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Toyota 5R 1969 Repair Manual

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  • Page 2 5R, 3R-B & 3R-C ENGINE REPAIR M A N U A L TOYOTA M O TO R SALES CO., LTD. EXPORT - TECHNICAL DIVISION...
  • Page 3 5 R , 3 R - B 3 R - C engines equipped on Toyota C ro w n , C orona, Light Stout, Stout, Dyna and Light Bus s e r ie s . It c o v e r s...
  • Page 4 SECTION IN D EX G R O U P IN D E X SECT GENERAL INFORMATION | ENGINE TUNE-UP ENGINE EXHAUST SYSTEM FUEL SYSTEM LUBRICATING SYSTEM COOLING SYSTEM ■ CHARGING SYSTEM STARTING SYSTEM IGNITION SYSTEM...
  • Page 6 G E N E R A L I N F O R M A T I O N G E N E R A L ............G E N E R A L S P E C I F I C A T I O N ....
  • Page 8 3 R - B model engine. T h e s e engines a re equipped on the Toyota C oron a s e r ie s . T h e construction of all engines is the same b a sica lly, but their specification a re slightly different from each other.
  • Page 9 G E N E R A L I N F O R M A T I O N - General...
  • Page 10 G E N E R A L I N F O R M A T I O N - General...
  • Page 11 G E N E R A L I N F O R M A T I O N - General T h e crankshaft thrust bearings a re located at the center main bearing, and are of steel backed babbit metal • T h e camshaft is of chilled casting, and the camshaft timing gear is of bakelite.
  • Page 12 G E N E R A L I N F O R M A T I O N - General Specification '£ < o q q o o < y Q Q Q Q h D Q D Q h _ I CD ro LO <D tu a)
  • Page 13 G E N E R A L I N F O R M A T I O N - General Specification 0 1 0 t u a ) 0 0 0 0 t u < u < u (U (U £...
  • Page 14 G E N E R A L I N F O R M A T I O N - General & Specification ' CQ "u ti - t- £ ,1 1 ,w - 4 - 5 C D f J ©...
  • Page 15 G E N E R A L I N F O R M A T I O N - General Specification < < D C D ai C D C D ai 0 C D C D < D C D C D C D <...
  • Page 16 G E N E R A L I N F O R M A T I O N - Recommended S . S . T . R E C O M M E N D E D S . S . T . Engine Imput Shaft Front B earin g Pu ller 09303-...
  • Page 17 1-10 M E M O R A N D U M MEMO * 4...

  • Page 18: Table Of Contents

    E N G I N E T U N E - U P G E N E R A L ........I N S P E C T I O N & A D J U S T M E N T ....B a t t e r y ............

  • Page 20: General

    E N G I N E T U N E - U P General In o rd er to maintain the full performance originally built in the engine, a p erio d ic engine tune-up is essential. If any deficien cy is encountered during operation of the c a r , it must be diagnosed immediately, and p ro p e r ca re should be taken by tuning up the engine.

  • Page 21: Fuel Filter

    E N G I N E T U N E - U P Adjust the belt tension if n eces­ fa r as possible, then release the sa ry . ro tor, if the rotor r e ­ turns to its original position. If the rotor does not return re a d ily , the distributor must be disassem­...

  • Page 22: Ignition Timing

    E N G I N E . T U N E - U P When cleaning with the abrasive cleaner, do not prolong the clean­ ing to prevent porcelain damage. 3. Inspect each spark fo r make p l u g and heat ra n g e .

  • Page 23: V A Lv E Clearance

    E N G I N E T U N E - U P relation with the characteristic of the 3 R - C engine, r e fe r to Emission the vacuum advancer. Control System Repair Manual N o . 98218.
  • Page 24 E N G I N E T U N E - U P N O T E : A lw a y s use a fully charged If n e cess a ry , adjust the choke r e ­ battery to obtain the engine r e v o ­...
  • Page 25 M E M O R A N D U M * % MEM O...
  • Page 26 E N G I N E T R O U B L E S H O O T I N G ........ M A J O R S E R V I C E ........... R e m o v a l ............Disassembly ...........
  • Page 28 E N G I N E - Trouble Shooting T R O U B L E S H O O T I N G T h e possible faults, and their remedies a re listed in the following table. When the symptoms of troubles a re detected, proper ca re must be taken immediately before proceeding to the next probable cause.
  • Page 29 E N G I N E - Trouble Shooting B ra k es dragging Adjust brakes j. In correct valve clearance Adjust valve clearance k. Exhaust system partially Clean o r replace exhaust system restricted Incorrect g r a d e , and viscosity Replace with co rrect oil oil being used m .
  • Page 30 E N G I N E - Trouble Shooting Adjust points b. Points incorrectly adjusted Adjust spark plug gap c. S park plugs gap incorrectly adjusted Tighten o r replace spark plug w ir e s d. L o o s e or defective spark plug w ire s Replace ignition coil e .

  • Page 31: C Arbu Retor

    E N G I N E - Trouble Shooting c. Weak valve springs Replace springs Cylinder head Carbon deposits in combustion Rem ove carbon chambers Cylinder head w a ter tube Clean o r replace water tube partially clogged Cylinder head gasket defective Replace gasket Rough Engine Idling Carburetor...
  • Page 32 E N G I N E - Trouble Shooting Overhaul and rep a ir engine b. P o o r compression Replace gasket c. L e a k y cylinder head gasket Tighten manifold o r replace gaskets d . L ea k y manifold gaskets N oisy Engine One of the most difficult of all trouble shooting operation is to locate the sou rce of noise in the engine.

  • Page 33: M A Jo R S E R V I C E

    E N G I N E - Maior S e r v i c e M A JO R S E R V I C E transmission r e a r , insert any a- vailable universal joint sleeve yoke. Removal 5 .

  • Page 34: Disassembly

    E N G I N E - Major S e r v i c e c o v e r and the flywheel to relocate d. Fuel hose. the original positions upon assem ­ Radiator inlet and outlet h o s e s . bly, and rem ove the clutch c o v e r f.
  • Page 35 E N G I N E - Maior S ervic e 13. Rem ove the w a te r pump assembly- 22. Rem ove the oil pump outlet pipe together with the fan and the w ater from the cylinder block, and r e ­ outlet.

  • Page 36: Inspection & R Epair

    E N G I N E - Maior S e r v i c e 1. Check the cylinder head fo r crack , and inspect the gasket surface fo r burr and n ick s. Replace the cylinder head if de­ fective .

  • Page 37: V A Lv E Guide Bushing

    3-10 E N G I N E - Major S er vic e cylinder head r e a r plate. lapping the seat to obtain p ro p e r width of 1.4 mm ( 0 . 0 5 5 " ) . 6.

  • Page 38: V A Lv E

    E N G I N E - Major S e r v i c e 3-11 F i g . 3-12 Reaming V a lv e V3150 F ig . 3-9 Easy Method G1709 Guide Bushing V a lv e [ 0 9 2 0 1 - 4 0 0 10 ) Check the valve fa c e s , and the...

  • Page 39: V A Lv E Spring

    3-12____E N G I N E - Major S e r v i c e R em ove all g r o o v e s , and s c o r e s surface plate. P la c e the spring from end of the valve stem,...

  • Page 40: V A Lv E Lifter

    E N G I N E - Major S e r v i c e 3-13 facing machine. ing, replace it with the ro ck e r 5 . Check the ro c k e r shaft spring for sub-assembly possible.

  • Page 41: Push Rod

    3-14 E N G I N E - Major S ervice Push Rod Inspect the push rods fo r damage, bend and twist. Replace the rod/s if n e c e s s a ry . Cylinder Block 1. Check fo r c r a c k s , and damage after cleaning the block thoroughly.

  • Page 42: Cylinder Boring

    E N G IN E - Major S e r v ic e 3-15 Mark: 88.485 Cylinder Boring Piston diameter: 88.478 ~ 88.488 mm 1. Select the cylinder with the most (3.4834 ~ 3 .4 838") w e a r first to determine the o v e r ­ Mark: 88.495 size piston to be used.
  • Page 43 3-16 E N G I N E — Major S e r v i c e Mark: 89.420 Piston diameter: Piston diameter: 88.730 ~ 88.740 mm 89.414 ~ 89.424 mm (3.4960 ~ 3.5 964") (3.5202 ~ 3 .5 2 0 6 ") O / S - l .00: Mark: 88.965...

  • Page 44: Cylinder Sleeve

    E N G I N E - Major S e r v i c e 3-17 o v e r s iz e 060 fo r t h e 3 R - B , 3 R - C and 1.50 fo r the 5R pistons Can­ not be utilized .

  • Page 45: Piston & Piston Pin

    3-18____E N G I N E - Major S e r v i c e 4. B o r e the slee ves to fit the stand­ correspond the size of the piston. ard size pistons. Hone the bo res Th e rings a re provided with the after boring.

  • Page 46: Connecting Rod

    E N G I N E - Major S e r v i c e 3-19 2. Check the connecting rod fo r bend 3. Check ring to piston ring twist with a Connecting Rod groo ve clearance with a fe e le r A lig n e r as shown in figure 3-30.

  • Page 47: Connecting Rod Bearing

    3-20 E N G I N E - Maior S er vic e gines and 09222-30010 fo r 5R en­ crankshaft while the Plastigage is gine. in p la c e . A ft e r installing the bushing, hone Specified torque: the bushing in a pin hole honing...

  • Page 48: Crankshaft

    E N G I N E - Major S e r v i c e 3-21 (0.0739 ~ 0 .0 7 4 3 ") 1.520 ~ 1.530 mm Crank pin finished diameter: (0.0598 ~ 0 .0 602") 54.230 ~ 54.240 mm U/S-010: (2.1367 ~ 2.1371") Bearing thickness:...

  • Page 49: Crankshaft Bearing

    3-22 E N G I N E - Major S e r v i c e ( 0 . 0 0 4 " ) , grind crank w a rd s the crankshaft thrust sur­ journals the crankshaft jo u r­ face .

  • Page 50: Crankshaft Timing G Ea R

    E N G I N E - Major S e r v i c e 3-23 defective, replace the timing U/S-030: g e a r . Bearing thickness: rem ove the timing g e a r , use 2.876 ~ 2.886 mm Timing G ear T o ol...

  • Page 51: Camshaft

    3-24 E N G I N E - Maior S e r v i c e teeth, c r a c k s , and w e a r . Exhaust: 38.29 ~ 38.39 mm If defective, replace the ring g e a r . (1.506 - 1 .5 1 1 ") 4.

  • Page 52: Camshaft B Earing

    E N G I N E - Major S e r v i c e 3-25 measuring the ^difference between 46.340 - 46.350 mm the camshaft journal diameter and (1.8244 ~ 1.8 248") the bearing inner diameter. N o . 2 T h e clearan ce should be 0.025 to 46.090 ~ 46.100 mm 0.066...

  • Page 53: Camshaft Timing G Ear

    3-26 E N G I N E - Major S e r v i c e rect, and p rop erly installed, only 3. Check the backlash between the a slight reaming is required. crankshaft timing g e a r and the camshaft timing g e a r with a dial 8.

  • Page 54: Intake & Exhaust Manifolds

    E N G I N E - Major S e r v i c e 3-27 A ssem bly Crankshaft Oil Retainer B e fo r e assembling, thoroughly clean It is recommended that the oil retain­ the disassembled parts especially the e r should be replaced w h en ever the oil p a ssa ges, bearings, bearing holes engine is overhauled.
  • Page 55 3-28 E N G I N E - Mai o r S e r v i c e properly installed into the valve should be faced towards the same stem g r o o v e . side as the connecting rod front m a r k .
  • Page 56 E N G I N E - Major S e r v i c e 3-29 When installing the bearing cap, the " A R R O W " marks on the b e a r ­ ing caps must be faced towards the front of the cylinder block.
  • Page 57 3-30____E N G I N E - Major S e r v i c e Tighten the thrust plate retaining bolts to 1.5 - 2.0 m-kg (11 to 15 ft-lb) torque. A ft e r installing the camshaft, r e ­ check the backlash.
  • Page 58 E N G I N E - Major S e r v i c e 3-31 35. Rem ove the engine from the engine 23. Install the push rod c o v e r s , oil w o r k stand, and install the r e a r p ressu re sender gau ge, tempera­...

  • Page 59: Installation

    3-32 E N G I N E - Major S er vic e (14 ~ 21 ft-lb) torque. Engine oil capacities with the oil install the clutch disc, install filter: the protruded side ©f the clutch On R S 5 0 , 56, R T 4 3 L , 5 2 L , disc tow ard s...
  • 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 ..........E X H A U S T P I P E ..........R e m o v a l ............Inspection ..........

  • Page 62: D E S C R I P T I O N

    E X H A U S T S Y S T E M - Description D E S C R I P T I O N T ail P ip e E x h a u s t P ip e F r o n t P r e - m u f fle r M ain m u ffle r F i g .
  • Page 63 E X H A U S T S Y S T E M - Description E x h a u s t P ip e C e n te r No. 2 F i g . 4-3 Exhaust System on R T 4 3 L & R T 5 2 L S e r ie s G3120 F i g .
  • Page 64 E X H A U S T S Y S T E M - Description F i g . 4-6 Exhaust System on RK171 S e r ie s G3123...
  • Page 65 E X H A U S T S Y S T E M - Description. Exhaust Pipe F i g . 4-7 Exhaust System on RK176 S e r i e s G3124 T h e exhaust system on the R S 5 0 , R T 4 3 L and R T 5 2 L s e ries consists of the exhaust pipe front, p re-m u ffler, exhaust pipe center,...

  • Page 66: Exhaust Pipe

    E X H A U S T S Y S T E M - Exhaust Pipe 2. Lo osen the exhaust pipe clamp, pipe front, and then rem ove the exhaust pipe center RS50 and rem ove the muffler. s e r ie s , and the main muffler, on 3.

  • Page 67: M E M O R A N D U M

    M E M O R A N D U M * M EM O * +...
  • Page 68 F U E L S Y S T E M D E S C R I P T I O N ..........T R O U B L E S H O O T I N G ......C A R B U R E T O R - O n R S , R T 4 3 L , 52L s e r ie s ....

  • Page 69: Description

    In sp ection ........5-31 A i r hone ............. 5-31 Main body ..........5-31 Flange ............5-32 A s s e m b l y * ........... 5-32 A d ju stm en t............5-33 Float l e v e l ........... 5-33 S econ d ary throttle valve initial opening angle .........
  • Page 70 F U E L S Y S T E M - Description D E S C R I P T I O N F ig . 5-1 Fuel System on C row n Sedan S e r ie s Y6710 T h e fuel system consists of the fuel tank, fuel filter, fuel pump, ca rb u retor and the pipes which connect the components.
  • Page 71 F U E L S V S T E M - Trouble Shooting T R O U B L E S H O O T I N G Carburetor B e fo re diagnosing the trouble shooting of the carburetor, check the manifold mounting bolts, cylinder compression, and the ignition system.
  • Page 72 F U E L S Y S T E M - Trouble Shooting Adjust linkage d. Defective accelerator linkage Replace p o w e r piston spring e. Defective operation of p o w er piston Replace p o w e r valve f.
  • Page 73 F U E L S Y S T E M - Trouble Shooting, Carburetor 4. Noisy fuel pump a. L o o s e fuel pump mounting Tighten mounting bolts b . Worn o r defective ro c k e r arm Replace ro c k e r arm Broken o r w eak ro c k e r arm...
  • Page 74 F U E L S Y S T E M - Carburetor mm (0.020 ') Main air bleeder diameter: primary mm (0.020 ') secondary mm (0.020 11 Pump jet diameter 0.55 mm (0.022 ') on 5R P o w e r jet diameter 0.50 mm (0.020 ') on 3 R - mm (0.110 ') primary...
  • Page 75 F U E L S Y S T E M - Carburetor T h e carb u retor is a three group construction consisting of the air horn group, main body group and the flange g ro u p . T h e primary bore provided with a double venturi consists of the slow system, high speed system, accelerating system, automatic choke system and the ther­...
  • Page 76 F U E L S Y S T E M - Carburetor Th e fuel from the float chamber flows through the main jet, then to the slow jet ( 1 ) , mixes with the air from the primary air bleeder N o .
  • Page 77 F U E L S Y S T E M - Carburetor and uniform distribution of the air-fuel mixture to the cylinders. the engine revolution in crea se s, the air flow becomes strong enough to o verc o m e the weight of the high speed valve weight, then the high speed valve opens gradually, and starts the secondary fuel flow into operation.
  • Page 78 F U E L S Y S T E M - Carburetor p o w e r requires additional rich fuel mixture. H o w e v e r , when the throttle valve is opened suddenly, the effect is to ''dump" air into the intake manifold, thus sudd'enly reducing the manifold vacuum.

  • Page 79: Fast Idle

    5-10 F U E L S Y S T E M - « Carburetor When the engine is started, the choke valve opens slightl^due to the vacuum and also with the aid of the p re s s u re from the air draVvn into the air horn which provides sufficient air to operate the engine without stalling.
  • Page 80 F U E L S Y S T E M - Carburetor 5-11 8. Thermostatic valve system When the temperature around the fro m A ir carburetor ris es in summer H o n e season, with slow cruising, the fuel will evaporate rapidly.

  • Page 81: Idle Adjusting S C R E W

    — —i 2l ----- F U E L S Y S T E M - Carburetor Pum p damping sprin g 18. S to p p e r le v e r s e cu rin g B od y 36.

  • Page 82: Removal

    F U E L S Y S T E M - Carburetor 5-13 solvent. T h e s e removal parts Removal should be kept in a clean container to facilitate the assem bly. 1. Rem ove the air clean er assembly . 1.
  • Page 83 5-14 F U E L S Y S T E M - Carburetor P o w e r V a lve Wrench 09860- 1 1 0 1 0 10. Rem ove the p o w e r jet from the p o w e r va lve.

  • Page 84: Flange

    F U E L S Y S T E M - Carburetor 5-15 retainer located under the pump cylinder using a pincers, and r e ­ move the steel ball. 15. Rem ove the stopper leve r securing s c r e w , and rem ove the high speed stopper le v e r (1) with the spring as shown in figure 5-24.
  • Page 85 5-16 F U E L S Y S T E M - Carburetor spring (4) and the needle valve necting s c r e w , rem ove the ( 5 ) , then rem o ve the needle valve choke valve and shaft in the same seat ( 6 ) .

  • Page 86: A Ssem Bly

    F U E L S Y S T E M - Carburetor 5-17 defective tab, and also check for p ressed a ir, rem ove the dirt. w e a r deformation of the float Wash the die-cast parts with a soft le v e r pin hole, bracket and the...
  • Page 87 5-18 F U E L S Y S T E M - Carburetor Automatic Choke 5. A ssem b le the piston connector onto the choke shaft with the connector 1 . A ssem b le the thermostat case and retaining s c r e w .
  • Page 88 F U E L S Y S T E M - Carburetor 5-19 of the prim ary throttle va lv e . A i r Horn 8. A ssem ble the union fitting and the strainer with two gaskets. 9. Install the p o w e r piston spring and the p o w e r piston, then install the p o w e r piston stopper.
  • Page 89 5-20 F U E L S Y S T E M - Carburetor then calk the throttle valve retain­ 20. Install the idle adjusting s c r e w with ing s c r e w ends. the spring, and s c r e w in the s c r e w clockw ise until it is slightly seated 16.

  • Page 90: Adjustment

    F U E L S Y S T E M - Carburetor 5-21 28. Install the body onto the flange with A fte r adjusting the valve, check the gasket. if the operation of the valve is longer bolt among the three smooth, then calk retaining...

  • Page 91: S Econ D Ary Throttle Valve Initial Opening Angle

    5-22 F U E L S Y S T E M - Carburetor end of the float and the air horn with the Adjust Gauge when the float is low ered as shown in figure f o r R a is e d p o s i t i o n 5-47.

  • Page 92: Fast Idle

    F U E L S Y S T E M - Carburetor 5-23 Gauge onto the choke v a l v e . Adjust the opening angle of the choke valve (1 ) so that it will open from the closed position (choke valve at 50...
  • Page 93 5-24 F U E L S Y S T E M - Carburetor Idle Adjusting S c r e w Installation Th e idle adjusting s c r e w should be 1. Follow the removal p rocedu res in co rrectly adjusted after the ca rb u retor the r e v e r s e o rd e r .
  • Page 94 F U E L S Y S T E M - Carburetor 5-25 C A R B U R E T O R - On R K s e ries Description & Construction T h e general construction and operation of the carburetor equipped on the R K 4 4 , 101 and 171 s e ries are similar to those of the carburetor equipped on the R S , R T 4 3 L and R T 5 2 L se rie s with the exception of the choke system, thermostatic valve system...
  • Page 95 5-26 F U E L . S Y S T E M - Carburetor Specification T yp e Down-draft, two b arrels Float level 22 mm 0.867 from body surface A i r horn outer diameter 70 mm 2.758 P r im a r y venturi inner d ia m eter: main 24 mm 0.946 small...
  • Page 96 F U E L S Y & T E M - Carburetor 5-27 1. A i r horn 13. Float pin collar ' 25. S e c o n d a r y main jet 2. B ody gasket 14. Float 26.
  • Page 97 5 — 28____F U E L S Y S T E M — Carburetor 1. High speed va lve stopper le v e r 17 . Throttle le v e r 18. " E " snap ring 2. Throttle shaft link w a s h e r 19.
  • Page 98 F U E L , S Y S T E M - Carburetor 5-29 air horn and the cable holder on Disassembly the RK101 s e r ie s and the spring hanger on the RK171 s e r ie s . F o r disassembling and assembling the c a rb u reto r, the Carburetor Adjust...
  • Page 99 5-30 F U E L S Y S T E M - Carburetor the float level gauge glass clamp, and rem ove clamp, level gauge glass with the ga sk et, float pin collar and the float. 8 . R em ove the p o w er jet valve using G ro o ved S c r e w d r i v e r , then rem o ve...

  • Page 100: High Speed Valve

    F U E L S Y S T E M - Carburetor 5-31 16 . R em ove the vacuum piston by pull­ speed v a l v e , valve shaft and the out straight fo r w a r d using a high speed valve stopper lever...
  • Page 101 5-32 F U E L , S Y a T E M — Carburetor 5 . Check the jets fo r defective threads 10. Check the flange fo r cracks , dam­ and slot. age on the fitting surface and de­ fective threads, and also check for 6 .
  • Page 102 F U E L S Y S T E M - Carburetor 5-33 a re r e m o v e d , check if these valves (0 . 0 3 1 1 ) by the variation of one a re co rrectly operating after the gasket shim, assembly, and then calk the valve...

  • Page 103: Idle Adjusting S C R E W

    5-34 F U E L S Y S T E M - Carburetor position. T o perform this check, High Speed V a lve Stopper L e v e r use the A n g le Gauge as shown in figure 5-73, if n ecess a ry ,...

  • Page 104: F U E L F I L T E R

    F U E L S Y S T E M - Fuel Filter. 5-35 F U E L F I L T E R G1733 F ig . 5-75 C r o s s Sectional V ie w of Fuel Filter Description T h e fuel filter...

  • Page 105: F U E L P U M P

    5~36 F U E L S Y S T E M - Fuel Filter. Fuel Pump 2. Check the body and the bowl for In stallation cra c k s , damage and deformation . If defective, replace as n ecessary . Follow the removal p rocedu res in the r e v e r s e o r d e r .
  • Page 106 F U E L S Y S T E M - Fuel Pump 5-37 Specification: Diaphragm T yp e 1.6 liters/min (1 .7 U S qts/min., D elivery capacity at 2,500 rpm 1.4 Imp. qts/min.) of cam shaft 0 .2 ~ 0.3 kg/cm2 (2.84 ~ 4 . 27 psi) D elivery pressu re -400 mmHg (15.7 inHg) Vacuum...
  • Page 107 5-38 F U E L S Y S T E M - Fuel P„m p Removal 3. Check the valves fo r p rop e r ope­ ration . 1. Disconnect the inlet hose and the outlet pipe from the pump. 4.

  • Page 108: T E Sting

    F U E L S Y S T E M - Fuel Pump 5-39 the valves with the valve retainer T e sting and the s c r e w s . 1. R em ove the carburetor fuel pipe, and connect a p ressu re gauge onto 7.

  • Page 109: F U E L T A N K & F U E L P I P E

    5-40 F U E L S Y S T E M - Fuel Tank & Fuel Pipe F U E L T A N K & F U E L P I P E . Fuel hose . Fuel pipe .
  • Page 110 F U E L S Y S T E M - Fuel Tank & Fuel Pipe 5-41 1 . Fuel front pipe 2. Joint hose 3. Fuel r e a r pipe 4. Fuel pipe protector 5. Fuel sender gauge 6.
  • Page 111 5-42 F U E L S Y S T E M - Fuel Tank & Fuel Pipe 1 . Fuel hose 7 . Tank upper band Fuel tank 8. Plug gasket Fuel sender gauge 9. Drain plug Fuel sender gauge gasket 10.
  • Page 112 F U E L S Y S T E M - Fuel Tank & 1 Fuel Pipe 5-43 2. Rem ove the fuel hose union bolt tank. with the gaskets, and disconnect sender gauge w ir e from the 3. Rem ove the fuel sender gauge...
  • Page 113 5-44 F U E L S Y S T E M - A i r Cleen^r A I R C L E A N E R Description T h e air cleaner functions mainly to rem ove the dust and dirt from the air drawn into the ca rb u retor.
  • Page 114 - A i r Cleaner 5-45 F U E L S Y S T E M 1. Wing nut 2. S e a l w a sh er 3. A i r cleaner cap Cap gasket 5. Element gasket 6. A i r cleaner element 7.
  • Page 115 5-46 F U E L S Y S T E M - A i r Cleaner 1 . A i r cleaner cap 2. A i r cleaner hose 3. Intake air connector 4. Clamp 5. Connector gasket 6 . C lamp bolt 7.

  • Page 116: R E M O V A L

    L U B R I C A T I N G S Y S T E M D E S C R I P T I O N ..........O IL P U M P ............Description ............. R e m o v a l ............Disassembly ..........
  • Page 118 L U B R I C A T I N G S Y S T E M - Description D E S C R I P T I O N F i g . 6-1 5 R -E ngine Lubricating S ystem Y6170 Th e lubricating system utilized on the 5 R , 3 R - B and 3 R - C engines is of an all fo rce d -feed and full-flow filtering type insuring positive lubrication, and the lubri­...

  • Page 119: Description

    L U B R I C A T I N G S Y S T E M - Oil p limp O IL P U M P Description F i g . 6-2 C r o s s Sectional V ie w of Oil Pump Y6171 T h e oil pump is of a trochoid type, and is driven by the distributor shaft which engaged with the camshaft.

  • Page 120: Removal

    L U B R I C A T I N G S Y S T E M - Oil Pump construction of the oil pump and the operation of the relief valve a re shown in the illustration figure 6-2 and 6-3.

  • Page 121: Disassembly

    L U B R I C A T I N G S Y S T F . M - Oil P,.™p R em ov e pump assembly 0.12 mm (0.0026 ~ 0 .0047" ) , and with the strainer. if the clearance exceeds 0.2 mm ( 0 .

  • Page 122: A Ssem Bly

    L U B R I C A T I N G S Y S T E M - Oil Pump, Oil Filter Check the pipe and other parts fo r cracks and damages, and check the strainer fo r clog and d a m a ge. Replace if defective.

  • Page 123: Description

    L U B R I C A T I N G S Y S T E M - Oil Filter Description Th e oil filter is of a paper element type which is treated with a special resin. N orm ally, the oil from the oil pump is fully filtered before lubricating each inter­ nal component.

  • Page 124: Removal

    L U B R I C A T I N G S Y S T E M - Oil Filter < o = l A ssem bly Removal Follow disassembly p rocedu res Rem ove the three attaching bolts , and in the r e v e r s e o r d e r with the fo llow ­...
  • Page 125 L U B R I C A T I N G S Y S T E M - Oil Filter new gasket onto the cylinder 2. Lo osen oil filter cartridge block, and tighten the bolts to 1.0 guide, and rem ove the filter case m-kg (7 .5 ~ 11.0 ft - lb ) with the cartridge guide.
  • Page 126 C O O L I N G S Y S T E M D E S C R I P T I O N ..........T R O U B L E S H O O T I N G ........ W A T E R P U M P ..........
  • Page 128 C O O L I N G S Y S T E M - Description D E S C R I P T I O N T h e r m o s t a t W a te r P u m p B y - p a s s H o s e W a te r P ip e R a d ia to r...

  • Page 129: Description

    — —2----- C O O L I N G—b Y S T E M - Trouble Shooting. Water Pumn T R O U B L E S H O O T I N G Symptoms & P robable Causes Remedies 1 .
  • Page 130 C O O L I N G S Y S T E M - Water Pump Th e bearing outer ra c e is secured onto the bearing case by calking the bearing case edge. A ls o the bearing inner race and the rotor are secured onto the pulley...
  • Page 131 C O O L I N G S Y S T E M — Water Pump head of 5 meters (1 6 .4 ft) at 3,500 rpm at 80° C (1 7 6 ° F ) Water seal type Mechanical seal B earing type Dual ball bearing Fluid couplinq :...

  • Page 132: Water Pump

    C O O L I N G S Y S T E M - Water Pump T o rem ove the pulley with the fluid tension, and rem ove the belt. coupling bearing case from w ater pump bearing shaft, use a 6.

  • Page 133: Water Pump

    7— 6 C O O L I N G S Y S T E M — Water Pump 4 . P r e s s out the rotor from the w ater Fluid Coupling pump bearing shaft with the Water Pump R o tor P u lle r 09239-40010 Inspect...

  • Page 134: Installation

    C O O L I N G S Y S T E M - Water Pump 4. Coat the w a te r pump g r e a s e onto the pump c o v e r until the bearing is flush with the upper end the surface of the floating seat and of the c o v e r as shown in figure...

  • Page 135: T H E R M O S T A T

    7 — 8 C O O L I N G S Y S T E M — Thermostat T H E R M O S T A T Description T h e thermostat equipped on the R S and R T s e ries is of a wax type, and a bel­ low type is equipped on the R K s e r ie s .

  • Page 136: Description

    C O O L I N G S Y S T E M - Thermostat. Radiator at 73°C (1 9 4 ° F ) fo r T h e valve should start to open at s e r ie s , and the valve lift is more 80.5 ~ 8 3 .5 °C (177 ~ 1 8 2 °F ) fo r than 8 mm (0 .

  • Page 137: Removal

    7-10 C O O L I N G S Y S T E M - Radiator r<lv4^, lU i series R K 1 7 1 , 176 series T y p e P r e s s u r e cooling same C o r e type Plate fin &...
  • Page 138 C H A R G I N G S Y S T E M D E S C R I P T I O N ..........T R O U B L E S H O O T I N G ........ A L T E R N A T O R &...

  • Page 140: D E S C R I P T I O N

    C H A R G I N G S Y S T E M - Description D E S C R I P T I O N Ig n itio n Coil D is tr ib u to r F ig . 8-1 Charging System Wiring Diagram G0149 T h e purpose of the charging system in a c a r is to adequately charge the battery...

  • Page 141: T R O U B L E S H O O T I N G

    C H A R G I N G S Y S T E M - Description. Trouble Shooting erated at higher revolution than the D C generator, and the rotational ratio to the engine can be designed m ore la rg e ly . E o r these reason s, the alter­ nator can be designed compact and light.

  • Page 142: A L T E R N A T O R & R E G U L A T O R

    C H A R G I N G S Y S T E M - Trouble Shooting. Alternator & Regulator Adjust regulator e . Regulator voltage adjusted too high R ep air o r replace wiring f. Opened o r poor connection of wiring between alternator "...
  • Page 143 C H A R G I N G S Y S T E M - Alternator & 1 Regulator rotor coil wound in the shape of a doughnut is connected to the two slip rings which a re actuated by an exciting current from the two brushes, and the rotor is mounted onto the bearings located at the end fra m es, and re volv es within the stator.

  • Page 144: Operation

    C H A R G I N G S Y S T E M - Alternator & Regulator 11,000 rpm Perm issible maximum revolution -40 °C ~ 80 °C (-40 ° F ~ 176 ° F ) Allow able surroung temperature Negative Ground Clockw ise as seen from pulley...

  • Page 145: Inspection In C A R

    8— 6 C H A R G I N G S Y S T E M — Alternator b * Regulator direct current by the six rectifiers. This direct current voltage is actuated be­ tween the 1 1 B " terminal and the 1 1 E " terminal. A ls o the output voltage of the stator...
  • Page 146 C H A R G I N G S Y S T E M - Alternator & Regulator " F " and " E " terminals using the 2. P r e - c h e c k of this test. regulator tester as shown in figure L o o s e installation of the alter­...

  • Page 147: Removal

    C H A R G I N G S Y S T E M - Alternator & Regulator. Alternator 7. Check the resistance between the A L T E R N A T O R alternator " F " and " E " terminals with a circuit tester.

  • Page 148: 10. Rotor

    C H A R G I N G S Y S T E M - Alternator & Regulator 1. Key B earing 1 2 . 2. Alternator pulley Stator 3. Alternator fan Rectifier holder 4. S p a ce collar Brush 5.

  • Page 149: Stator

    8-10 C H A R G I N G S Y S T E M — Alternator 7. R em ove the brush holder assem ­ coil is shorted o r opened, and the bly in the following manner. slip rings a re defective, the rotor assembly should be replaced.

  • Page 150: Brush & Brush H Older

    C H A R G I N G S Y S T E M - Alternator 8-11 Check the four leads of the stator coil fo r conductance between them . If the tester needle does not m o v e , the stator coil is opened, and must be replaced.

  • Page 151: Rectifier

    8-12 C H A R G I N G S Y S T E M - Alternator Rectifier sistance, if it indicates high resistance, the rectifier is opened. Good o r defective rectifier is classi­ Next,turn the polarity of the tester, fied by the resistance value between and check again.

  • Page 152: A Ltern Ator Output T E S T

    C H A R G I N G S Y S T E M - Alternator 8-13 rotor shaft bearing through 2. Position the stator with the recti­ the space ring with' the T r a n s m is ­ fie r holder onto the rectifier end sion Oil Plu<f'•(59325-12010.

  • Page 153: Installation

    8-14 C H A R G I N G S Y S T E M - Alternator. Regulator with the circuit shown in the following 3. Rem ove the regulator retaining illustration. bolts, rem ove the regulator assem bly. Electrical Adjustment If the alternator regulator does not actuate properly in accordance with...

  • Page 154: Voltage Regulator

    C H A R G I N G S Y S T E M - Regulator. 8-15 tact of the voltage regulator points the ammeter needle registers maxi­ " P L 1 " and " P L o " is poor . mum .

  • Page 155: Voltage Relay

    8-16 C H A R G I N G S Y S T E M - Regulator 5. Connect the circuit tester between A r m a tu r e G ap the " B " and " E " terminals. T h e resistance should be infinite.

  • Page 156: Installation

    C H A R G I N G S Y S T E M - Regulator 8-17 F i g . 8-37 Checking Point V2155 E ig .8 -3 5 Checking Point V1185 GO 182 G0181 Voltage Regulator 1. Check the armature gap with the fe e le r gauge.

  • Page 157: M E M O R A N D U M

    8-18 M E M O R A N D U M MEMO *...
  • Page 158 S T A R T I N G S Y S T E M D E S C R I P T I O N ....T R O U B L E S H O O T I N G . S T A R T E R ......
  • Page 160 S T A R T I N G S Y S T E M - Description D E S C R I P T I O N Ig n itio n Coil D is tr ib u to r P ig . 9-1 Starting System Wiring Diagram G3134 T h e purpose of the starting system is to crank the engine to draw in the com ­...
  • Page 161 S T A R T I N G S Y S T E M - Trouble Shooting T R O U B L E S H O O T I N G Symptoms & ]Rr*olDcitale Cdusss Remedies S ta rte r d oes not turn S ta rte r spins, but does not crank the engine P o o r contact of starter switch Replace ignition switch...
  • Page 162 S T A R T I N G S Y S T E M - Starter S T A R T E R Construction M a g n e tic S w itc h F ig . 9-2 C r o s s Sectional V ie w of S ta rte r G3135 T h e principle components of the starter consist of the armature, starter clutch, field coil, d rive end fram e,yoke,com m utator end fram e, brushes and the magnetic...
  • Page 163 S T A R T I N G S Y S T E M - Starter acts a cushion in the pushing motion of the pinion drive le v e r for meshing with the ring g e a r . A n armature brake is provided at the commutator end, and it is designed to use friction between...
  • Page 164 S T A R T I N G S Y S T E M - Star ter ture brake. T h en , the armature quickly stops, ready fo r the start­ a n d b e c o m e s e r re-operation.
  • Page 165 S T A R T I N G S Y S T E M - Starter Removal 1 . Disconnect the battery ground c a ­ ble from the battery term inal. 2 . Disconnect the w ir e s to the starter m o to r.
  • Page 166 S T A R T I N G S Y S T E M - Star ter T h e p ro p e r depth should be 0.5 a tool similar to the one as shown to 0.8 mm (0.02 ~ 0 . 0 3 " ) . in the illustration.
  • Page 167 S T A R T I N G S Y S T E M - Starte F i g . 9-11 Testin g A rm a tu re V2187 F i g . 9-13 Testing Field B0035 Coil fo r Short Coil fo r Open Circuit Repeat test fo r...
  • Page 168 S T A R T I N G S Y S T E M - Starter F i g . 9-15 Pull-in Coil G1265 F i g . 9-17 Plunger Return V1812 T est T e s t G1267 condition, connect the battery ne­ 4.
  • Page 169 9-10 S T A R T I N G S Y S T E M - Starter If defective, replace the starter clutch assembly. 2. Check the starter clutch fo r dam­ a g e , sticky against the fre e -w h e e l movement and slippage in opposite direction to the fre e -w h e e l move­...
  • Page 170 S T A R T I N G S Y S T E M - Starter 9-11 6. Install the commutator end f r a m e , and tighten the through bolts. 7. Install the brake spring and the lock plate onto the armature shaft en d.
  • Page 171 9-12 S T A R T I N G S Y S T E M - Starter, Battery stop co lla r. T h e clearance should With the armature lo ck ed , the current be 1 ~ 4 mm (0.0 4 ~ 0 . 1 6 " ) when draw should be less than 550 amperes starter is operated under no volts producing...
  • Page 172 S T A R T I N G S Y S T E M - Starter 9-13 H ydrogen , and oxygen gases 1.260 is 100% fully charged state produced during normal battery ope­ 1.210 is 75% fully charged state ration.
  • Page 173 9-14 M E M O R A N D U M MEMO fife.
  • Page 174 I G N IT I O N S Y S T E M D E S C R I P T I O N ..........10-1 T R O U B L E S H O O T I N G ......... 10-2 D I S T R I B U T O R ..........
  • Page 176 IG N IT I O N S Y S T E M - Description 10-1 D E S C R I P T I O N Ig n itio n Coil D is tr ib u to r F ig . 10-1 Ignition System Wiring Diagram G3138 T h e...

  • Page 177: Description

    10-2 IG N I T I O N S Y S T E M - Tr ouble Shooting, Distributor T R O U B L E S H O O T I N G Symptoms & P robable Causes Rem edies 1.
  • Page 178 IG N IT IO N S Y S T E M - Distributor 10-3 G o v e rn o r S p rin g A d v a n c e D riv in g P l a t e A ngle G o v e rn o r W eig h t...
  • Page 179 10-4 I G N I T I O N S Y S T E M - Distributor Vacuum advance characteristics: P o r 5R Engine Begins at 70 ~ 90 mmHg (2.76 3.54 inHg) T iming advances 6.5 ~ 10.5, m m H g ( 5.12 inHg)
  • Page 180 IG N I T I O N S Y S T E M - Distributor 10-5 1. Distributor cam 10. Distributor housing 19. Contact point G overn or spring 11. A d ju ster c o v e r 20. B r e a k e r plate 3.

  • Page 181: Inspection

    10-6 I G N I T I O N S Y S T E M - Distributor 2. R em ove the b r e a k e r snap ring ( 1 ) , contact point retaining s c r e w and the b r e a k e r arm lead w i r e , then rem o ve...

  • Page 182: B R E A K E R Plate & Stationary Plate

    IG N I T I O N S Y S T E M - Distributor 10-7 0.2m m (0.00 8") G o v e rn o r W eig h t Limit 7 mm (0.27") GO 190 F ig . 10-9 Checking Pin F i g .

  • Page 183: Other Items

    10-8 IG N I T I O N S Y S T E M - Distributor 4. Check the diaphragm of the v a ­ cuum advancer for damage. 5. Check the spiral ge a r fo r w e a r . A ssem bly 1.
  • Page 184 I G N IT I O N S Y S T E M - Distributor 10-9 F i g . 10-16 Assem bling V3684 F ig . 10-19 Installing Cap V3685 G overn or Spring 6. Install the vacuum advancer and the condenser.

  • Page 185: P Erfo Rm A N C E T E S T & A D Ju Stm En T

    10-10 IG N IT I O N S Y S T E M - Distributor A l s o align the center line with the setting m a r k . 10. Install the adjuster c o v e r , adjust the point gap re fe rr in g to the P e r fo r m a n c e T e s t in the follow p a ra g ra p h .

  • Page 186: Condenser

    IG N IT I O N S Y S T E M - Distributor 10-11 Vacuum A dvan ce Specification: speed to the initial setting listed in the specification. Move the protruded scale so that F o r 5R Engine one of the flashes aligns with the A dvan ce angle z e r o d e g re e mark.

  • Page 187: Ig N It Io N C O I L

    10-12 I G N I T I O N S Y S T E M - Distributor. Ignition Coil time, be sure to check if the push It may be necessary to crank the rods of the N o . l cylinder a r e engine...

  • Page 188: Rem Oval

    I G N I T I O N S Y S T E M - Ignition Coil, High Tension Wires 10-13 T h e ignition coil is utilized to transform the battery voltage to the high voltage sufficient to spark a cro ss the spark plug gap. It is composed of the prim ary and secondary windings, and the latter is wound to thousands of windings of v e r y fine w ir e .

  • Page 189: Installation

    10-14 I G N I T I O N S Y S T E M - High Tension Wires Installation replace the w ir e . N e v e r try to alter the length of Follow rem oval p roce d u res the w i r e , and do not make a sharp the r e v e r s e o r d e r .

  • Page 190: Installation

    IG N IT I O N S Y S T E M - High Tension Wires 10-15 : Norm al condition 6. Clean the plugs with a sandblast B : Overheating c le a n e r . C : Carbon deposits D o not prolong the use of the a - D : Abnorm al w e a r b ra s ive blast as it will ero d e the...

  • Page 191: M E M O R A N D U M

    10-16 M E M O R A N D U M MEM O s p *...
  • Page 192 P r e p a r e d By T O Y O T A M O T O R S A L E S C O . , L T D . E x p o rt-T ech n ica l Division Haruhi Plant...

This manual is also suitable for:

3r-b 19693r-c 1969

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