operating p ressu re at oil temperature 70 75 C 158 167 F Using oil S A E 30 Oil leak Paper element Approximately 0 8 liter 0 85 US qts or 0 7 Imp qts Approximat...

Page 124: ...heck the element and replace it if it is excessively dirty or dam aged 2 Check the filter cap and the case If these are distorted or damaged replace as necessary 3 Check the lifter valve for fitting condition and scores on the sliding surface Replace if damaged Assembly Follow the disassembly procedures in the reverse order with the follow ing precautions 1 Alw ays replace the gasket upon assembly...

Page 125: ...ement 1 Remove the drain plug from the filter case and drain the engine oil 2 Loosen the oil filter cartridge guide and remove the filter case with the cartridge guide 3 Clean the case and the cartridge guide and install the new element at correct position and then tighten the cartridge guide to 1 0 1 5 m kg 7 5 11 0 ft lb 4 Fill the engine oil up to the spe cified level 5 Start the engine and che...

Page 126: ...ng 7 5 Water pum p 7 5 Inspection 7 6 Fluid coupling 7 6 Water pum p 7 6 A s s e m b ly 7 6 Water pum p 7 6 Fluid coupling 7 7 Installation 7 7 T H E R M O S T A T 7 8 Description 7 8 R em oval 7 8 Inspection 7 8 Installation 7 9 R A D IA T O R 7 9 Description 7 9 R em ov a l 7 10 Inspection 7 10 Installation 7 10 D E S C R I P T I O N 7 1 ...

Page 127: ...1 1 ...

Page 128: ...ovided in the engine A t this time the majority of the coolant is directly delivered to the water pipe located within the cylinder head to cool the surrounding of the combustion chambers where the engine heats up to the highest temperature during the engine operation The balance is delivered to the cylinder block through the by pass hose and is cir culated from the cylinder wall to the cylinder he...

Page 129: ...et f Cracked cylinder head or block 4 Noisy cooling system a Defective water pump bearing b Loose or bent fan blades c Defective fan belt W A T E R P U M P Description The water pump equipped on 5R en gine is of a direct driven fan type for stable cooling effect under excessive heavy load operation but on 5R en gine equipped with the Toyoglide A u tomatic transmission and R T 4 3 L 52L which is eq...

Page 130: ...s not only avoid the unnecessary engine power loss but also decreases the fan noise The water pump body is constructed with the thermostat chamber and the rotor is of a centrifugal type having six blade s The advantages are as follows it is compact the delivery quantity is large and even though the outlet port is made smaller the pressure will not increase therefore it is quite convenient to p er ...

Page 131: ...r Pump Components for Fluid Coupling Type G3132 Removal F o r R S series 1 Drain the coolant 2 Remove the inlet and the outlet hoses from the radiator and the by pass hose 3 Loosen the fan belt tension and remove the fan and the fan belt 4 Remove the fuel pipe clamp from the water outlet 5 Remove the water pump retaining bolts and remove the water pump assembly F o r R T 4 3 L and 52L series 1 Dra...

Page 132: ...e protecting the pulley with a suitable material Do not deform the pulley when securing in a vise T o remove the pulley with the fluid coupling bearing case from the water pump bearing shaft use a bolt with the thread diameter of 10 mm thread length of 30 mm and thread pitch of 1 25 S crew in the bolt into the pulley and remove the pulley with the fluid coupling bea_ring case from the water pump b...

Page 133: ... ear and dam age If defective replace as ne cessary Check the hole snap ring groove thrust washer 1 and the floating seat 2 If defective replace it using the water pump rotor kit 09238 40010 F ig 7 10 Removing Bearing V4645 7 Rem ove the floating seat and the gasket from the water pump cover Inspection Wash all parts except the fluid coup ling water pump bearing and the water pump shaft rubber par...

Page 134: ...vided on the cover will be towards the lower side and confirm that the rotor is not contacting with the body If these are contacting adjust the clearance between the rotor end surface and the body by increasing the pump cover gasket The specified clearance should be 0 3 0 7 mm 0 012 0 0 2 8 8 Install the thermostat and the water outlet Fluid Coupling 1 P r e s s in the pulley with the fluid coupli...

Page 135: ...all on the thermostat the water flow into the radiator is large 3 The construction is very durable and the life of the thermostat is prolonged due to no valve vibration 4 It is heat proof cold proof and pressure proof Specification Type Starts to open at Fully opens at Valve lift F o r R S R T series Wax 80 5 83 5 C 177 182 F 95 C 2 0 3 F 8 mm 0 315 W ax C a se C losed F o r RK series Bellows 63 5...

Page 136: ...y 0 0 5 kg cm2 0 7 psi within the cooling system When the pressure within the radiator increases above 0 5 kg cm2 7 psi the pressure relief valve allows the pressure to escape through the over flow pipe When the pressure decreases lower than atomospheric pressure as the coolant is cooled the vacuum relief valve allows the outside air to enter preventing the formation of vacuum within the radiator ...

Page 137: ...then remove the ra diator assem bly F o r RK171 176 f71B series 1 Drain the coolant qts RK171 176 series same same 305 Kcal min same 5 liters 5 25 U S qts 4 40 Imp qts 11 0 kg 24 4 lbs 2 Remove the radiator inlet and out let hoses 3 Remove the radiator wind guide 4 Remove the three radiator support retaining bolts and remove the radiator assembly with the fan shroud and the radiator support from u...

Page 138: ...Inspection R e p a ir 8 10 Bearing 8 10 Rotor 8 10 S ta to r 8 10 Brush Brush h o ld e r 8 11 R e c tifie r 8 12 A s s e m b ly 8 12 Alternator Output T e s t 8 13 Installation 8 14 R E G U L A T O R 8 14 Removal 8 14 Electrical Adjustment 8 14 Voltage relay 8 14 Voltage regulator 8 14 Regulator Circuit T e s t 8 15 Inspection Mechanical Adjustm ent 8 16 Voltage relay 8 16 Voltage regu lator 8 17 ...

Page 139: ......

Page 140: ...g light equipped on the R S series and also by the charging warning light equipped on the R T and RK series The alternator has the following excellent features in comparision with the con ventional DC generator 1 It provides a very high output at cruising speeds and also at lower engine revolution 2 Since the alternator uses the silicone diodes for rectification there is no increase of temperature...

Page 141: ...ct of r e gulator low speed points h Melted regulator high speed points i Lack or insufficient electrolyte j Shorted battery plates k P o o r connection of battery terminals 1 Opened or poor connection of wiring between ignition switch and regulator IG terminal m Burnt or poor contact of fuse n Opened or poor connection of wiring between regulator 1 1 F 1 1 terminal and alternator 1 1 F 1 1 termin...

Page 142: ...unction of rectifier s c Grounded or shorted stator coil A L T E R N A T O R R E G U L A T O R Construction Adjust fan belt tension Tighten or repair connections Adjust or replace regulator Replace bearing s Replace rectifier s Replace stator F ig 8 2 C ross Sectional View of Alternator Y5118 The components and the specification of the alternator for R S R T and R K series are slightly different b...

Page 143: ...rent control such as a cut out relay and a current limiter are not required for the alternator The alternator regulator is composed of the voltage regulator and the voltage re la y The function of the voltage regulator in the charging system is to regu late the generating voltage of the stator coil to a pre set value controlling the exciting current of the rotor coil The voltage relay is provided ...

Page 144: ...htly different The R S series are equipped with the ammeter together with the charge warning light but the R T and RK series are equipped only with the charge warning light deleting the ammeter W When the ignition switch is closed the current flows from the battery to the voltage relay points P o and M P 1 M through the charge warning light therefore the charge warning light glows A t the same tim...

Page 145: ...he point P L o repeats the intermittent movement to control the alternator output voltage Inspection In C ar 1 Precaution for operation with the alternator a Take care when connecting any test equipment onto the alter nator as the alternator output M B M terminal is connected to the battery at all times and if the ignition switch closes the voltage of the 1 1 F M terminal is the same b A lw ays pa...

Page 146: ...wing symptoms a Voltage regulator low speed point gap is too wide b Voltage regulator low speed points melted or high pressure contact c Voltage regulator high speed point gap is too wide d Poor contact of voltage regu lator high speed point e Voltage regulator or relay coil circuit opened f Poor contact of voltage relay points g Defective regulator ground 5 Stop the engine and turn the igni tion ...

Page 147: ...d or opened If the battery is in full charged state and the amperage reading is less than the specified am perage It is recommended to discharge the battery to perform the load test Disconnect the high tension lead from the ignition coil and turn the starter for about 5 10 seconds to discharge the battery A L T E R N A T O R Removal 1 Disconnect the battery to ground cable from the battery 2 Remov...

Page 148: ...l insulator Bushing Fig 8 9 Alternator Components for RS R T series Y6168 rotor shaft with the Injection Purrip Spline Shaft Puller 09286 46011 5 Remove the bearing retainer from the drive end frame and remove the bearing and the felt cover 6 Remove the rectifier holder r e taining nuts B 1 1terminal nuts and insulators then separate the stator with the rectifier holders from the rectifier end fra...

Page 149: ...nd RK171B series and 4 1 4 3 ohms on R K series except on RK171B series If there is little or no resistance the coil o r slip rings indicate a short or ground and considerably higher than that specified above indicates an opened coil or con nection defect If the test shows that the rotor coil is shorted or opened and the slip rings are defective the rotor assembly should be replaced Fig 8 14 Testi...

Page 150: ...ur leads of the stator coil for conductance between them If the tester needle does not m ove the stator coil is opened and must be replaced Brush Brush Holder 1 Check the brush for crack and w e a r If the brush is worn beyond 9 mm 0 3 5 replace the brushes The brush should slide smoothly Fig 8 19 Brush Length V1143 2 If replacing the brush install the new brush and the brush spring into the brush...

Page 151: ...ositive side r e c tifiers is found defective always replace the positive side rectifiers with the holder assembly 2 Rectifier holder negative side Connect the tester lead onto the rectifier holder and lead onto the rectifier lead as shown in figure 8 22 and check the r e sistance Good rectifier will indicate no r e sistance and if it indicates high resistance the rectifier is opened Next turn the...

Page 152: ...ultipurpose grease into the rear bearing and press in the bearing onto the rotor shaft at the slip ring side the rotor shaft bearing through the space ring with the Transm is sion Oil Plu f 59325 12010 Fig 8 26 Installing Drive B0045 End Frame 6 P re s s in the brushes against the brush spring tensions into the brush holder Next insert a w ire through the access hole in the rectifier end frame and...

Page 153: ...assembly Electrical Adjustment If the alternator regulator does not actuate properly in accordance with the electrical adjustment check the resistance of the regulator circuits If defective repair the defective por tion and repeat the electrical adjust ment after performing the mechanical adjustment A lw ays use a fully charged battery to perform the electrical adjustment Voltage Relay circuit as ...

Page 154: ... T 5 2 L RK171B series and on R K ex cept on RK171B series this must be 11 ohms If the resistance is considerably higher than the specified resistance value the control resistor is de fective 2 Connect the circuit tester between the fr i and E 1 1 terminals The resistance should be zero If there is any resistance the contact of the voltage relay points P I and P o is poor P r e s s down the armatu...

Page 155: ...L o and nP L 2 n is poor Inspection Mechanical Adjustment This mechanical adjustment described here should be performed when the specified values are not obtained in the regulator test Dirty contact points should be dressed with a suitable paper or a suitable fine emery cloth A rm atu re Gap F ig 8 33 Nomenclature of G0174 Voltage Regulator After dressing the points wash them thoroughly with clean...

Page 156: ...d check the angle gap with the feeler gauge This gap should be more than 0 2 mm 0 0081 1 If not replace the regulator F ig 8 36 Checking V1186 Armature Gap 2 Check the point gap with the feeler gauge This point gap should be 0 25 to 0 45 mm 0 010 0 018 If necessary adjust the gap by bending the high speed point holder B as shown in figure 8 37 3 P re s s the armature and check the contact spring d...

Page 157: ...8 18 M EM O RAND U M MEMO ...

Page 158: ... IN G S T A R T E R Construction O peration R em ov a l Disassembly Inspection Repair A rm a tu re Field c o il Magnetic switch Brush holder brush Starter clutch A s s e m b ly Testing After Assembly Installation B A T T E R Y Inspection Adjustment Charging M EM O RAN D U M ...

Page 159: ......

Page 160: ...he battery This chemical action actuates the starter motor to convert the electrical energy to mechanical en ergy The starter motor has the following characteristics It is compact and light The output is large and the end frames arK e of a sealed type to prevent the entry of dirt and dust The slippage of the over running clutch is very little and the armature is not over ru n The operation of the ...

Page 161: ...older 1 Worn bushings Replace bushings m Weak battery Recharge battery n Shorted battery cell s Replace battery o P o o r contact of battery terminal s Clean and tighten terminal s P Open circuit between starter switch and magnetic switch Repair q P o o r battery ground cable con nection Clean and tighten Starter turns but pinion does not mesh with ring gear a Starter clutch pinion gear worn Repla...

Page 162: ...pring the turning of the pinion occurs due to the helical splines and this enables a smooth engagement of the pinion with the ring gear Also as the starter clutch pinion is engaged with the ring gear the turningforce of the armature pushes the starter clutch pinion into a complete mesh without further force of the pinion drive spring F o r these reasons the pulling force of the magnetic switch is ...

Page 163: ... t this time the pinion is partially engaged with the ring gear smoothly before the magnetic switch contact plate is closed When the magnetic switch is closed the battery current flows directly into the field coil and to the armature through the contact plate and energizes the arma ture to spin creating a large torque This moves the starter clutch pinion further to completely engage with the ring ...

Page 164: ...imately 5 8 kg 12 8 lbs 40 70 A H 11 volts L ess than 45 amperes More than 6 000 rpm 7 0 volts L ess than 550 amperes More than 1 4 m kg 10 1 ft lbs 6 7 8 9 10 I I 1314 15 16 17 1319202122 23 2425 1 End frame c o v e r 10 Housing bushing 19 Brush 2 Through bolt 11 Bushing c o v er 20 Field coil 3 Armature 12 L o c k washer 21 Po le c o re 4 Starter clutch 13 B rak e spring 22 Insulator 5 Magnetic ...

Page 165: ... drive lever with the drive spring 5 F i g 9 5 Removing Magnetic V1806 Switch 3 Remove the end frame c o v e r and remove the lock washer brake spring and the rubber ring 4 Remove the two through bolts and remove the commutator end frame 5 Take out the brushes from the brush holder and remove the brush holder from the armature shaft 6 Remove the yoke from the drive housing 7 Remove the drive lever...

Page 166: ...diameter of the commutator is out of round more than 0 3 mm 0 012 cut the commutator on a lathe The out of round should be less than 0 1 mm 0 0 0 4 The serviceable limit of the com mutator is 36 8 mm 1 4 5 and if the limit exceeds replace the armature The specified commutator diameter is 38 8mm 1 5 3 3 Check the mica depth and file off the mica if the depth is less than 0 2 mm 0 0 0 8 In c o rre c...

Page 167: ...ound Connect one test prod onto the field coil lead and the other lead on the yoke If the tester needle m oves the F ig 9 13 Testing Field B0035 Coil for Open Circuit field coil has a ground circuit Repair or replace the field coil 8 F ig 9 14 Testing Field B0036 Coil for Ground Magnetic Switch The following magnetic switch tests described in paragraphs 1 through 3 should be performed with the con...

Page 168: ...length by loosening the lock nut to obtain the correct position of the pinion travel as shown in figure 9 18 Fig 9 16 Holding Coil Test G1266 3 Check the plunger return motion by connecting the battery positive lead onto the F terminal and the negative lead onto the magnetic switch body After pulling out the pinion until it reaches to the pinion stop collar with the hand release the hand from the ...

Page 169: ...m a g e sticky against the free wheel movement and slippage in opposite direction to the free wheel move ment If defective replace the starter clutch assembly Assembly When assembling each part coat with multipurpose grease onto the sliding surface or moving portion of the a r mature shaft splines starter clutch bushing end frame bushings drive lever and the moving stud 1 Install the starter clutc...

Page 170: ... 1 3 and the thrust play limit is 0 8 mm 0 0 31 1 8 Pack multipurpose grease into the end frame cover and install it on to the end frame 2 m m F ig 9 23 Installing Rubber V1819 Plate 5 Install the brush holder onto the armature and install the brushes into the brush holders Fig 9 24 Installing Brush V1808 Holder Fig 9 25 Installing End V1821 Frame C over 9 Install the magnetic switch onto the driv...

Page 171: ... producing a torque of 1 4 m kg 10 1 ft lb or more Installation Follow the removal procedures in the reverse order B A T T E R Y Inspection Adjustment 1 Check the electrolyte level in each cell Add sufficient electrolyte to level line Always use distilled water to re plenish the battery 2 Check the specific gravity of the electrolyte with a hydrometer If the specific gravity reading is below 1 200...

Page 172: ... filler caps while charging and do not allow the battery electrolyte temperature to rise 45 C 113 F Hydrogen and oxygen gases are produced during normal battery ope ration This gas mixture can explode if flames or sparks are brough near the vent openings of the battery The sulphuric acid in the battery elec trolyte can cause a serious burn if spilled on the skin or spattered in the eyes It should ...

Page 173: ...9 14 M EM O RAND UM MEMO fife ...

Page 174: ...ce Test Adjustment 10 10 Breaker point g a p 10 10 Cam dwell angle 10 10 Advance characteristics 10 10 C on d en ser 10 11 Installation 10 11 IGNITION C O IL 10 12 Description 10 12 R em ov a l 10 13 Inspection 10 13 Installation 10 14 HIGH T E N S IO N W IRES 10 14 Description 10 14 R em ov a l 10 14 Inspection 10 14 Installation 10 14 S P A R K P L U G 10 14 R em o v a l 10 14 Inspection Adjustm...

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Page 176: ...ker points condenser and the ignition coil primary windings The secondary circuit consists of the ignition coil secondary windings distributor cap rotor high tension wirings and the spark plugs When the breaker points are closed the primary current flows from the battery through the ignition switch to the primary windings in the coil then to ground through the closed breaker points When the breake...

Page 177: ... a Defective spark plug s Clean adjust or replace plug s b Defective breaker points Replace points c Loose connection in primary Tighten or repair circuit d Defective condenser Replace condenser e Defective coil Replace coil f Defective cap or rotor Replace cap or rotor 3 Engine misses a Dirty or defective spark plug s b L oose ignition wire s or de fective insulation c Cracked distributor cap d I...

Page 178: ...the gear on the camshaft in time with the engine A s the spark timing varies according to the load and the engine revolution the automatic spark advance mechanism is provided in the distributor The centri fugal governor advances the position of the cam according to the engine revo lution and also the vacuum advancer controls the position of the breaker plate according to the load on the engine Als...

Page 179: ...ctor advance at 400 600 rpm 4 0 6 0 at 1 000 rpm 13 0 15 0 at 1 900 rpm 15 0 17 0 at 2 500 rpm at 320 480 rpm 6 0 8 0 at 1 000 rpm 8 5 10 5 at 1 200 rpm 13 0 15 0 at 2 500 rpm at 320 480 rpm 8 7 10 7 at 1 000 rpm 12 0 14 0 at 1 200 rpm 16 5 18 5 at 2 500 rpm One complete turn is about 2 3 O One graduation is about 5 2 Removal 1 Disconnect the high tension w ires from the spark plugs and the igni t...

Page 180: ...r weight 12 Housing cap spring 21 Stationary plate 4 Governor shaft plate 13 Oil cup 22 Spring set 5 Steel washer 14 Distributor cap 23 Vacuum advancer 6 Bakelite washer 15 Cap center piece 24 O ring 7 Terminal insulator 16 Rotor 25 Washer 8 Terminal bolt 17 Dust proof cover 26 Spiral gear 9 Condenser 18 B reaker 27 Pin Fig 10 5 Distributor Components G3424 ...

Page 181: ... cam F ig 10 8 Removing V3678 Distributor Cam 7 Remove the governor springs and the governor weights 8 Remove the pin and then remove the spiral gear T o remove the pin drill the riv etted pin end Take care of the 3 7 washers installed on the governor and plate at both sides of the distributor housing Inspection Wash all the parts with the exception of the vacuum advancer and the con denser in cle...

Page 182: ...ry Plate 1 Remove the snap ring 1 and remove the washer 2 set spring 3 balls 4 washers 5 stationary plate 6 and the break er plate 7 liiiaSF 5 3 2 1 Fig 10 10 Checking Thrust V3681 Clearance Distributor Cap Check the cap for cracks carbon tracks and the burnt or corroded terminals and also check the center carbon piece for w ear The piece length is 9 mm 0 3 5 and the limit is 7 mm 0 2 7 F ig 10 12...

Page 183: ... spiral gear for w ear Assembly 1 Insert the thrust washers 2 3 and 4 onto the governor shaft and plate 1 and then install the governor shaft and plate onto the housing 5 after lubricating the shaft with engine oil The bakelite washer should be installed between the steel wash ers F ig 10 15 Assembling V3683 Governor Shaft 2 Assem ble the washers 6 spiral gear 7 and the pin 8 onto the shaft and th...

Page 184: ...ng 6 Install the vacuum advancer and the condenser 7 Install the terminal bolt and the insulators and tighten the nut finger tight together with the con denser lead w ire 8 Install the contact point and the breaker arm onto the breaker plate with the snap ring and the retainer s c r e w Connect the breaker arm lead w ire onto the terminal and tighten the nut Coat the cam lobes with grease Do not a...

Page 185: ...ap is wide the angle will be small and if the gap is n arrow the angle will be large B rea k er Point Gap Rotate the distributor shaft until the breaker arm rubbing block is at the top of the cam Check the point gap with a feeler gauge and adjust the gap to 0 4 to 0 5 mm 0 015 0 0 2 0 T o adjust the gap loosen the contact point retaining s c r e w and insert a slot type screw d river into the cut ...

Page 186: ...0 7 12 0 14 0 16 5 18 5 Vacuum advancer Connect the test set vacuum line onto the fitting on the vacuum ad vancer Set the tester to 0 advance zero vacuum at the distributor 1 000 rpm Check the advance at the first va cuum setting specification in the specification If necessary replace the advancer Vacuum mmHg Advance angle inHg 70 90 Advance begins 2 76 3 54 130 5 12 6 5 19 5 180 7 09 9 1 13 1 260...

Page 187: ...e necessary to crank the engine slightly with the starter after the distributor drive gear is partially engaged with the oil pump shaft 3 Rotate the distributor housing coun terclockwise until the points are starts to open and tighten the clamp s c r e w 4 Connect the primary w ire and the vacuum pipe 5 Install the dust proof cover rotor and the distributor cap 6 Install the high tension w ires wi...

Page 188: ...nce from center to three negative electrodes should be more than 8 mm 0 315 at distributor revolution of 75 rpm and at 12 volts Sparking distance from center to three negative electrodes should be more than 6 mm 0 236 at distributor revolution of 3 000 rpm and at 12 volts Approximately 0 7 kg 1 5 lb s Removal 1 Disconnect the w ires connecting to the ignition coil 2 Remove the ignition coil retain...

Page 189: ...val Disconnect the high tension wires from the spark plug terminals and remove the spark plugs using the Spark Plug Wrench Inspection Adjustment 1 Check the plugs for cracks and chips on the insulators 2 Check the electrodes for w ear Removal T o disconnect the high tension w ir e s pull only on the end insulating fitting Do not pull or jerk the w ir e b e c a u s e pulling on the w ire might caus...

Page 190: ...blast cleaner Do not prolong the use of the a brasive blast as it will erode the insulation 7 Adjust the plug gap to 0 7 0 8 mm 0 027 0 031 by bending the ground electrode Installation F ig 10 28 Cleaning Spark Plu V2205 Follow the removal procedures in the reverse order The specified spark plug tightening torque is 1 0 2 5 m kg 7 2 18 0 ft lb ...

Page 191: ...10 16 M E M O R A N D U M MEMO s p ...

Page 192: ...Prepared By T O Y O T A M O TO R S A L E S C O L T D Export Technical Division Haruhi Plant Haruhi mura Nishikasugai gun Aichi P r e f Japan April 1969 N o 98022 Printed in Japan ...

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