5r 1969

5R, 3R-B & 3R-C ENGINE
REPAIR M A N U A L
TOYOTA M O TO R SALES CO., LTD.

EXPORT - TECHNICAL DIVISION
F O R E W O R D
This manual has been prepa red to provide the

S e r v ic e - m e n with complete information fo r proper
servicin g of the 5 R , 3 R - B and 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 all the s e r v ic e procedu res in detail and
will s e r v e as a re a d y re fe re n c e book in s e r v ic e
training of the less experienced men and also in
w o r k supervising of the fully qualified men.
T h e section index on the title page enables the

user to quickly locate any desired section. A t the
beginning of each section is a title page which lists
each main subjects in the section.
T h e s e r v ic e p rocedu res on these engines a r e almost

sim ilar, h o w e v e r , there a r e some major o r minor
differences between each model en gin es.
In this manual, e v e r y re p a ir p ro ce ss is detailed
respectively to c o v e r the models thoroughly.
If the s e r v ic e p roced u res a re the s a m e , the repair
p ro ce ss and the figures a r e described basing on
the 5R engine.
A ll the information and the specifications contained

herein a r e the most up-to-date at the time of
publication, and w e r e s e r v e the right to change
them without further notice and without incurring
obligation.
SECTION IN D EX
G R O U P IN D E X 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
G E N E R A L INFO RM ATIO 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
RECOMMENDED S . S . T ............................ 1-9
MEMORANDUM .................................. ........... 1-10

GENERAL I N F O R M A T I O N - General 1-1
GENERAL
T h e 5R model engine is designed based on the 3 R model engine with the various
different features such as increased displacement, modified combustion chambers
and manifold ports, raised p o w e r and torque, together with improved durability
and reliability. This engine is equipped on the Toyota G ro w n , Stout, Dyna and
Light Bus s e r ie s .
T h e 3 R -B model engine w as also developed from the 3R model engine by im

proving the reliability.
T h e 3 R - C model engine is incorporated with the cran kcase ventilation and the
exhaust emission control systems on the 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. T h e r e fo r e , the general information is described
in accordance to the 5R model engine, and different features only will be d es
cribed fo r the 3 R - B and 3 R - C model engines.
T h e 5 R , 3 R - B and 3 R - C model engines a r e of fou r-cylinder in -lin e, overhead

valve, w a ter-co oled type.
Th e cylinder head is of a cast iron, and incorporates a bath-tub type combustion

ch a m b ers.
T h e cylinder block is also of durable cast iron, and incorporates the oil passage
within the cylinder block front at the right side to lubricate the valve r o c k e r arm
mechanism.
T h e pistons a r e of a low-expansion type which is of aluminum silicone alloy with

excentric finished slightly la r g e r at the right angle to the piston pin b o r e . M o r e
o v e r , these pistons a re cast in with a steel ring under the oil ring g r o o v e to
minimize the heat expansion of the piston.
T h e piston rings a re of two compression rings and one oil ring fo r each piston ,
and both rings a r e chrome-plated fo r durability.
T h e piston pin is off-sett 1.0 mm (0 .0 3 9 M) towards the camshaft side which

contributes to smooth engine operation, and is secured onto the piston with snap
rings at both ends of the piston pin .
T h e connecting rods a re of fo rged steel with " H " beam section, and bron ze
piston pin bushings a r e installed at the small ends.
T h e connecting rod of the 5R model engine is provided with the lubrication hole
at the right side of the la r g e r end upper, and the piston pin bushing is lubricated
through this hole by p re s s u re discharge.
A ls o , the lubrication hole is drilled within the connecting rod from the la rg e end
to the small end on the 3 R - B and 3 R - C model engines.
T h e crankshaft is of carbon steel, and the bearing journals a r e induction hard

ened .
T h e crankshaft main bearings and the connecting rod bearings a r e of micro p r e

cision type, and a re composed of tri-metal; lead o v e r la y , kelmet seam , and
steel back plate for smoothness and durability.
1-2
G E N E R A L IN FO RM ATIO N
- General
Y6177
Fiq.1-1 Cross Sectional View of 5R Model Engine Y5973
G E N E R A L I N F O R M A T I O N - General
G3422
1-3
Fig. 1-2 Cross Sectional View of 3R-C Model Engine G3423

1-4 G E N E R A L IN FO R M ATIO 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.

T h e camshaft is supported by five bearings, and these bearings a re of steel
backed white metal.
T h e exhaust valve head is of austenite heat resisting ste e l, and dual valve springs
a re utilized fo r both intake and exhaust v a lves .
T h e springs a r e made with irregu la r pitch to prevent the valve surging.
T h e valve lifters a re installed with off-set from the center of the cam to s e r v e the
lubrication of the lifter and to prevent the uneven w e a r of the lifter.
T h e push rods a r e made of steel pipe with the diameter of 9 mm (0.31 '*) , and
both ends of the pipe a re welded to the steel balls by butt welding.
Precauition
Whenever any w ork is perform ed on the c a r , special c a r e should be taken to

prevent scratching the body, fen ders o r spoiling the seats. T o perform a satis
factory w o r k , fender c o v e r s o r seat c o v e r s must be used during the operation.
T h e use of S e r v i c e S pecial T o o ls must be emphasized as these tools a re so

designed to prevent damaging of the components, and also will quicken the w o r k .
During disassembling any components, it is essential that parts disassembled

from the c a r o r main components should be placed in sequence to facilitate the
final inspection, and assem bly. Certain mating parts should be marked before
disassembling from the main assembly to identify the mating position o r fo r baP
ancing with the main assem bly.
S e r v i c e T o rq u e Specification should be adhered w h e n ev er tightening the bolts

o r nuts.
G E N E R A L I N F O R M A T I O N - General Specification 1-5
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1-8 G E N E R A L IN FO RM ATIO N - General Specification
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G E N E R A L I N F O R M A T I O N - Recommended S . S . T . 1-9
RECOMMENDED S . S . T .
Engine
09303- 35010 Imput Shaft Front B earin g Pu ller

09213- 60013 Crankshaft Pulley & G ear Pu ller
09201- 40010 V a lve Guide Bushing R e m o v e r & R ep la c er
09222- 30010 Connecting Rod Bushing R e m o v e r & R ep lacer
09222- 40011 Connecting Rod Bushing R e m o v e r & R ep lacer
09210- 31010 Timing Gear T o ol Set
09215- 40010 Camshaft Bearing R e m o v e r & R ep la c er
09505- 20010 Differential Side B earing R ep lacer
09214- 60010 Crankshaft Pulley & G ear R ep lacer
09304- 30012 Imput Shaft Front B earin g R ep la c er
09301- 36010 Clutch Guide Tool
Carburetor
09860-11010 C a rb u reto r S c r e w d r i v e r Set

09240-44010 C a rb u reto r Adjust Kit (fo r R S , R T s e r ie s )
09240-40021 C arbu retor Adjust Kit (fo r R K s e r ie s )
Water Pump
09239-40010 Water Pump R otor P u lle r

09238-40010 Water Pump B earin g R e m o v e r & R e p la c e r
Alternator
09286-46011 Injection Pump Spline Shaft Pu ller

09325-12010 Transm ission Oil Plug
1-10 MEMORANDUM
o.
MEMO * 4
ENGINE T U N E - U P
G E N E R A L .................................. 2-1
I N S P E C T I O N & A D J U S T M E N T ................ 2-1
B a t t e r y ...................................................... 2-1
Engine Oil .......................................... 2-1
C o o la n t .................................. 2-1
Pan Belt ............. . 2-1
Fuel Filter ..................................................... 2-2
A i r Cleaner ...................... 2-2
D is trib u to r .................................................. 2-2
S park Plug ........... 2-2
Ignition Timing ............................................... 2-3
Octane S e l e c t o r ................................ 2-3
V alve Clearance .................................. 2-4
C arbu retor .......................... 2-4
Com pression T e s t ......................................... 2-5
MEMORANDUM 2-6
E N GINE T U N E - U P 2-1
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. Th e p r o g r e s s of modern engineering standard has been
developed so quickly that it necessitates the use of p ro p e r instrument, and well
trained mechanics. T h e compression ratio has increased, also incorporates a
numerous electrical equipment, and other components which can only be taken
bare with special knowledge and p roper c a r e . In o r d e r to accomplish the w ork
co rrectly, and prop erly, a reliable tune-up equipment a re n e c e s s a r y . T h e p r o
cedures decribed in the following o rd e r s should be carefully studied.
Inspection & Adjustment R K 4 4 , 101 series:

4 .5 liters (4 .7 U S q t s .,
Battery 4 .0 Imp . q ts . )
Oil filter capacity:
1. Check the electrolyte level in the
0 .8 liter (0 .9 U S qt. ,
battery cells.
0 . 8 Imp . q t. )
Normal electrolyte level should be
about 10 mm ( 0 . 4 11) above the 2. Check the oil fo r deterioration.
plates. If n ecessary, replenish the Check if the coolant o r gasoline
cells with distilled w a ter. is present within the oil.
Replace the oil if n e c e s s a r y .
2. T h e specific gravity of a fully
charged battery should be 1.260 C oolant
at 20°C (6 8 ° F ) .
If the specific gravity is below 1. Check the cooling system fo r leak,
1.200, o r the difference of the weak h oses, loose hose clamps
specific gravity between each cell and c o r r e c t coolant level.
is above 0.025, the battery should Replenish with drinkable w a te r if
be' charged by disconnecting the n ecessary.
battery ground ca b le.-
If the difference exceeds 0.025 Cooling system capacity:
after fully charging the battery, R S 5 0 , 56 series:
the battery should be. inspected 7.5 liters (7 .9 U S q ts .,
at a battery s e rv ic e station. 6 . 6 Imp. q t s . )
3 . Clean the terminals and top of the R T 4 3 L , 52L series:

battery* 8.5 liters (9 .0 U S q t s .,
7 . 5 Imp . qts . )
4. Check the battery terminals, and R K 4 4 , 101 series:
tighten them if n e c e s s a r y . ' 9.1 liters (9.6 U S q ts .,
Check the battery case fo r cracks 8 .0 Imp . q t s . )
o r other damages.
R K 1 7 1 , 176 series:
Apply g re a s e onto the terminals
9.5 liters (10.0 U S qts.
to retard further c o r r o s io n .
8 .4 Imp . qts . )
Engine Oil
2. U s e a reliable brand a nti-freeze
1. Check the engine oil level, and in cold w eath er.
replenish if n e c e s s a ry .
Oil pan capacity: Fan Belt
R S 5 0 , 56, R T 4 3 L , 5 2 L , RK171,
176 series: 1 . T h e fan belt deflection should be
4.0 liters (4 .2 U S q ts ., 13 ~ 20 mm (0 .5 0 ~ 0 . 7 5 11) when
3 , 5 Imp. q ts . ) 11 kg (24 lbs) p r e s s u r e is applied.
2-2 EN GINE TU NE -U P
Adjust the belt tension if n eces fa r as possible, then release the

sa ry . ro tor, and see 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
b le d , and the cause of the trouble
should be co rrected .
4. Check the vacuum advancer me

chanism by pushing in the octane
selector, then relea se the selector
to see if the selector returns to
its retarded position.
A n y stiffness in the operation of
the vacuum advancer mechanism
will affect the ignition timing.
C o r r e c t any interference o r bind
Fuel Filter ing.
1. Check the fuel filter bowl fo r crack, 5. Clean the b re a k e r points with a
and check the body fo r deform a point file if n e c e s s a r y .
tion. If n e c e s s a r y , replace as ne If the points a r e excessively burnt
c e s s a ry . o r pitted, replace the b rea k er
points.
2. Check and clean the element fo r
damage o r e x c e s s iv e dirt. 6. Check and adjust the point gap.
Replace the element with the g a s T h e gap should be Q . 4 ~ 0 . 5 mm
ket if n e c e s s a r y . (0.016 ~ 0 . 0 2 0 " ) .
A i r C lean er 7. Check the tyreaker arm tension

with a sprinfg tension tester by
1 . Clean the element with com pressed pulling at right angle of the b rea k er
air of low p r e s s u r e . arm point. .v
Replace the element if damaged o r Read the tester just when the point
e x c e s s iv e dirty. opens.
T h e tension should be 400 ~ 550
2. Clean the inside of the afr clean er gram s (14 ~ 19 o z ) .
c a s e , and check the seal w a sh e r
f. and the gasket. 8. Lubricate the cam lobes, point
If d efective, replace as necessahy . arm rubbing block and pcint arm
pivot.
Distributor
9. Check the cam dwell angle with
1. Clean the distributor cap, and in the t e s t e r . o
spect for c r a c k , carbon track, T h e dwell angle should be 52 .
and burnt o r co rro d e d term inals.
Replace the cap if d efective. S p a rk Plug
2. Clean the ro to r , and check fo r 1. Inspect each plug individually fo r

d a m a g e. e x c e s s iv e electrod es w e a r , g l a z e d ,
Replace the rotor if d e fe c tiv e . broken o r blistered porcelain, and
replace the plug/s as n e c e s s a r y .
3. Check the distributor centrifugal
advance mechanism by turning the 2. Clean the spark plugs thoroughly
ro to r in a clo ck w ise direction as using a sand blast clean er.
EN G INE .T U N E - U P 2-3
V P
When cleaning with the abrasive

cleaner, do not prolong the clean
ing to prevent porcelain damage.
3. Inspect each spark p l u g fo r make

and heat ra n g e .
A ll spark plugs must be same in
make and also in heat range.
If ex cessive carbon deposits a re
observed on the insulation tip, r e
place with a hot range type spark
plugs.
If the spark plugs show burning
white o r rapid ' electrode w e a r , F ig . 2-3 Ignition Tim ing B0264
replace with a cold range type Marks
spark plugs.
2. T o adjust, loosen the distributor
clamp attaching bolt, and then turn
the distributor housing in the d ir e c
tion required to align the timing
m arks. T o advance the timing,
turn the distributor housing coun
terc lo c k w is e , and to retard the
timing, turn it clock w ise.
Octane S e le c to r
Wm
1. Depending on the gasolin^: |&ctane
rating, the ignition timincfjffeiust be
F i g . 2-2 S park Plug V2204 adjusted. T o test, run the c a r a t
Conditions 20 kilos (12 miles) p e r hour in
top g e a r , and d ep ress the a c c e le
A indicates normal codition rator pedal all the way to the flo o r.
B indicates overheating
C indicates carbon deposits 2. If the engine has a slight engine
D indicates abnormal w e a r ping, and it fades out gradually as
the <far picks up the s p e e d , the
4. Adjust the spark plug gap by bend ignition timing is c o r r e c t .
ing the ground electrode to obtain
the specified gap of 0.7 ~ 0 .8 mm 3. If the engine pings e x c e s s iv e ly ,
(0.027 ~ 0 .0 3 1 11) with the spark turn the adjuster tow ards the MR n
plug gauge. mark to retard the timing.
Ignition Timing 4. If the engine does not ping, turn

the adjuster tow ards the " A 11 mark
1. Check the timing using the timing to advance the timing.
light with the engine at idling speed ,
and adjust so that the timing pointer N O T E : a. One graduation of the ad
will align with the timing ball. A t juster is equal to 10.4 of the
this time, the octane selector must crankshaft angle.
be set at z e r o advance.
Ignition timing: b. T h e limit of adjustment of the
5R: 8 /550 rpm B . T . D . C . - adjuster is 20 of crankshaft.
3 R - B : 12°/400 rpm B . T . D . C .
3 R - C : 5 °/650 rpm B . T . D . C . c. The octane selector has no
2-4 ENGINE 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.
1. Start the engine, and check the

carburetor fuel level.
If the level is not satisfactory , ad
just the float le v e l.
2. T h e adjustment of the engine idling

should be performed with the air
cleaner installed.
a. Rem ove the intake manifold

suction hole plug, then install the
F ig . 2-4 Octane S e le c to r G1701 adapter to connect the vacuum
gauge. Connect the vacuum gauge
V a lv e Clearance hose to the adapter •
1. Warm up the engine till the coolant b . Connect the tachometer onto the
temperature reach es 75 ~ 85 C ignition coil.
(167 ~ 185 ° F ) ,
c . Tu rn the throttle adjusting
2. Tighten the cylinder head and the s c r e w until the engine operates
r o c k e r shaft support bolts to spe smoothly without stalling at lowest
cified torque. possible revolution.
Specified torque:
Cylinder head bolts: d. Tu rn the idle adjusting s c r e w
11-12 m-kg (80 ft-lb) and the throttle adjusting sc re w
R o c k e r shaft support bolts: alternately to obtain a steady and
2 .0 - 2 .5 m -kg (15 ft-lb) maximum vacuum reading with
smooth engine operation at lowest
3. S e t the engine at idling speed to possible revolution. T h e engine
about 550 rpm. idling speed should be approxi
mately 550 rpm, and the vacuum
a . Check the r o c k e r arm and reading should be 460 - 530 mmHg
valve stem clearan ce with a fe e le r (18 ~ 21 in H g ) .
gauge.
N O T E : Adjust the engine idling at
b. T o adjust, loosen the lo c k , nut the "D " range fo r the c a r equipped
and turn the adjusting s c r e w until with the Toyoglide Automatic trans
the specified clearan ce is obtained. mission .
Specified clearance:
Intake: 0.203 mm (0 .0 0 8 " ) 3. T o check the acceleration pump,
Exhaust: 0.356 mm (0 .0 1 4 " ) the air cleaner must be removed
from the ca rb u retor, and the en
c . Tighten the lock nut securely gine must be stopped. Next, open
after adjustment, and recheck the the throttle valve completely from
c le a r a n c e . the closed position, and ob serve
the condition of the fuel spray from
C a rb u reto r the pump jet.
F o r detail operation and p roce d u res , 4.. On the R S , R T 4 3 L , 52 s e r ie s ,

r e fe r to C a rb u reto r in Fuel S ystem , check the automatic choke set po
and fo r idling adjustment method on sition .
ENGINE T U N E - U P 2-5
If n e cess a ry , adjust the choke r e N O T E : A lw a y s use a fully charged

ferrin g to the C arbu retor in Fuel battery to obtain the engine r e v o
S y s te m . lution m ore than 250 rpm.
On the R K s e r ie s , check if the
choke valve opens and closes 4. T h e specified compression p r e s
smoothly. sure should be m ore than 11.0
kg/cm2 (153 psi) at 250 rpm on
Com pression T e s t the 5R , 3 R - B and 3 R - C engines.
T h e limit is 9 .0 kg/cm2 (128 p s i ) .
1. A ft e r warming up the engine to T h e difference of the com pression
operating temperature, rem ove all reading between the cylinders
spark plugs. should be within 1.0 kg/cm2 o r
14 p s i ) .
2. Disconnect the secondary w ir e
from the ignition c o il, 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.
2-6 MEMORANDUM
* % MEM O
ENGINE
TROUBLE S H O O T I N G ................................ 3-1
M A J O R S E R V I C E ........................................... 3-6
R e m o v a l ........................................................... 3-6
Disassembly ................................................... 3-7
Inspection & R e p a i r ....................................... 3-9
Cylinder h e a d ............................................. 3-9
V a lve guide bushing ................................. 3-10
V a lve . .................................... .................. 3-11
V a lve s p r i n g ................ * ............................ 3-12
V a lve ro c k e r arm & s h a ft ....................... 3-12
V a lve lifter ................................................. 3-13
Push r o d .............................. ...................... 3-14
Cylinder block .................. ........................ 3-14
Cylinder b o re .............. .................... 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
C r a n k s h a ft.................. ................................ 3-21
Crankshaft bearing ................................... 3-22
Crankshaft timing g e a r ............................. 3-23
Flyw heel ..................................................... 3-23
Camshaft .................. 3-24
Camshaft b e a r i n g ....................................... 3-25
Camshaft timing g e a r ............................... 3-26
Intake & exhaust m a n ifo ld s ...................... 3-27
A s s e m b l y ......................................................... 3-27
Installation ............................................... 3-32
E N G I N E - Trouble Shooting 3-1
TROUBLE S H O O T IN 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.
Symptoms & Probable Causes Rem edies
L a ck of P o w e r
1. P o o r compression
a . Incorrect valve clearance Adjust valve clearance

b. Compression leak from valve La p valves and seats
seat
c. Sticky valve stem Replace va lves and guides
d. Weak o r broken valve springs Replace valve springs
e . L e a k y cylinder head gasket Replace gasket
f. Sticky o r broken piston rings Replace piston rings
g . Worn piston rings o r cylinder Overhaul engine
2. Ignition system im properly adjusted
a. Incorrect ignition timing Adjust ignition timing

b. Defective spark plug/s Clean, adjust o r replace spark plug/s
c . Defective distributor points C o rr e c t o r replace points , and inspect
condenser capacity
d. Incorrect octane selector Adjust octane selector
3. L a c k of fuel
a. Clogged carburetor jet Disassemble and clean carburetor

b. Clogged fuel pipe Clean fuel pipe
c. Dirt in fuel tank Clean o r replace fuel tank
d. A i r in fuel system Check connections, and tighten
e. Fuel pump not functioning R ep air o r replace fuel pump
properly
f. Clogged fuel filter element Clean o r replace filter element
4. Insufficient carburetor air intake
a. Restricted air cleaner Clean air cleaner

b. Choke valve partially closed R ep a ir o r replace choke mechanism
5 . Overheating
a. Insufficient coolant Replenish coolant

b. L o o s e fan belt Adjust fan belt
c. Fan belt w orn o r damaged Replace fan belt
d. Inoperative thermostat Replace thermostat
e. Inoperative water pump R ep air o r replace w a te r pump
f. Clogged o r leaky cooling Clean, rep a ir o r replace cooling
system system
g . Incorrect ignition timing Adjust ignition timing
h. Incorrect ignition system Tune-up engine
3-2 E N G I N E - Trouble Shooting
i. 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
1. Incorrect g r a d e , and viscosity Replace with co rrect oil
oil being used
m . Fuel mixture too lean Overhaul o r adjust carburetor
n. Radiator fins clogged or Clean radiator fins
obstructed
E x c e s s iv e Oil Consumption
1. Oil leak
a. Oil pan drain plug loose Tighten drain plug

b. Oil pan attaching bolts loose Tighten attaching bolts
c. Oil pan gasket damaged R eplace gasket
d. Timing g e a r c o v e r attaching Tighten attaching bolts o r replace
bolts loose or gasket damaged gasket
e. Oil seal damaged Replace oil seal
f. Cylinder head c o v e r gasket Replace gasket
damaged o r valve push rod
c o v e r gasket damaged
g. Fuel pump attaching bolts loose Tighten fuel pump attaching bolts c
o r gasket damaged replace gasket
h. Oil filter attaching bolt loose Tighten attaching bolt o r replace
o r gasket damaged gasket
2. E x c e s s iv e oil consumption
a. Defective piston rings Replace piston rings

b . Ring gaps in line C o rre c t gap positions
c. Piston rings w o r n o r ring Replace piston rings
g r o o v e s sticky
d . Carbon deposit in oil return Replace rings
hole of oil ring
e . Piston o r cylinder w orn Replace pistons o r bore cylinders
e x c e s s iv e ly
f. V a lve stem " O " ring damaged Replace " O " ring
g . V a lve and guide bushing w o rn Replace valve and guide bushing
H a rd Starting
1 . S lo w cranking
a. Im proper oil viscosity Change to p rop e r viscosity oil

b. D isch arged battery Charge battery
c. Defective battery R ep lace battery
d. P o o r battery connections Clean and tighten o r replace battery
connections
e . Defective starter motor Overhaul and rep a ir o r replace
starter motor
2. Defective ignition system
a. Burnt distributor points Replace points

b. Points incorrectly adjusted Adjust points

c. S park plugs gap incorrectly Adjust spark plug gap
adjusted
d. L o o s e or defective spark Tighten o r replace spark plug w ir e s
plug w ire s
e . Defective ignition coil Replace ignition coil
f. L o o s e primary circuit Tighten connections
connections
g . Defective condenser Replace condenser
3. Engine condition
a. Burnt valves Rep air o r replace valves

b . L e a k y manifold gasket Tighten manifold bolts o r replace
gasket
c. P iston s, piston rin gs, and Overhaul engine
cylinders w orn
d. Defective cylinder head gasket Replace gasket
e . L o o s e carburetor mounting Tighten bolts
bolts
4. Carburetion
a. Choke operating improperly Adjust o r repair choke mechanism

b. Incorrect engine idling Adjust engine idling
c. Carburetor dirty and passages Overhaul and clean carburetor
restricted
d . L o o s e carburetor attaching Tighten attaching bolts
bolts
e . Carburetor o verflow s R ep a ir carburetor
Popping, Spitting and Detonation
1. Ignition system
a. L o o s e connections in ignition Inspect and tighten connections

system
b . Defective spark plugs Clean and adjust o r replace spark
plugs
c. Incorrect ignition timing Adjust ignition timing
d . Incorrect heat range plugs Replace with c o rr e c t heat range
plugs
2. A ir -fu e l mixture
a. Lean combustion mixture Clean and adjust carburetor

b. Fuel pipe dirty o r restricted Clean o r replace fuel pipe
c. A i r leak at carburetor or Tighten carburetor attaching bolts
intake manifold o r manifold attaching bolts o r rep la ce
gasket
3. V a lves
a. Incorrect valve clearance Adjust valve clearan ce

b. V a lv e s sticky R ep a ir o r rep la ce va lves
3-4 E N G I N E - Trouble Shooting
c. Weak valve springs Replace springs
4. Cylinder head
a.Carbon deposits in combustion Rem ove carbon

chambers
b. Cylinder head w a ter tube Clean o r replace water tube
partially clogged
c. Cylinder head gasket defective Replace gasket
Rough Engine Idling
1. Carburetor
a. Incorrect idling adjustment Adjust idling

b . Carburetor float needle valve Clean and adjust o r replace
not seating p rop e rly.
2. A i r leaks
a. Leaking heat insulator, and Tighten carburetor attaching bolts

intake manifold gasket o r replace heat insulator and intake
manifold gasket
b . Cracked intake manifold Replace manifold
3. V a lv e s
a. Incorrect va lve clearance Adjust valve clearance

b. V a lv e not seated p roperly L a p valves
c. E x c e s s iv e clearance between Replace valve and valve guide
valve stem and valve guide
bushing
4. Cylinder head
a. L e a k y cylinder head gasket Replace gasket
Engine Misses at A ccele ra tio n
1. C arbu retor
a. Clogged accelerating system Disassemble and clean

b . Lea n fuel mixture Overhaul and rep a ir carburetor
2 . Ignition system
a. Defective spark plugs Clean o r replace spark plugs

b . Defective ignition w ir e s R eplace w ir e s
c . Incorrectly adjusted distributor Adjust o r rep la ce points
points
d . Defective ignition coil R ep lace ignition coil
3. Engine
a. Burnt o r in correctly adjusted Adjust o r rep la ce valves

va lves
b. P o o r compression Overhaul and rep a ir engine

c. L e a k y cylinder head gasket Replace gasket
d . L ea k y manifold gaskets Tighten manifold o r replace 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. E v e r y rotating o r reciprocating p a rtis a potential source
of n o ise.
Certain noises possess characteristics which can be detected. T h e s e ch aracter-
: 'tries v a r y , and experience is the best guide in most ca ses .
'rankshaft bearing
a. Worn bearings Replace bearings o r grind crankshaft

b. Worn crankshaft journals Grind o r replace crankshaft
c . Melted crankshaft bearings Replace bearings and check lubricat
ing system
2. Connecting rod & connecting rod bearings
a. Worn connecting rod bearings Replace bearings o r grind crankshaft

b. Worn crankpin journals Grind o r replace crankshaft
c. Bent connecting rod C o rr e c t o r replace connecting rod
d. Melted bearings Replace bearings and check lubricat
ing system
e . Worn connecting rod bushing Replace bushing
3. Piston, piston pin & piston rings
a. E x cess ive cylinder w e a r B o r e and hone cy lin d e rs, and install

new pistons and rings
b . Worn piston o r piston pin Replace piston and pin
c. Burnt piston Replace piston
d . Defective piston rings Replace rings
4. Other components
a. E x cess ive camshaft thrust R ep lace camshaft thrust plate

clearance
b. Worn crankshaft thrust w a sh er Replace thrust w a sh er
c. Worn timing ge a r R ep lace timing ge a r
d. Worn valve lifters Replace valve lifters
e. E x cess ive valve clearance Adjust clearance
3-6 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 . Rem ove o r disconnect the following
B e fo re rem oval, c o v e r the fenders p a rts .
with the fen der c o v e r s to protect the
painted surfaces , and also do not spill a. Transmission c o ver (on R K ).
any brake fluid o r anti-freeze solution b. Transm ission control links or
on the painted surface. rods.
c. Speedom eter cable.
On the R S , R T 4 3 L , 5 2 L , R K 4 4 and d. Parking brake cable.
101 s e r ie s , rem ove as follows e . Fron t exhaust pipe support
b ra c k e t.
1. Drain the cool&nt. f. Engine under co vers (if in
stalled ) .
2 . R em ove o r disconnect the following g . Clutch release cylinder with
p a rts . pipe (except with Toyoglide
Automatic) .
a. Battery ground cable.
b. Hood. 6. P la c e the jack under the trans
c. A i r cleaner. mission , and rem o ve the r e a r
d. Radiator grille (on R T ) . mounting.
e. Radiator upper baffle plate
(on R T ) . 7. Install a lifting hooks onto the en
f. Inlet and outlet radiator hoses . gine h a n g e rs , and carefully lift
g. Oil cooler flexible hoses (with the engine with the transmission
To yo glide Automatic) . towards the front and upward with
h. A c c e le r a t o r connecting ro d . a suitable hoist to rem o ve the en
i. Choke connecting rod (on R K ) gine.
j. Fuel hose. T a k e c a re not to damage other
k. Distributor prim ary lead w ir e components.
and high tension coil w i r e .
1. Battery to starter cable and On R K 1 7 1 , 171B and 176 s e r ie s ,
magnetic switch lead w i r e . rem o ve as follows
3. R em ove the radiator and the fan 1. R a ise the vehicle, and support the
shroud, and then re m o ve o r dis front and r e a r axles with stands.
connect the following p a r t s .
2. Drain the coolant and the engine
a. B ra k e booster vacuum hose
o il.
(if installed)
b. H ea ter hoses and w a te r valve
3. Lift the engine c o v e r with the a-
(if installed)
sistant d r iv e r 's seat, and support
c. Clutch flexible hose (except
it with the hook belt (on D yna)
with T oyoglide Automatic)
R em ove the engine s e r v ic e hole
d. A ltern ator lead w i r e s .
c o v e r (on Light B u s ) .
e. Exhaust pipe.
f. Engine front mounting bolts and
4. R em o v e o r disconnect the following
nuts.
parts.
g. T em p era tu re and oil p r e s s u re
gauge unit lead w i r e s .
a. Battery ground cable.
4. Jack up the c a r , and support with b. Battery to starter w ir e and
stands. magnetic switch lead w i r e .
Drain the engine oil, and rem o ve c . High tension coil w ir e and dis
the prop eller shaft. tributor prim ary lead w i r e .
T o prevent the oil leak from the
E N G I N E - Major S e r v i c e 3-7
d. Fuel hose. c o v e r and the flywheel to relocate

e . Radiator inlet and outlet h o s e s . the original positions upon assem
f. A i r cleaner outlet hose and bly, and rem ove the clutch c o v e r
pipe. and the clutch d is c .
g . -Alternator lead w ir e s .
h. Tem peratu re and oil pressu re 4. R em ove the torque co n verter a s
sender gauge unit w ir e s . sembly on c a r equipped with the
i. Choke and throttle ro d s, Toyoglide Automatic.
j . A c c e le r a to r torque rod and
bracket. 5. If n e c e s s a r y , rem ove the input
shaft front bearing using the Input
5. R em ove the radiator wind guide, Shaft Fron t B earin g P u ller 09303-
and rem ove the radiator assem 35010.
bly with the fan shroud and r a
diator support dow nw ard.
6 . Rem ove o r disconnect the following

parts.
a . Engine under c o v e r .
b . Transm ission control links.
c . Back-up light switch lead w ir e s
(if installed)
d . B ra k e booster vacuum hose.
e. Front exhaust pipe.
f. P r o p e lle r shaft.
g. Speedometer cable. F i g . 3-1 Removing B earin g B0270
h. Parking brake cable.
i. Clutch relea se cylinder with 6. Rem ove the flywheel o r the drive
pipe. plate and the r e a r end plate, and
then mount the engine onto a w o r k
7. P la ce an engine holder onto the stand.
jack, and support the engine with
the j a c k . 7. R em ove the air pump, air control
va lve, air injection manifold and
8. Rem ove the engine front mountings the hoses on the 3 R - C engine.
and the r e a r mounting bolt.
N ext, lo w e r the jack gradually, 8. R em ove the oil level gauge, c a r
and carefully rem ove the engine buretor fuel pipe and vacuum p ip e .
with the transmission from under
the veh icle. 9. R em ove the distributor assembly
T a k e c a r e not to damage the other together with the spark plug co rd s
components. and the coil cord if not rem o ved .
Disassembly 10 . R em ove the engine mounting b r a c k

et front R H , fuel pump if not r e
1. R em ove the flexible hose bracket, moved and the spark plugs.
oil co o le r tubes and the clamps
on c a r equipped with the Toyoglide 11. R em ove the oil filter assem bly,
Automatic. engine mounting bracket front L H
if not rem oved and the altern ator.
2 . Rem ove the starter motor and the
transmission. 12. R em ove the fan belt, w a te r b y
pass hose, and the heater w a te r
3. Stamp mating marks onto the clutch pipe o r hose on the c a r with the
h e a te r.
3-8 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. move the oil pump assembly with
the stra in er.
14. A ft e r removing the automatic choke
stove inlet and outlet pipes if in 23. Using the Crankshaft Pulley and
stalled , and then rem ove the c a r G ea r Pu ller 09213-60013, r e
buretor and the heat insulator. move the pulley.
15. R em ove the manifold assembly and 09213-60013

the gasket.
16. R em ove the temperature sender

gauge, oil p r e s s u re sender gauge,
ventilation tube, w a te r drain cock,
oil level gauge guide and the w a ter
plug.
17. R em ove the cylinder head c o v e r .

5 i-v
18. A ft e r removing the valve ro c k e r
supports with the r o c k e r arm s and F ig . 3-3 Crankshaft Pulley V4667
the r o c k e r shaft, then re m o ve the Removal
push ro d s. In this c a s e , the push
rods should be arran ged in the 24. R em ove the timing g e a r c o v e r ,
o r d e r of the cylinder numbers. and rem ove the oil n ozzle.
19. R em ove the cylinder h ea d , and the 25. Rem ove the camshaft thrust plate
cylinder head gasket.When loosen attaching bolts, and rem ove the
ing the cylinder Tiead bolts, r e fe r camshaft with the timing g e a r with
to figure 3-2. out damaging the camshaft bearing.
26. Rem ove the front end plate.
27. Rem ove the connecting rod caps

with the bearings, and rem ove the
pistons with the co n -ro d s from the
top of the cylinder block. A t this
tim e, do not mix the mated parts
with the others.
28. Rem ove the crankshaft bearing

caps with the bearings.
F ig . 3-2 Cylinder Head B0290 29. R em ove the crankshaft, and then
Bolts Removal rem ove the upper bearings.
20. R em ove the push rod c o v e r s and 30. Using a suitable piston ring ex
the v a lve lifters. T h e valve lifters pander, rem ove the piston rings.
should be a rran ged in the o r d e r T h e rem oved piston rings should
of the cylinder numbers. be laid in accordance with the cy l
inder numbers.
21. T u rn the engine, and position the
bottom side up, then rem o ve the 31. A fte r removing the hole snap^rings,
oil pan. heat the piston to 50 ~ 60 C o r
E N G I N E - Maior S e r v i c e 3-9
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 .
2. Check fo r w ater leak from the

cylinder head by applying w a ter
pressu re of 5 kg/cm2 (70 p s i).
If defective , repair o r replace the
cylinder h ea d .
3. Check the flatness of the cylinder

F ig . 3-4 Piston Ring B0271 head gasket surface with a straight
Removal edge and a fe e le r g a u g e .
If the w a rp a ge ex ceed s 0.05 mm
122 ~ 140° F with the piston heater , ( 0 . 0 0 2 " ) , grind the gasket s u r
and rem ove the piston pin from face with a surface grin d er.
the piston.
Do not mix the mated parts with
the o th e r s .
L im i t 0.05mm ( 0 . 0 0 2 ” )
32. Mark the v a lv e s , and rem ove the
valves using a valve spring com
pressor .
33. R em ove the valve r o c k e r shaft

lock s p r in g s , and rem ove the
ro c k e r a rm s, ro c k e r supports
and the springs from the ro c k e r
shaft.
F ig . 3-5 Measuring Cylinder V4668
Inspection & R epair Head W arpage
Wash the disassembled parts tho

roughly before inspection and rep a ir
to rem ove the dirt, oil carbon and
w ater s c a le .
Check the cylinder block and the cyl
inder head fo r cracks and w a ter leak
b efore w ashin g.
Blow all passages with com pressed
a i r , and rem ove the deposits.
Check that the passages a re not clo g
ged .
Rem ove the carbon deposits from the
top of the pistons, combustion cham F i g . 3-6 Measuring Points V4669
b e r s in the cylinder head, and also fo r W arpage
rem ove from the valves without dam
aging the p a r t s . 4- T o replace the w a te r pipe, r e
Do not mix the mated parts with the move the cylinder head r e a r plate ,
o th e rs . and then re m o ve the w a te r pipe
by driving out tow ards the fr o n t.
Cylinder Head N ext, install the w a te r pipe into
the cylinder h ea d , and install the
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. T h e valve seat angle is 45°, and

the width is 1.4 mm ( 0 . 0 5 5 " ) . If
the width exceeds 1.4 mm o r
( 0 . 0 5 5 " ) , cut the bottom with the
■ M O Q
15 cutter and the upper with 75
cutter to obtain p ro p e r width.
7. A ft e r cutting, the valve should

contact the valve seat exactly at
the center. T o check, apply a
thin coat of red lead on the seat,
F ig . 3-7 Cut-in of Water V4670 and insert the va lv e . Apply a light
Pipe p r e s s u re on the valve to check
the contact. If the seating is too
Install the w a te r pipe so that the high, use the 15 cutter and 45
mark provided at the end of the cutter, and if too lo w , use the
w a te r pipe faces tow ard s the valve 75 cutter and 45 cutter.
seat side.
8. L a p the valve and the seat with
2. Check the valve seat for damage a lapping compound to match the
and w e a r . seat. A ft e r lapping, clean the
If n ecess a ry to re fa c e , first check v a lves and the valve seats tho
the valve guide bushing fo r w e a r , roughly .
and replace the bushing if it is
w o r n , and then re fa c e the valve V a lv e Guide Bushing
seat with a valve seat grin d er o r
other cutters. 1. Check the clearance between the
If the va lve cutter is used, three va lve stem and the valve guide
different cutters of 15 , 45 and bushing.
75 a r e requ ired . If the clearan ce exceed s 0.1 mm
If these cutters a r e used, first, ( 0 . 0 0 4 " ) , replace the valve and
using the 15 cutter, cut the seat the valve guide bushing with the
surface roughly. N ext, use the V a lv e Guide Bushing R e m o v e r &
75 cutter, and cut the seat su r R ep la c er 09201-40010.
face to approximate s iz e . Finally, T h e specified clea ran ces a re as
use the 45 cutter, and cut to fo llo w s .
c o r r e c t s iz e . Intake sid e’. 0.025 ~ 0.052 mm
Cut lightly to leave allowance fo r ( 0 . 0 0 1 0 - 0 . 0 0 2 0 ")
Exhaust side: 0.040 - 0 .0 7 0 mm
(0.0016 ~ 0 .0 0 2 8 ")
T o check the clearance easily,
insert the valve into the guide bush
ing , and move the valve stem to
w a r d s the left and right.
If the movement at the valve stem
end ex ceed s 0.25 mm ( 0 . 0 1 " ) ,
the clearan ce may exceed 0 .1 mm
(0 .0 0 4 ").
2. Install the guide bushing into the

cylinder head so that the protrusion
F i g . 3-8 V a lv e Seat A n g le G1623 of the guide bushing will be 23 mm
F ig . 3-9 Easy Method G1709 F i g . 3-12 Reaming V a lv e V3150

Guide Bushing
V a lv e
[ 0 9 2 0 1- 4 0 0 10 )
1. Check the valve fa c e s , and the
edge of the valve head fo r pits,
g r o o v e s , s c o r e s and defects.
2. Check the valve stem fo r bent,

and g r o o v e s at the neck of the
valve stem .
3. Check the valve head fo r b u r r s

F i g . 3-10 V a lv e Guide V4671 w a rp a g e , cra c k and c o rr o s io n .
Bushing Replacement Replace it if ex cess ively w orn o r
dam aged.
( 0 . 9 6 " ) above the cylinder head.
4. If the valve head edge is w o r n ,
and is less than 0 . 8 mm (0 .0 3 1 " )
fo r the intake, and 1.0 mm o r
0 .039" fo r the exhaust, replace the
v a lv e s .
F ig . 3-11 Protrusion of G0826

V a lv e Guide
3. A ft e r installing the guide bushing,

ream the guide\bushing until the
specified clearan ces a re ob F i g . 3-13 V a lv e Head G1624
tained . E d ge Thickness
T h e finished diameter of the guide
bushing should be 9.01 ~ 9.03 5. Grind the va lves to 4 5 °. Rem ove
mm (0.3550 ~ 0 .3 5 5 8 " ). only sufficient stock to c o r r e c t the
run-out, and to rem ove the pits,
and g r o o v e s .
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 the end of the valve stem, against the square edge, and r o
then chamfer as n e c e s s a r y . Do tate the spring slowly.
not reface m ore than 0 .5 mm o r T h e space between the top coil
0 . 0 2 ". of the spring and the square edge
should be within the limit. If it ex
ceeds the limit, replace the spring.
Lim it
Inne r 1.6mn(0.063 ')
O u t e r 1 .9mm(0.074 ’ )
F ig . 3-14 Grinding V a lv e V2011
V a lv e specification: F i g . 3-15. Checking Spring G0832

Head diameter: Intake 42 mm Squareness
(1 .6 5 " )
Exhau st 35 mm V a lv e spring specification:
(1 . 3 8 " ) F r e e length: Inner 45.1 mm (1. 781
O verall length: Intake 124.8 mm Outer 54. 8 mm ( 2 . 161
(4 .9 1 ") F r e e length. limit:
Exhaust 124.8 mm Inner 43.7 mm (1 .72'
(4 . 9 1 " ) Outer 53.2 mm (2 .09'
Stem diameter: Intake 9 .0 mm Installed height:
CO. 354") Intake: Inner 39.5 mm (1 .56'
Exhaust 9 .0 mm Outer 47.5 mm (1 .87'
(0 .3 5 4 " ) Exhaust: Inner 39.6 mm (1 . 5 6 '
V a lve seat angle*. Intake 45° Outer 47.6 mm (1 . 8 8 ' )
Exhaust 45° Installed tension:
V a lv e head edge thickness: Intake: Inner 6 . 7 kg (14 .7 lb)
Intake 1 . 5 mm Outer 24. 5 kg (53 .9 lb)
(0 .0 5 9 " ) Exhaust: Inner 6 .6 kg (14 . 5 l b )
Exhaust 1.5 mm Outer 24.1 kg (53 .0 lb)
(0 .0 5 9 " ) Installed tension limit:
Intake: Inner 6 . 2 kg (13 . 6 l b )
V a lv e Spring Outer 22.0 kg (48 .4 lb)
Exhaust: Inner 6 .1 kg (13 .4 lb)
1. Measure the fr e e length of the Outer 21.5 kg (47 . 3 lb)
va lve springs. S qu areness limit:
Replace the spring if the fr e e length Inner 1 .6 mm (0 . 063")
is less than the limit. Outer 1. 9 mm (0 . 074")
2. M easure the spring tension with V a lv e R o c k e r A r m & Shaft

a spring t e s t e r .
R ep lace it if the tension is less 1. Check the valve r o c k e r arm and
than the limit. the shaft.
If ex cess ively w o r n , replace the
3. Check the valve spring squ are r o c k e r arm bushing o r shaft.
n ess using a steel squ are, and a If n ecess a ry to replace the bush-
ing, replace it with the ro ck e r facing machine.

arm sub-assembly as possible. 5 . Check the ro c k e r shaft spring for
dam age, and replace it if n ec e s
2. T o rem ove the bushing, use s a ry .
the Connecting Rod Bushing R e
mover & R ep lacer 09222-30010, V a lv e Lifter
and rem ove the bushing towards
the front. 1. Check the valve lifters fo r w e a r ,
and damage, and if n e c e s s a r y ,
replace the lifter/s.
2. Check the clearance between the

valve lifter and the lifter b o r e . If
the clearance exceeds 0.1 mm or
( 0 . 0 0 4 " ) , replace with an o v e r
size valve lifters reaming the bores
to obtain the clearance of 0.015
to 0.051 mm (0 .0006 ~ 0 .0020" ) .
F i g . 3-16 Bushing Removal V3135
3. T o install the bushing, apply oil

between the valve ro c k e r arm and
the bushing, and install the bush
ing from the front with a press .
F ig .3 - 1 8 Measuring Lifter V46 72

B ore
V a lve lifter specification :

S T D - Diam eter:
22.17 ~ 22.18 mm
(0.8720 ~ 0 .8 7 3 2 ")
F ro n t-
L ifte r b o re :
22.20 ~ 22.22 mm
F i g . 3-17 Bushing Section G1710 (0.8740 ~ 0 .8 7 4 8 ")
O / S -0 0 3 - Diam eter:
A ft e r installing, finish the bushing 22.25 ~ 22.26 mm
with an adjustable re a m er to ob (0.8760 ~ 0 .8 7 6 4 ")
tain proper clearance of 0.01 to L ifte r bore :
0.04 mm (0.000*4 ~ 0 .0 0 1 6 ") b e 22.28 ~ 22.30 mm
tween the ro c k e r shaft and the (0.8772 ~ 0 .8 7 8 0 ")
ro c k e r arm bushing. O / S -0 0 5 - Diam eter:
22.30 ~ 22.31 mm
If the valve ro c k e r arm shows (0.8780 ~ 0 .8 7 8 3 ")
ex cess ive w e a r at the valve stem Lifter b ore :
contact f a c e , replace the ro c k e r 22.33 ~ 22.35 mm
arm . If the w e a r is little, and the (0.8791 ~ 0 .8 8 0 0 ")
ro c k e r arm is still s e r v ic e a b le ,
reface the ro c k e r arm with a r e -
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.
Minute c r a c k s not visible to the
naked ey es may be detected with
an equipment if available.
Replace the block if not s e r v ic e F ig . 3-20 Measuring Points G0833
able . of Cylinder B o re
2. Check the w a te r leak from the

cylinder block by applying w a ter
p r e s s u re of 5 kg/cm2 (70 psi).
If defective, repair o r replace the
cylinder block.
3. Check the flatness of the cylinder

block gasket surface following the
p rocedu re recommended fo r the
cylinder head.
If the w a rp a ge ex ceed s 0.05 mm
(0 .002" ) , grind the gasket surface
with a suitable surface grin d er. F ig . 3-21 Measuring B0273
Cylinder B o r e
2. Refinish the cylinders scored

badly, burned and/or w orn out-
L im i t 0.05mm ( 0 . 0 0 2 " ) of-round o r taper m ore than 0 .2
mm ( 0 . 0 0 8 " ) , and use o v e rs iz e
pistons.
If one cylinder b o re requires
boring, the rest also require
boring, and new o v e r s iz e pistons
must be fitted.
Cylinder b o r e ’. 88.00 ~ 88.03 mm

F i g . 3-19 Checking Cylinder B0272 (3.4645 - 3.4651")
Block Flatness W ea r & taper limit: 0 .2 mm
(0 .0 0 8 ")
Cylinder B o r e
3. If the cylinder w alls have minor
1 . Check the cylinder b o re fo r out- surface defects, but the out-of
of-round and taper with a cylinder round and the taper a r e within the
b o re gauge. Measure the diameter limit, hone the cylinder w a lls , and
of each cylinder b o re at the top, also rem ove the ridge with a ridge
middle, and bottom with the gauge r e a m e r , then install new pistons
placed at right angle and parallel with p r o p e r clea ran ces.
to the cen ter line of the engine.
E N G IN E - Major S e r v ic e 3-15
Cylinder Boring Mark: 88.485

Piston diameter:
1. Select the cylinder with the most 88.478 ~ 88.488 mm
w e a r first to determine the o v e r (3.4834 ~ 3 .4 838")
size piston to be used. Mark: 88.495
Th e size and the piston diameter Piston diameter:
a re marked on the package and 88.488 ~ 88.498 mm
also on the piston head. (3.4838 - 3 .4 842")
O /S-030:
Mark: 88.725
Piston diameter:
88.722 ~ 88.732 mm
(2.4930 - 3 .4 9 3 4 ")
Mark: 88.735
Piston diameter:
88.732 ~ 88.742 mm
(3.4934 - 3 .4 9 3 8 ")
Mark: 88.745
Piston diameter:
88.742 ~ 88.752 mm
(3.4938 ~ 3 .4 9 4 2 ")
F i g . 3-22 Piston with Pin V4677 C /S -0 4 0 :
Mark: 88.980
Piston specification fo r 3 R - B and Piston diameter:
3R -C : 88.976 ~ 88.986 mm
STD: (3.5030 * 3 .5 0 3 4 ")
Mark: 87.965 Mark: 88.990
Piston diameter: Piston diameter:
87.960 : » 87.970 mm 88.986 ~ 88.996 mm
(3.4630 ~ 3.4 634") (3.5034 !? 3 .5 0 3 8 ")
Mark: 87.975 Mark: 89.00
87.970 - 87.980 mm 88.996 ~ 89.006 mm
(3.4634 - 3 .4 638") (3.5038 » 3 .5 0 4 2 ")
Mark: 87.985 O /S -050:
Piston diameter: Mark: 89.235
87.980 - 87.990 mm Piston diameter:
(3.4638 ~ 3 .4 642") 89.230 ~ 89.240 mm
O/S-010: (3.5130 » 3 .5 1 3 4 ")
Mark: 88.220 Mark: 89.245
88.214 ~ 88.224 mm 89.240 ~ 89.250 mm
(3.4730 - 3 .4 734") (3.5134 - 3 .5 1 3 8 ")
Mark: 88.230 Mark: 89.255
88.224 ~ 88.234 mm 89.250 ~ 89.260 mm
(3.4734 ~ 3 .4 7 3 8 ") (3.5138 ■* 3 .5 1 4 2 ")
Mark: 88.240 O /S-060:
88.234 ~ 88.244 mm Piston diameter:
(3.4738 ~ 3 .4 742") 89.394 ~ 98.404 mm
O/S-020: (3.5194 - 3 .5 1 9 8 ")
Mark: 88.475 Mark: 89.410
88.468 ~ 88.478 mm 89.404 * 89.414 mm
(3.4830 - 3 .4 8 3 4 ") (3.5198 - 3 .5 2 0 2 ")
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
Piston specification fo r 5R Piston diameter:
88.960 ~ 88.970 mm
STD: (3.5050 ~ 3.5 054")
Mark: 87.965 Mark: 88.975
87.960 ~ 87.970 mm 88.970 ~ 88.980 mm
(3.4630 ~ 3 .4 6 3 4 ") (3.5054 ~ 3.5058")
Mark: 87.975 Mark: 88.985
87.970 ~ 87.980 mm 88.980 - 88.990 mm
(3.4634 - 3 .4 6 3 8 ") (3.5058 ~ 3.5062")
Mark: 87.985 O / S - l .25:
87.980 - 87.990 mm Piston diameter:
(3.4638 - 3 .4 6 4 2 ") 88.210 ~ 89.220 mm
O / S - 0 .2 5 : (3.4755 - 3 .5 153")
Mark: 88.215 Mark: 88.225
88.210 ~ 88.220 mm 89.220 ~ 89.230 mm
(3.4755 ~ 3 .4 7 5 9 ") (3.5153 ~ 3 .5 1 5 7 ")
Mark: 88.225 Mark: 88.235
88.220 - 88.230 mm 89.230 ~ 89.240 mm
(3.4759 ' 3 .4 7 6 3 ") (3.5157 ~ 3 .5 161")
Mark: 88.235 O / S - l . 50:
88.230 ~ 88.240 mm Piston diameter:
(3.4763 ~ 3 .4 7 6 7 ") 89.460 ~ 89.470 mm
0 / S -0 .5 0 : (3.5247 ~ 3 .5 251")
Mark: 88.465 Mark: 89.475
88.460 ~ 88.470 mm 89.470 ~ 89.480 mm
(3.4853 ~ 3 .4 8 5 7 ") (3.5251 ~ 3 .5 255")
Mark: 88.475 Mark: 89.485
88.470 ~ 88.480 mm 89.480 ~ 89.490 mm
(3.4857 - 3 .4 8 6 1 ") (3.5255 ~ 3 .5 2 5 9 ")
Mark: 88.485
Piston diameter: 2. T o b o re the cylinder, measure
88.480 ~ 88.490 mm the piston skirt at right angle to
(3.4861 ~ 3 .4 9 6 5 ") the piston pin boss with a m icro
O / S - 0 .7 5 : m eter. T h e piston pin should be
M a rk : 88.715 removed before measuring, and
Piston diameter: the temperature should be about
88.710 ~ 88.720 mm 20°C (68° F ) when checking the
(3.4952 ~ 3 .4 9 5 6 ") diameter of the piston.
Mark: 88.725 A ft e r measuring the piston, b ore
Piston diameter: the cylinders with a boring ma
88.720 - 88.730 mm chine according to the piston dia
(3.4956 - 3 .4 9 6 0 ") meter .
M a rk : 88.735
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 .
O /S-160:
S le e v e outer diameter:
92.151 ~ 92.186 mm
(3.6279 - 3 .6 293")
B o r e diameter:
92.060 ~ 92.095 mm
(3.6244 ~ 3.6 257")
O /S-180:
S le e v e outer diameter:
92.661 ~ 92.696 mm
F i g . 3-23 Measuring Piston V4673 (3.6490 ~ 3 .6 4 9 4 ")
Diameter B o r e diameter:
92.570 ~ 92.605 mm
3. Check the clearance between the (3.6444 ~ 3 .6 458")
cylinder b o re and the piston. O /S -200:
T h e clearance should be 0.03 to S le e v e outer diameter:
0.05 mm (0.0012 * 0 .0 0 2 0 " ). 93.171 | 93.206 mm
T o check the clearan ce, position (3.6681 ~ 3 .6 6 9 5 ")
the fe e le r gauge of 0.03 mm o r B o r e diameter:
(0 .0 0 1 2 ") thickness and of 12 to 93.080 ~ 93.115 mm
15 mm (0 .5 ~ 0 . 6 " ) wide into the (3.6645 ~ 3 .6 6 5 9 ")
cylinder extending the entire length
of the piston at 90 from the pis 2. B o r e the cylinder in accordance
ton pin boss location. Invert the with the sleeve size to be installed .
piston, and install into the cylinder T h e fitting tolerance between the
b o re with the piston pin parallel cylinder block and the liner should
to the crankshaft axis. Attach a be 0.04 ~ 0.06 mm (0.0015 to
pull s c a le , and pull up straight- 0 . 0 0 2 4 " ).
w a rd reading the scale.
T h e c o r r e c t reading should be 3. T h e installing pressu re required
1.0 1 2.5 kg (2 .2 ~ 5.5 lb s ). is 2,000 ~ 3,000 kg (4,400 to
6,600 lb s ) , and the sleeve must
be installed so that the top of the
sleeve is flush with the cylinder
block gasket surface. If the p r e s
sure required is less, select the
next o v e r s iz e sleeve.
F ig . 3-24 Checking Piston V4676

Fit
Cylinder S leeve
1. T h e use of cylinder sleeve is r e

commended only when the cylinder F i g . 3-25 Installing Cylinder G0834
bore is w orn e x c e s s iv e ly , and S le e v 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. marks, and these marks should
be faced upward when installed.
5. If the o v e r s iz e is no longer s e r
viceable , rem o ve the sleeve to
Size
w a rd the cylinder head with a
p r e s s . If the removal by press is
difficult, b o re the sleeve to facilitate
the rem oval. T h e next o v e rs iz e
slee ves may be reinstalled if the
slee ves a r e to be u sed .
Piston & Piston Pin
1 . Inspect the piston and ring g r o o v e s

M aker 'R jn g No.
f o r w e a r , b u rrs o r nicks, and
if n e c e s s a r y , replace them. F i g . 3-27 Piston Rings V2062
Measure the ring g r o o v e s fo r w e a r
by re fe rrin g to F ig . 3-29. 2. Install each ring individually into
the cylinder b o r e , and check the
2. Each piston is marked with an end gap of the ring with a fe e le r
"indent" indicating the piston dia gauge.
m eter, the piston pin size and the Specified gap:
front mark on the h ea d . Compression ring N o . l :
0.20 ~ 0.40 mm
3. Check the piston pin fitness by (0.0078 n 0 .0 1 5 8 ")
pressing the pin with the thumb Compression ring N o . 2:
with the piston heated to 50 to 0.15 ~ 0.35 mm
60°C (122 ~ 140°F ) . (0.0059 ~ 0 .0 1 3 7 ")
If the fitness is loose, replace both Oil ring:
the pin and the piston. 0.15 ~ 0.35 mm
(0.0059 ~ 0 .0 137")
If only the rings a re replaced

without refinishing the cylinder
b o r e s , check the ring end gap
placing the ring at the lo w e r po
sition in the cylinder b o re w h e re
the w e a r is minimum.
#
F i g . 3-26 Piston Marks on B0274
Head
Piston Ring
1. Check the rings fo r w e a r and

other defects. If the pistons a re
r e p la c e d , the rings should be r e
placed at the same time. F ig . 3-28 Checking Piston V4678
T h e ring size must be selected to Ring End Gap
3. Check the ring to piston ring 2. Check the connecting rod fo r bend
groo ve clearance with a fe e le r o r twist with a Connecting Rod
gauge by inserting between the A lig n e r as shown in figure 3-30.
ring and its lo w er land. T h e allowance of bend and twist
If n e cess a ry , replace the pistons. p er 100 mm ( 3 . 9 4 " ) is 0.15 o r
Specified clearance: 0 .0 0 6 ".
Compression ring N o . l : If it exceeds the limit, c o r r e c t it
0.03 ~ 0.07 mm so that the three points of the " V "
(0.0012 ~ 0 .0 0 2 7 ") block contact with the face plate
Compression ring N o . 2: evenly o r replace the connecting
0.03 ~ 0.07 mm rod.
(0.0012 ~ 0 .0 027")
Oil ring: 3. Install the connecting rod onto the
0.025 - 0.070 mm crankshaft, and check the thrust
(0.0010 ~ 0.0 027") p la y.
T h e thrust play should be 0.17 to
0.28 mm (0.0067 ~ 0 . 0 1 1 0 " ).
T h e limit of thrust play is 0.4 mm
( 0 . 0 1 5 7 " ).
F ig . 3-29 Checking Piston V4679

Ring Clearance
Connecting Rod
F i g . 3-31 Measuring Thrust V4682
1. Check the connecting rods fo r C leara n ce
damage at the thrust surfaces on
both sides. If n e c e s s a r y , replace 4 . Check the bushing of the connecting
the connecting r o d . rod fo r w e a r , b u rrs o r nicks,
If replaced, the cylinder number and if n ecess a ry , replace the bush
should be marked on the camshaft ing with the Connecting Rod Bush
side on the connecting r o d . ing R e m o v e r & R e p la c e r 09222-
40011 fo r the 3 R - B , 3 R - C en-
F ig .3 - 3 0 Checking Con- V3148

necting Rod V3149 F i g . 3-32 Replacing Bushing V4683
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 6.0 ~ 7.0 m-kg (43 ~ 51ft-lbs)
machine o r a re a m er to obtain
p r o p e r fitness with the piston pin 5. R em ove the c a p , and check the
and the bushing. width of the Plastigage with the
T h e piston pin fitness can be de Plastigage c o v e r scale.
termined by pushing in the pin into Read the widest point in o rd e r to
the bushing with the thumb applying obtain the minimum clearance.
engine oil onto the piston pin. Read the difference between the
two readings at both sides of the
Connecting Rod B earin g P la s tig a g e .
T h e connecting rod bearings a r e in

sert type, m icro-precision finished
with high quality and close to le ra n c e.
Do not scrape o r insert any shim,
and also do not file o r lap the b e a r
ing cap o r bearing to obtain the spe
cified clearan ce.
1 . Check the bearing fo r p o or con

tact, w orn thin, partially melted
o r heavily s c o r e d .
If n ecess a ry , replace the b e a r in g s .
F ig . 3-34 Measuring Oil V4685
2. R em ove any deposit of oil, dirt Clearance
o r foreign matter from the crank
pin journals, and also from the 6. If the clearance exceeds 0.08 mm
connecting rod bearings. (0 .0031" ) , the bearings must be
replaced with an under size b e a r
3. P la c e a piece of the Plastigage ings, and grind the crank pin jo u r
on the crank pin journal fo r the nals to obtain the specified c le a r
full width of the bearing, and ances .
parallel to the crankshaft avoiding B earin g clearance:
the hole in the journal. 0.025 ~ 0.060 mm
(0.0010 0 .0 0 2 4 ")
C learance limit:
0.080 mm (0 .0 0 3 1 ")
7. If the bearings a r e to be re p la ced ,

select the p ro p e r size bearings
re fe rr in g the following table.
Connecting rod bearings:
F o r 3 R - B & 3 R - C engines:
STD:
B earin g thickness:
1.508 ~ 1.518 mm
(0.0594 ~ 0 .0 5 9 7 ")
F i g . 3-33 Placin g Plastigage V4684 Crank pin finished diameter:
54.985 ~ 55.000 mm
4. Installing the connecting rod b e a r (2.1648 ~ 2 .1 6 5 4 ")
ing and cap, tighten the nuts to U / S -0 0 2 :
specified torque. Do not turn the B earin g thickness:
1.520 ~ 1.530 mm (0.0739 ~ 0 .0 7 4 3 ")

(0.0598 ~ 0 .0 602") Crank pin finished diameter:
U/S-010: 54.230 ~ 54.240 mm
Bearing thickness: (2.1367 ~ 2.1371")
1.622 ~ 1.632 mm U / S -1 .0 0 :
(0.0639 ~ 0 .0 643") B earin g thickness:
Crank pin finished diameter: 2.000 ~ 2.010 mm
54.731 ~ 54.741 mm (0.0788 ~ 0 .0 7 9 2 ")
(2.1548 ~ 2.1552") Crank pin finished diameter:
U/S-020: 53.980 ~ 53.990 mm
Bearing thickness: (2.1268 * 2 .1 272")
1.749 ~ 1.759 mm
(0.0689 ~ 0 .0 693") 7. If a new crankshaft is utilized, al
Crank pin finished diameter: w a y s use a standard size b e a r
54.477 - 54.487 mm ings.
(2.1448 - 2.1 452") When the bearing clearance e x
U /S-030: ceeds the limit, use under size
B earing thickness: bearings, and grind the crank pin
1.876 ~ 1.886 mm journals to the specified finished
(0.0739 ~ 0.0743*) diam eters.
Crank pin finished diameter: A ft e r grinding the crank pin jo u r
54.223 ~ 54.233 mm nals, always check the bearing
(2.1348 ~ 2.1 352") c le a r a n c e .
U/S-040:
Bearing thickness: Crankshaft
2.003 ~ 2.013 mm
(0.0789 ~ 0 .0 7 9 3 ") 1. Check the crankshaft fo r run-out,
Crank pin finished diameter: and straighten o r replace the
53.969 ~ 53.979 mm crankshaft if the run-out exceed s
(2.1248 fs 2.1252") 0.05 mm ( 0 . 0 0 2 " ) , attach a dial
F o r 5R engine: gauge to the center bearing jo u r
STD: nal , and rotate the crankshaft one
Bearing thickness: complete turn.
1.495 ~ 1.505 mm Read one-half the difference of the
(0.0589 ~ 0 .0 5 9 3 ") maximum gauge reading.
Crank pin finished diameter:
54.985 ~ 55.000 mm
(2.1664 ~ 2.1 670")
U . S - 0 . 25:
Bearing thickness:
1.625 ~ 1.635 mm
(0.0640 ~ 0 .0 6 4 4 ")
Crank pin finished diameter:
54.730 ~ 54.740 mm
(2.1564 ~ 2 .1 568")
U / S - 0 .5 0 :
1.750 ~ 1.760 mm
(0.0690 - 0 .0 6 9 3 ") F i g . 3-35 Checking C ra n k - V4686
Crank pin finished diameter: shaft Run-Out
54.480 - 54.490 mm
(2.1465 I 2 .1 4 6 9 ") 2. Inspect the crank pin journals and
U / S - 0 .7 5 : the crankshaft journals fo r w e a r
B earing thickness: and s c o r e s , and if the out-of-
1,875 ~ 1.885 mm round o r taper exceed s 0.01 mm
3-22 E N G I N E - Major S e r v i c e
(0 .0 0 4 "), grind the crank pin w a rd s the crankshaft thrust sur

journals o r the crankshaft jo u r face .
nals. R e fe r to connecting rod
bearing and the crankshaft b e a r Crankshaft B earing
ing in this section.
Th e crankshaft bearings a re also of
3. Check the crankshaft journals and the insert type and selective fit with
the crank pin journals fo r w e a r . m icro-precision finished. T h e r e fo r e ,
If the w e a r ex ceed s the limit, r e the same procedu res of inspection,
place the crankshaft. and oil clearance check should be
Crankshaft journal diameter limit: perform ed as the connecting rod b e a r
58.96 mm (2 .2 8 3 " ) ings .
Crank pin journal diameter limit:
F o r 3 R - B & 3 R - C engines: 1 . Check the bearing fo r poor con
53.96 mm (2 .1 2 6 " ) tact, w orn thin, partially melted
F o r 5R engine: o r heavily sco red .
53.98 mm (2 .1 2 7 " ) If n e c e s s a r y , replace the b e a rin g s .
4. Check the crankshaft side c le a r 2. Check the crankshaft bearing

ance at the center bearing. clearance with the Plastigage.
If the clearance ex ceed s 0.30 mm T h e tightening torque of the crank
( 0 . 0 1 2 " ) , replace the crankshaft shaft bearing cap bolts is 10.0 to
thrust bearings. 11.0 m-kg (75 ~ 80 ft-lb) torque.
Specified clearance:
0.05 - 0.23 mm (0.002 ~ 0 .0 09" ). 3 . T h e specified clearance should be
T h e adjustment of clearan ce is 0.020-0.055 mm (0.0008-0.0022).
made by using the following thrust If the clearance ex ceed s 0.08 mm
b e a r in g s . ( 0 . 0 0 3 " ) , replace the bearings
STD: with the under size b e a r in g s , and
T h ickn ess: 2.925 ~ 2.975 mm grind the crankshaft journals to
(0.1151 ~ 0 .1 1 7 1 ") fit the bearings.
O / S -005: STD:
Th ickn ess: 2.990 ~ 3.040 mm B earin g thickness:
(0.1177 ~ 0 .1 1 9 7 ") 2.493 - 2.503 mm
O / S -010: (0.0982 ~ 0 .0 9 8 6 ")
Th ickn ess: 3.050 - 3.100 mm Journal finished diameter:
(0.1201 ~ 0 . 12 2 0 ") 59.985 ~ 60.000 mm
(2.3634 ~ 2 .3 6 4 0 ")
U / S -0 0 1 :
B e a rin g thickness:
2.508 ~ 2.518 mm
(0.0988 ~ 0 .0 9 9 2 ")
U / S -0 1 0 :
2.622 - 2.632 mm
(0.1033 ~ 0 .1 0 3 7 ")
Journal finished diameter*.
59.730 - 59.740 mm
(2.3534 ~ 2 .3 538")
U / S -0 2 0 :
F i g . 3-36 Checking Side V4687 B earing thickness:
C le a ra n ce 2.749 ~ 2.759 mm
(0.1083 - 0 .1 0 8 7 ")
T h e side on which the oil g r o o v e Journal finished diameter:
is provided must be positioned to 59.475 - 59.485 mm
(2.3433 - 2 .3 4 3 7 ")
U/S-030: If defective, replace the timing

Bearing thickness: gear.
2.876 ~ 2.886 mm T o rem ove the timing g e a r , use
(0.1133 ~ 0 .1 137") the Timing G ear T o ol 09210-
Journal finished diameter: 31010.
59.220 ~ 59.230 mm
(2.3333 ~ 2.3337") 2. T o assem ble, install the g e a r onto
U/S^-040: the crankshaft using the Timing
B earing thickness: G ear T o ol Set 09210-31010.
3.003 ~ 3.016 mm
(0.1183 ~ 0 .1 188")
Journal finished diameter:
58.960 ~ 58.970 mm
(2.3230 r 2.3234")
4. If a new crankshaft is installed,

alw ays use standard size bearings
When the bearing clearance e x
ceeds the limit using the standard
bearings, use U /S-001 b e a r in g s .
If the clearance exceeds 0.055 mm
(0 .0022") with the U /S-001 b e a r
ings, grind the crankshaft journals F ig . 3-38 Installing Timing B0278
to fit the U /S-010 bearings. G ear
Even after grinding the crankshaft
journals to the regular dimension , Flywhe'el
always check the oil clearance
before installation. 1. Inspect the contacting surfaces b e
tween the flywheel and the clutch
Crankshaft Timing G ea r disc fo r w e a r and damage.
If defective, replace the flyw heel.
T h e crankshaft timing g e a r should be
only removed when it is to be r e 2. P la c e a dial gauge indicator against
placed, and the timing g e a r can be the flywheel surface, and check
replaced on the c a r using the Timing the run-out.
Gear T o o Set 09210-31010. T h e run-out should be less than
0.2 mm (0 .008" ) .
1. Check the crankshaft timing ge a r If the run-out ex c e e d s , replace
fo r w e a r,d a m a g e and chipped teeth. the flyw heel.
L im it 0.2mm
( 0 . 008 ” )
F i g . 3-37 Removing Timing B0276 F i g . 3-39 Checking Run-Out V4688

G ear
3. Check the ring g e a r fo r chipped
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. T o rem ove the ring g e a r , Heat the 3. Check the distributor drive g e a r
ring g e a r by rotating the flywheel fo r s co re and w e a r .
on a suitable stand to about 150 If n e c e s s a r y , replace the camshaft.
to 200 C (300 ~ 390 F ) , and tap
lightly, and rem ove the ring gear 4. Check the camshaft end p la y, and
from the fly w h e e l. if the play exceeds 0.3 mm o r
0 .0 1 2 ", replace the thrust plate.
5. T o install the ring g e a r , heat the End play: 0.06 ~ 0.13 mm
ring g e a r to about 200 °C (300 ° F ) (0.0023 - 0 .0 051")
and install the ring g e a r while still Limit: 0.3 mm (0 .0 1 2 ")
hot.
Camshaft
1. Check the camshaft fo r run-out

with a dial gauge, and if the run
out exceeds 0.05 mm (0 .0 0 2 11) ,
the camshaft must be straightened
o r rep la ce.
T h e run-out is one-half difference
of maximum reading.
F ig 3-41 Checking End P la y V4690
5. Inspect the camshaft journals fo r

pits, s c o r e s and abnormal w e a r .
T h e out-of-round o r taper should
not be m ore than 0.05 mm o r
0 . 002 ".
If w o r n , grind the journals to the
size as to the following table s e
lecting the under size bearings.
Camshaft journal diameter:
F i g . 3-40 Checking C am - V4689 S T D : N o .l
shaft Run-Out 46.460 ~ 46.475 mm
(1.8291 2 1 .8 297")
2 . Inspect the camshaft cam lobes fo r N o .2
pits, s c o r e s and abnormal w e a r . 46.210 ~ 46.225 mm
If the cam lobe height is less than ( 1.8 1 9 2 ~ 1 . 819 8")
38.06 mm (1 .4 9 8 11) fo r the intake N o .3 .
and 37.94 mm (1 .4 9 3 " ) fo r the 45.960 ~ 45.975 mm
exhaust, replace the camshaft. (1.8094 ~ 1.8100")
If the cam lobes a r e pitted o r No .4
scored slightly and the pitting o r 45.710 ~ 45.725 mm
scorin g is not detrimental to the (1.7996 ~ 1.8 002")
operation of the camshaft, the lobes No.5
may be d r essed with an oil stone. 45.460 ~ 45.475 mm
Cam lobe height: (1.7898 ~ 1 .7 904")
Intake: 38.39 ~ 38.49 mm U / S -0 0 5 :
(1.511 ~ 1 .5 1 6 ") N o .l
46.340 - 46.350 mm measuring the ^difference between

(1.8244 ~ 1.8 248") the camshaft journal diameter and
N o .2 the bearing inner diameter.
46.090 ~ 46.100 mm T h e clearan ce should be 0.025 to
(1.8146 ~ 1.8 150") 0.066 mm (0.0010 - 0 .0 0 2 5 " ).
N o .3 If the clearance exceed s the limit
45.840 ~ 45.850 mm of 0.1 mm ( 0 . 0 0 4 " ) , replace the
(1.8047 ~ 1.8051") b e a r in g s .
N o .4
45.590 ~ 45.600 mm 3. Rem ove the expansion plug instal
(1.7949 ~ 1.7 953") led at the r e a r of the camshaft
N o.5 r e a r bearing. PI ace the Camshaft
45.340 - 45.350 mm Bearing R e m o v e r & R ep lacer
(1.7850 ~ 1.7854") 09215-40010, and fit a wrench
U / S -0 1 0 : into the slot of the Shaft to prevent
N o.1 the shaft from turning, and tighten
46.210 ~ 46.220 mm the Nut with an another w ren ch ,
(1.8193 ~ 1.8197") and then rem ove the bearings.
No. 2
45.960 - 45.970 mm
(1.8094 - 1 . 8 0 9 8 " )
No. 3
45.710 - 45.720 mm
(1.7996 - 1 .8 000")
No .4
45.460 ~ 45.470 mm
(1.7937 ~ 1.7 941")
N o .5
45.210 - 45.220 mm
(1.7799 ~ 1.7 803")
U /S-020:
N o.1 F i g . 3-42 Replacing Camshaft V4691
45.955 ~ 45.965 mm B earings
( 1.8092 ~ 1 . 8096")
N o .2 4. If the camshaft bearings require
45.705 ~ 45.715 mm replacement, the camshaft journals
(1,7994 - 1 .7 998") should be checked thoroughly , and
No. 3 grind the camshaft first to d e te r
45.455 - 45.465 mm mine the under size bearings.
(1.7895 ~ 1 .7 899")
N o .4 5. B e fo r e installing the bearings,
45.205 ~ 45.215 mm align the oil holes in the bearings
(1.7797 - 1 .7 801") with the holes in the b o r e s .
No. 5
44.955 * 44.965 mm 6. Install the new selected bearings
(1.7699 ~ 1 .7 7 0 3 ") with Camshaft B earin g R e m o v e r
& R ep la c er 09215-40010.
Camshaft B earing
7. A ft e r installing the under size
1. Check the bearings fo r poor con bearings, ream the bearings with
tact, w orn thin, partially melted a line re a m er to obtain the c le a r
o r heavily s c o r e d , ance of 0.025 ~ 0.066 mm (0.001
If n ecessary , replace the b e a r in g s . to 0 .0 0 2 5 ") .
If the b earings selected a r e c o r
2. Check the bearing clearance by
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. Install a new expansion plug applied gauge o r a fe e le r gauge.
with liquid sea ler into the r e a r of Th e backlash should be between
the cylinder block at the r e a r of 0.08 ~ 0.15 mm o r 0.0031" to
the camshaft bearing. 0 .0 0 5 9 ".
If the backlash exceeds 0.3 mm
Camshaft Timing G ear ( 0 . 0 1 2 " ) , replace the camshaft
timing g e a r , and/or the crankshaft
T h e camshaft timing g e a r should be timing g e a r .
also rem oved only fo r replacement,
and the timing g e a r can be removed 4. T o rem ove the camshaft timing
on the c a r by using the Timing G ea r g e a r , rem ove the g e a r retaining
T o ol Set 09210-31010 same as the bolt and w a s h e r s , then remove
crankshaft timing g e a r . the timing g e a r using the Timing
G e a r T o o l Set 09210-31010.
1. Check the timing g e a r fo r c r a c k s ,
damage, w e a r and chipped teeth. 5. T o assemble the camshaft timing
If n e c e s s a r y , replace the timing g e a r , install the thrust plate and
gear. the key, then install the timing gear
onto the camshaft using the Timing
2. Check the timing g e a r run-out, G ear T o o l Set 09210-31010.
and if it ex ceed s 0.25 mm ( 0 . 0 1 11) , A ft e r installing the g e a r , install
replace the timing g e a r . the w a s h e rs and the retaining bolt,
then check the camshaft end play .
F ig . 3-43 Checking Timing V4692

G ear Run-Out F i g . 3-45 Removing Timing B0281
Gear
F i g . 3-44 Checking Timing B0280

G e a r Backlash F ig . 3-46 Installing Timing B0283
G ear
Crankshaft Oil Retainer A ssem bly
It is recommended that the oil retain B e fo r e assembling, thoroughly clean

e r should be replaced w h en ever the the disassembled parts especially the
engine is overhauled. oil p a ssa ges, bearings, bearing holes
T o rem ove the oil retainer from the and the cylinder w alls.
timing gear c o v e r , pry out the r e Apply engine oil onto the sliding o r
tainer towards the front. rotating portion of the cylinder w a l l s ,
T o install, use the Differential Side pistons, bearings, g e a r s and etc.
Bearing Replacer 09505-20010. It is recommended that all gaskets,
packings and seals be replaced with
new ones.
T o prevent oil leak, use liquid sea ler
on bolts, packings and the gaskets if
necessary.
Recheck the oil clea ran ce, backlash
and thrust clearan ce upon a ssem b ly.
1. Install the com pression springs,

ro c k e r a rm s, ro c k e r supports,
tension springs and the lock springs
onto the ro c k e r shaft.
The hole fo r the support lock
F i g . 3-47 Installing Oil V4693 s c r e w should face tow ards the
Retainer front.
Intake & Exhaust Manifolds
1. Inspect the manifolds fo r corrosion ,

cra c k s , o r other defects.
If n e cess a ry , repair o r replace
the manifolds.
2. Check the distorsion of the mani

folds .
If the distorsion exceeds 0.4 mm
(0 . 0 2 " ) , grind the surfaces with
a surface grin d er.
F ig . 3-49 R ocker A rm V4694
Installation
L im it 0.4mm ( 0 .0 2 ')
2. P la c e the valve into the va lve
guide, and install the 11O " ring,
inner and outer springs and the
spring retainer into position.
C o m p ress the valve springs with
a spring c o m p r e s s o r, and install
the retainer locks onto the valve
stem .
T h e side painted " y e l l o w " of the
inner and the outer v a lve springs
F i g . 3-48 Checking Manifold V4702 should be faced tow ard s the c y l
Distorsion inder head side.
A ft e r installing the retainer lock,
check if the retainer locks a re
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 ark.
4. Install the piston rings onto the

piston.
T h e piston rings a re provided with
the marks as shown in figure
3-52.
When installing the rin g s , face the
marks upw ards, and install the
rings so that the ring number will
be in o r d e r from the piston head
s id e .
F ig . 3-50 Installing Spring V4695 5. Clean the bearing fitting portion

of the connecting rod and the
3. Heat the piston to about 50 ~ 60 C b e a r in g s .
(104 ~ 140 ° F ) , and install the Install the bearings and the caps,
connecting rod, piston pin and the then tighten the nuts lightly.
snap rings.
T h e connecting rod front mark is 6. Fit the oil seal into the groo ve
indicated with the nT n mark. located at the r e a r end of the cyl
When assembling the piston, the inder block and the r e a r bearing
front mark on the piston head cap using a cylindrical tool, and
cut the protruding portion of the
seal ends from the cylinder block
s u rfa c e .
F ro n t mark (?) mark
F i g . 3-51 Piston & B0285

Connecting Rod
F ig . 3-53 Installing Oil S eal B0286
7. Install the upper halves of the

crankshaft N o . l , N o . 2 and N o . 3
bearings onto the cylinder block.
8. Install the upper halves of the

crankshaft thrust bearings.
T h e oil g r o o v e s side of the thrust
bearing must be positioned tow ards
the crankshaft' thrust surface as
shown in figure 3-54.
F i g . 3-52 Piston Ring Marks V2062
9. Install the crankshaft.
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.
A ft e r tightening the bolts, check
the crankshaft thrust clea ran ce.
11. D riv e in the side packings into the

g r o o v e s after applying a liquid
s e a le r .
12. Install the piston into the cylinder

block using the piston ring com
F i g . 3-54 Installing Thrust V4696 p r e s s o r facing the piston front
B earing mark tow ards the front of the cyl
inder block.
10. Install the lo w e r halves of the When installing the piston, it is
crankshaft bearings and the thrust advisable to insert vinyl tubes onto
bearings onto the bearing caps, each of the connecting rod cap
and then install the bearing caps bolts to prevent scoring the cy l
onto the cylinder block. inder wall and the crankshaft pin .
Tighten the cap bolts gradually Make sure that the end gap of
from the center, r e a r and the front each ring is not directed to the
to 10 - 11 m -kg (75 ~ 80 ft-lb) thrust face of the piston, and also
to r q u e . that each ring is not coinsided
with the other ring end gap as
T h ru st
Face
F ig . 3-55 Tightening Cap B0287

3olts
F ig . 3-57 Installing Piston B0289
G0987
13. Install the connecting rod bearing

c a p s , and tighten the cap bolts to
6 .0 ~ 7 .0 m-kg (43 ~ 51 ft-lb)
torque.
14. Install the front end plate with the

ga sk et.
15. Install the camshaft assembly align

ing the mating marks on the cam
F i g . 3-56 Driving In B0288 shaft and the crankshaft timing
Packings gears.
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.
F ig . 3-60 Installing C rank- V4698

shaft Pulley
19. Install the oil pump assembly with

the oil pump outlet pipe.
F i g . 3-58 Installing Camshaft V4697 Tighten the securing bolt to 1. 5 to
2.0 m-kg (11 - 15 ft-lb) torque.
16. S c r e w in the timing g e a r oil noz
zle onto the cylinder block, and 20. Install the oil pan with the gasket,
lock the oil n ozzle in place by and tighten the attaching bolts to
punching at two places to prevent 0 .4 ~ 0 . 6 m-kg (2 .5 - 4.0 ft-lb)
it from loosening. to r q u e .
When installing the oil n ozzle, po
sition the oil supply hole of the oil 25. Tu rn the engine, and position the
nozzle to discharge the oil onto top side up, and install the cyl
the timing g e a r s . inder head with the gasket.
Tighten the cylinder head bolts as
shown in figure 3-61 in three p r o
g r e s s iv e steps.
Finally tighten the bolts to 11 - 12
m -kg (80 - 85 ft-lb) torque.
F i g . 3-59 Installing Oil G1711

N o z z le
17. Install the timing g e a r c o v e r with

the gasket, and tighten the s e c u r
ing bolts to 1.0 - 1.6 m -kg o r F i g . 3-61 Tightening O r d e r B0290
7.0 ~ 11.5 ft-lb torque.
22. Install the valve lifters and the
18. Install the crankshaft pulley with push ro d s , and install the valve
the Crankshaft Pulley & G ea r R e r o c k e r shaft assembly onto the
p la c e r 09214-60010, and tighten cylinder head.
the pulley attaching bolt to 4 .3 to Tighten the securing bolts to 2.0
5.7 m -kg (31 ~ 41 ft-lb) torque. to 2.5 m-kg (15 ~ 18 ft-lb) torque.
23. Install the push rod c o v e r s , oil 35. Rem ove the engine from the engine
p ressu re sender gau ge, tempera w o r k stand, and install the r e a r
ture sender gauge, drain cock, end plate.
ventilation tube and the oil level
gauge guide. 36. Install the flywheel o r drive plate,
and tighten the securing bolts to
24. Install the manifolds with the gas specified torque.
kets onto the cylinder head. Tightening torque of flywheel bolts:
Tighten the attaching bolts to 2.0 6 .0 ~ 7.0 m -kg (43 ~ 49 ft-lb)
to 3.0 m-kg (14 ~ 22 ft-lb) to r Tightening torque of drive plate
que . 6.0 ~ 6.5 m -kg (43 ~ 47 ft-lb)
25. Install the heat insulator and the 37. If the imput front bearing w a s r e
carburetor assembly. moved upon d isassem bly, pack the
A ft e r installing the carburetor, multipurpose g r e a s e into the b e a r
c o v e r the carburetor air horn with ing, and install it with the Input
a clean cloth o r suitable material Shaft Fron t B earin g R e p la c e r
to prevent entry of dust o r dirt. 09304-30012.
26. Install the automatic choke stove

inlet and outlet pipes on R S , R T
43L. and R T 5 2 L s e r ie s .
27. Install the oil filter assembly.
28. Install the engine mounting bracket

front L H and the alternator.
29. Install the w a te r pump assembly,

w a ter outlet, thermostat, w ater
b y-pass hose and the fan belt.
Adjust the fan belt deflection to 13 F i g . 3-62 Installing Input B0291
to 20 mm (0 . 50 ~ 0 . 75" ) at p r e s Shaft Bearing V4700
sure of 11 kg (24 l b s ).
38. Install the clutch disc and the clutch
30. Install the heater w a te r pipe o r c o v e r aligning the mating marks
hose on the c a r with the heater. with the Clutch Guide T o o l 09301-
36010 , and tighten the clutch c o v e r
31. Install the distributor clamp and the securing bolts to 2.0 ~ 3.0 m-kg
distributor.
T o install the distributor, r e fe r to
the Installation of the Distributor
in the Ignition System .
32. Install the spark plu gs, fuel pump ,

carburetor fuel pipe and the v a
cuum pipe.
33. Install the engine mounting front

R H , oil level gauge and the cy l
inder head c o v e r .
34. Install the air pump, air control F i g . 3-63 Installing Clutch B0292
va lv e , air injection manifold and Cover V4701
the hoses on the 3 R - C engine.
3-32 E N G I N E - Major S er vic e
(14 ~ 21 ft-lb) torque. Engine oil capacities with the oil

T o 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 the p re s s u re plate R K 1 7 1 , 176 series:
side fo r the "9 inch disc" and to 4 .8 liters (5.1 U S qts. ,
w a r d s the flywheel side fo r the 4. 3 Imp . q ts . )
"8 inch d is c " . On R K 4 4 , 101 series:
If the c a r is equipped with the 5.3 liters (5 .6 U S q ts .,
T o y o g lid e Automatic, install the 4 . 8 Imp. q ts . )
torque co n v erter onto the drive Coolant capacities:
plate. On R S 5 0 , 56 series:
7.5 liters (7 .9 U S q ts .,
6 .6 Imp. qts. )
On R T 4 3 L , 52L series:
8.5 liters (9 .0 U S q ts .,
7 . 5 Imp. q ts . )
On R K 4 4 , 101 series:
9.1 liters (9.6 U S q ts .,
8 .0 Imp . q ts . )
On R K 1 7 1 , 176 series:
9.5 liters (10.0 U S q t s .,
8 .4 Imp . q ts . )
F ly w h e e l s id e ( 8 ” D i s c ) F ly w h e e l s id e ( 9 ' D is c )
Automatic transmission fluid
capacity: 7 liters (7 .4 U S q ts .,
F ig . 3-64 Positioning Clutch V4103 6 .1 Imp. q ts . )
D isc V4704
2. Check and adjust the clutch r e
39. Install the starter and the trans lease fork end play to obtain c o r
mission . rect clutch pedal p la y .
Specified play:
40. Install the oil c o o le r tubes, clamps On R S 5 0 , 56 series:
and the flexible hose bracket on 35 ~ 50 mm (1 .4 ~ 2 . 0 " )
the c a r equipped with the T o yo glid e On R T 4 3 L , 52L series:
Autom atic. 20 - 30 mm (0 .8 ~ 1 . 2 " )
On all R K series:
Installation 40 ~ 70 mm (1 .6 ~ 2 . 5 " )
T o install, follow the removal p r o c e 3. Check the transmission g e a r lu

dures in the r e v e r s e o r d e r , and after bricant .
installation, perform the following If n ecess a ry , refill the transmission
operation s. c a s e up-to the level with g e a r lu
bricant S A E - 9 0 .
1. Refill the engine with engine oil
and coolant, and also refill the 4. Tune-up the engine by re ferrin g
T o y o g lid e Automatic Tran sm ission to the Engine Tu n e-U p section.
with automatic transmission fluid
if equipped. 5. A fte r performing the engine tune-
u p, recheck if the oil level is c o r
rect, and check fo r w a te r and
oil le a k s .
EXHAUST SYSTEM
D E S C R I P T I O N ................................................. 4-1
EXHAUST P I P E ............................................. 4-4
R e m o v a l ........................................................... 4-4
Inspection ............................................... 4-5
Installation ....................................................... 4-5
M E M O R A N D U M ............................................... 4-6
EXHAUST SYSTEM - Description 4-1
D E S C R IP T IO 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 . 4-1 Exhaust System on R S 50 S e r ie s Y5847
S ile n c e r
E x h a u s t P ip e F r o n t T ail P ip e
F i g . 4-2 Exhaust System on R S 5 6 S e r ie s Y6007

4^2 EXHAUST SYSTEM - 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 . 4-4 Exhaust System on R K 4 4 S e r ie s G3121

EXHAUST SYSTEM - Description 4-3
F i g . 4-6 Exhaust System on RK171 S e r ie s G3123

4-4 EXHAUST SYSTEM - 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, tail pipe and the main
muffler.
On the R S 56 s e r ie s , the silen cer is provided behind the main muffler to prevent
the resonance of the exhaust sound.
A ls o on R K s e r ie s it consists of the exhaust pipe front, main muffler, exhaust
pipe center (R K 4 4 , 101 s e r ie s ) and the tail pipe.
T h e exhaust system on each model is of a three separated type; the front, cen
ter and the r e a r , and the different exhaust systems on the various s e ries are
illustrated through figures 4-1 to 4 -7 .
EXHAUST P IP E
Rem oval R S 50 s e r ie s and the tail pipe from

the main muffler on RS56 s e r ie s ,
On R S S e rie s and then rem ove the main muffler
on R S 50 s e r ie s and the tail pipe
1. Jack up the c a r , and support the on R S 56 s e r ie s .
c a r with stands.
4. Disconnect the exhaust pipe center
2. Disconnect the main muffler on the on R S 50 s e r ie s and the main muf
R S 5 0 s e r i e s , and the tail pipe on fle r on RS56 s e r ie s from the ex
the R S 5 6 s e r ie s from the exhaust haust pipe support.
pipe support.
5. Disconnect the exhaust pipe center
3. Disconnect the main muffler from on R S 50 s e r ie s and the main muf
the exhaust pipe center on the fle r on R S 5 6 s e r ie s from the ex-
EXHAUST SYSTEM - Exhaust Pipe 4-5
pipe front, and then rem ove the 2. Lo osen the exhaust pipe clamp,
exhaust pipe center on RS50 and rem ove the muffler.
s e r ie s , and the main muffler, on
RS56 s e r ie s . 3. Lo osen the exhaust pipe clamp,
and rem ove the exhaust pipe center
6. Rem ove the nuts retaining the from the exhaust pipe front on
exhaust pipe front flange onto the R K 4 4 , 101 s e r ie s .
exhaust manifold.
4. R em ove the nuts retaining the
7. Disconnect the exhaust pipe front flange onto the exhaust manifold,
from the exhaust pipe support and and disconnect the exhaust pipe
the support bracket, and then r e front from the exhaust pipe sup
move the exhaust pipe front. port, then rem o ve the exhaust
pipe front.
On R T 4 3 L & R T 5 2 L series
Inspection
1. Jack up the c a r , and support the
c a r with stands. T h e exhaust system must be fr e e from
leaks, binds, contacts and e x cess ive
2. Disconnect the exhaust pipe center vibration.
N o . 2 with the muffler from the Check the respective components fo r
supports. burnt condition, c ra c k s and corrosion,
If defective, replace the defective
3. L oosen the clamp, and rem ove component with the sub-assem bly.
the exhaust pipe center N o . 2 with
the muffler from the exhaust pipe Installation
center N o . 1.
Follow the removal p roce d u res in
4 . Rem ove the nuts retaining the flange the r e v e r s e o r d e r , and follow the
onto the exhaust manifold, and following precautions.
disconnect the exhaust pipe front
with the pipe center from the e x 1. When installing each components,
haust pipe support and the sup c a r e should be taken to have these
port bracket, and then rem ove parts in p r o p e r relation with each
the exhaust pipe front with the o th e r.
pipe center N o . l .
2. T h e exhaust pipes should n e v e r
On R K se rie s contact directly with the body o r
fr a m e .
1. Disconnect the tail pipe from the
supports, and loosen the exhaust 3. A ft e r starting the engine, check
pipe clamp, then rem ove the tail fo r gas leaks.
pipe from the muffler. If defective, apply a s e a le r onto
the pipe connection.
-6 MEMORANDUM
* M EM O * +
FUEL SYSTEM
D E S C R I P T I O N ................................................. 5-1
TROUBLE S H O O T IN G .............................. 5-2
C A R B U R E TO R - O n R S , RT43L,
52L s e r ie s .................... 5-4
Description ..................................................... 5-4

Construction & O p e r a tio n ............................. 5-5
R e m o v a l ........................................................... 5-13
Disassembly ................................................... 5-13
Main body ................................................... 5-13
Flange .................................................
A i r hone .....................................................
Automatic c h o k e .........................................
In spection .........................................................
A i r hone .....................................................
5-15
5-15
5-16
5-16
5-17
E
Main body i ....................................... 5-17
Flange ......................................................... 5-17
A s s e m b l y ......................................................... 5-17
Automatic c h o k e ......................................... 5-18
A i r hone ..................................................... 5-19
Flange ......................................................... 5-19
Main body ................................................... 5-20
A dju stm en t....................................................... 5-21
Float l e v e l ...................... ............................ 5-21
Secondary throttle valve
initial opening a n g l e ............................. 5-22
High speed valve stopper le v e r . . . . . . . 5-22
Fast idle ..................................................... 5-23
Unloader .............................................. . . . 5-23
Automatic c h o k e ......................................... 5-23
Idle adjusting s c r e w ............ .................... 5-24
Installation ....................................................... 5-24
C A R B U R E T O R - On R K s e r ie s .............. 5-25
Description & Construction ......................... 5-25

Removal . . . .................................................... 5-26
Disassembly .......................................... 5-29
Main body ................................................... 5-29
Flange ........................ 5-31
A i r hone ..................................................... 5—33
In sp ection ........................................ 5-31
A i r hone ..................................................... 5-31
Main body ................................................ 5-31
Flange ......................................................... 5-32
A s s e m b ly * ........................................... 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 ......................................... 5-33
Fast idle ..................................................... 5-33
High speed v a l v e ......................................... 5-34
High speed valve stopper le v e r .............. 5-34
Idle adjusting s c r e w ................ 5-34
Installation ....................................................... 5-34
FUEL F IL T E R ............................................... 5-35
Description ..................................................... 5-35

R e m o v a l ........................................................... 5-35
Disassembly ................................................ 5-35
In sp ection ........................................ 5-35
A s s e m b l y ......................................................... 5-36
Installation ...................................... 5-36
FUEL PUM P ................................. 5-36
Description .......... 5-36

R e m o v a l ........................................................... 5-38
Disassem bly ................................................ 5-38
In sp ection ......................................................... 5-38
A s s e m b l y ......................................................... 5-38
Installation ....................................................... 5-39
T e s t i n g ............................................................. 5-39
FUEL TANK& FUEL P I P E ....................... 5-40
R e m o v a l ........................................................... 5-43
In sp e ction ......................................................... 5-43
Installation ....................................................... 5-43
A IR CLEANER ............................................... 5-44
Description ..................................................... 5-44

FUEL SYSTEM - Description 5-1
D E S C R IP T IO 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.
T h e fuel tank is installed under the luggage compartment floor on the C row n
Sedan s e r ie s , and under the flo or member of the floor end on the C ro w n Wagon
s e r ie s . Th e fuel tank on the Stout and Dyna s e r ie s is installed at the left side
fram e while the Light Bus s e r ie s is provided at the right side fra m e.
T h e 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. T h e fuel p a sse s the
filter element from the outside to theinside of the element, and the fuel is filtered
to rem ove dirt o r w a te r if contained within the fuel.
T h e fuel pump produces a constant controlled fuel p r e s s u r e , and supplies the

fuel into the carburetor through the fuel pipe which is required fo r engine ope
ration .
T h e fuel delivered from the fuel pump through the fuel filter mixes with the air
drawn in from the air cleaner adequately fo r various operating conditions of the
engine by the carb u retor.
5-2 FUEL S V S T E M - Trouble Shooting
Carburetor
B e fo re diagnosing the trouble shooting of the carburetor, check the manifold

mounting bolts, cylinder compression, and the ignition system.
Symptoms & Prob a b le Causes Rem edies
1. Flood ing
a . Improper seating o r damaged D r e s s o r replace the needle valve

float needle valve and seat and seat
b . Incorrect float level Adjust float
c . Worn float tab Replace float
d. Worn float pin & related parts Replace float pin & related parts
e . Defective air-h orn gasket o r Replace gasket & tighten s c r e w s
loose attaching s c r e w s
f. Fuel pump ex c e s s iv e p ressu re Check pump disphragm spring
Rough idling
a. Incorrect idle adjustment Adjust idling

b. Defective idle adjusting s c r e w Replace idle adjusting s c r e w
c. Plugged idle pa ssa ge, idle port Clean passage & port
d. Plugged low speed jet Clean jet
e. Improper low speed jet seating Tighten jet o r replace
f. Worn throttle shaft Replace shaft
9• L o o s e vacuum pipe union Tighten union
h. Plugged econ om izer jet Clean jet
i. Improper low speed jet Tighten plug o r replace seal
passage seal
j • Defective body flange gasket Replace gasket
E x c e s s iv e fuel consumption
a . Float level too high Adjust float level

b . Plugged air bleeder Clean o r replace air bleeder
c . L o o s e plug o r jet Tighten plug o r jet
d. D efective p o w e r valve Replace p o w e r valve
e . Defective gaskets Replace gaskets
f. Vacuum leaks from p o w e r Check vacuum passage
piston vacuum passage
9- Choke valve opens improperly Check & repair automatic choke,
choke linkage & related parts
h . Clutch slippage Adjust o r replace clutch
i . D ra ggin g brake Adjust brakes
j« In co rrect tire inflation C o r r e c t tire p re s s u re
P o o r acceleration (L a c k of rich fuel mixture fo r acceleration)
a . D efective accelerating pump Replace plunger

b. Plugged pump jet Clean o r replace pump jet
c . D isch a rg e check valve operating Replace discharge check valve
improperly
FUEL SYSTEM - Trouble Shooting 5-3
d. Defective accelerator linkage Adjust linkage

e. Defective operation of p o w er Replace p o w e r piston spring
piston
f. Defective p o w e r valve Replace p o w e r valve
g. Plugged p o w e r jet Clean o r replace jet
h. Float level too low Adjust float level
i . Incorrect throttle opening Adjust throttle linkage
5. Stalling (L a c k of fuel mixture at high speed)
a. Plugged main jet Clean main jet

b . Incorrect float level Adjust float level
c . Defective operation of p o w e r Replace p o w e r piston spring
piston
d. Defective p o w e r valve Replace p o w e r valve
e . Worn throttle valve shaft Replace throttle valve shaft
f. Defective gaskets Replace gaskets
g. Incorrect throttle opening Adjust throttle linkage
6. P o o r cold weather operation
a. Improper choke operation Check related parts o r replace choke

assembly
b. Incorrect fast idle Adjust fast idle
c . Improper unloader Adjust unloader
Fuel Pump
Symptoms & Prob a b le Causes Rem edies
1. Fuel leaks from fuel pump
a. L o o s e pump c o v e r s c r e w s Tighten s c r e w s
b. Defective o r deteriorated Replace diaphragm
diaphragm
c . Defective threads of union Replace fitting/s
fitting o r cracked fitting
2. Oil leaks from fuel pump
a. L o o s e fitting of ro c k e r arm pin R ep lace pump body and pin o r replace

pump assembly
b. L o o s e fuel pump mounting Tighten attaching bolts o r replace
gasket
3. Insufficient fuel delivery
a. L o o s e fuel pipe connections Tighten connections

b. Defective diaphragm Replace diaphragm
c. Defective valves Replace va lves
d. C racked o r broken fuel pipes Replace fuel pipes
5-4 FUEL SYSTEM - 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
c . Broken o r w eak ro c k e r arm Replace spring
spring
5. E x c e s s iv e fuel delivery
Improper fuel pump spring Replace with a p ro p e r spring
C A R B U R E T O R - On R S , RT43L
& R T 5 2 L S e rie s
Description
T h e carb u retor installed on the R S 5 0 , R S 5 6 , R T 4 3 L and R T 5 2 L s e ries is a

tw o -b a r r e l type to insure efficient perform ances of the carburetor under various
operations. It is similar to two single b a rre l carb u retors built into one single
unit with special features. T h e prim ary system incorporates a double type ven
turi while the secondary system is provided with a triple type venturi. Each
system consists of the air horn, main nozzle and the throttle va lve. One set
fo rm s the prim ary while the other set form s the secondary side. T h e primary
system com poses of the low speed, high speed, p o w e r va lve, accelerating,
choke system and the thermostatic valve systems which enable to supply the
air-fuel mixture fo r normal operation. When the throttle valve is opened w ide fo r
full load o r fo r acceleration, the secondary system also operates to supply the
air-fuel mixture together with the prim ary system. T h e throttle valves of both
the prim ary and the secondary systems a r e operated with linkage, and a re inter
locked enabling the throttle va lves to wide-open positions at the same tim e. T h e
high speed valve installed in the secondary system together with the p o w e r valve
enables the perform an ces extrem ely smooth.
Specification:
Type D ow n -draft, tw o-b a rrel

Float level: at raised position 9 . 3 mm (0 . 366'
at lo w e red position 2 2 . 0 mm (0.867
A i r horn outer diameter 70 mm (2.758
P r im a r y venturi inner diameter:
main 23 mm (0.906
small 9 mm (0.355
S e c o n d a r y venturi inner diameter:
main 29 mm (1.143
la rg e 15.5 mm (0.611
small 7 mm (0.276
Throttle b o re diameter: prim ary 35 mm (1.379
secondary 35 mm (1.379
Main jet diameter: prim ary 1.06 mm (0.042
secondary 1.45 mm (0.057 on 5R
1.50 mm (0.0 59 on 3 R - B , 3 R -C
S lo w jet diameter: prim ary 0.47 mm (0.019
S lo w a ir b lee d er diameter: N o . l 0.7 mm (0.028
No. 2 1.3 mm (0.051
FUEL SYSTEM - Carburetor 5-5
Main air bleeder diameter: primary 0.5 mm (0.020 ')

secondary 0.5 mm (0.020 ')
Pump jet diameter 0.5 mm (0.020 11
P o w e r jet diameter 0.55 mm (0.022 ') on 5R
0.50 mm (0.020 ') on 3 R -
Main nozzle diameter: primary 2.8 mm (0.110 ')
Econom izer jet diameter 1.06 mm (0.042 n
Emersion hole diameter: primary 0.33 mm (0.013 ')
P o w e r valve operating vacuum 80 - 100 mmHg (3 .15 ~ 3
130-150 mmHg( 5 .12 -5.90
A c c e le r a t o r pump stroke: normal 3.5 mm (0.138 " ) 0 .4 - 0.7 cc
cold 5.0 mm (0.197 " ) 0.6 ~ 0.9 cc
Throttle valve fully closed angle:
primary 9
secondary 20 ‘
Choke valve fully closed angle 20'
Construction IV Operation
10 II 12 13 14 15 16 17
1819202122 23 24 25 26 27 28 29 30 31 32 33 34
1 . Pump p lu n g e r 13. E c o n o m ize r je t 25. S econdary bore

2. S e c o n d a r y m a in a i r b l e e d e r 14. S lo w a ir b le e d e r N o .l 26. P rim a ry bore
3. S econ dary m a in n o zzle 15. S lo w je t 27. P rim a ry th ro ttle v a lv e
4. A i r vent 16. P ow er p iston 28. Id le p o r t
5. Secondary s m a ll ven tu ri 17. S tra in e r 29. S lo w port
6 . P u m p je t 18. S econ dary m a in j e t 30. Id le a d ju stin g screw
7. Choke v a lv e 19. C heck b all re ta in e r 31. P ow er v a lv e
8. P rim a ry sm a ll ven tu ri 20. S teel b all (in le t) 32. P rim a ry m a in je t
9. A ir vent 21, Pum p d is c h a rg e w e ig h t 33. F lo a t
10. P rim a ry m a in n o zzle 22. S teel b all (o u tlet) 34. N e e d le v a lv e
11. P rim a ry m a in a ir b le e d e r 23. H igh speed v a lv e
12. S lo w a ir b lee d e r N o .2 24. S econ dary th ro ttle v a lv e
F ig . 5-2 C r o s s Sectional V ie w of C a rb u reto r Y6712

5-6 FUEL SYSTEM - 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
mostatic valve system enabling the air-fuel mixture to be supplied to the engine
as required fo r normal driving conditions.
T h e secondary bore provided with a triple venturi consists only of the high speed
system to meet the requirement for high speed, and fo r sudden acceleration.
5
1. Float chamber & air vent system
T h e float chamber s e r v e s as a
constant level fuel r e s e r v o ir . It is
n ecessary to maintain the fuel level
at a constant height re ga rd le ss of
whether small o r large amount of
fuel is being withdrawn.
T h e level gauge glass is installed

as a c o v e r fo r visual inspection
of the fuel level. T o maintain the
fuel level at a constant height, the
float chamber is provided with a F i g . 5-3 Float Chamber Y6713
float pivotted on an arm , a needle & A i r Vent
valve and a seat.
If the fuel enters into the float chamber faster than it is withdrawn into the
engine, the float (1) r is e s , 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. T h e s e
items a r e v e r y important to obtain p ro p e r perform ances of the carb u retor.
A i r vent tubes (5 ) a re provided to maintain the same air p ressu re in the

air horn, and the float chamber. This type compensates the clogging effect
of the a ir clean er.
2. Idling & low speed system
When the throttle valve is fully

closed, o r slightly opened, the
main n ozzle will not discharge any
fuel.
A s the air passing through the
venturi being v e r y slow and little
t h e re fo re , no vacuum is generated
in the venturi. F o r this reason ,
the ca rb u reto r is incorporated with
another circuit (idle and low speed
system ) to supply air-fuel mixture
during this type of operation. F ig . 5-4 Idle & L o w G1735
S peed System
T h e p r e s s u r e difference between
the float chamber and the idle port (6 ) is due to the high manifold vacuum
which fo r c e s the fuel through the idle and low speed system.
Th e fuel from the float chamber flows through the main jet, then to the slow
jet ( 1 ) , and mixes with the air from the primary air bleeder N o . l . A fte r
passing through the econom izer (2) , mixes with the air from the primary
air bleeder N o . 2 ( 3 ) , and flows down into the slow port ( 5 ) , and the idle
port (6) to be discharged in spray form into the intake manifold.
When the throttle valve (4) starts to open slightly, and as the edge of the
throttle valve moves past the slow port ( 5 ) , the intake manifold vacuum is
applied onto the slow port ( 5 ) , and this port starts discharging the air -fu<
mixture same as the fdle port (6) .
3. P r im a ry high speed system
This system is provided to supply

the air-fuel mixture for interme
diate throttle opening o r part-load
operating requirements.
Th e main nozzle (3 ) located in

the small venturi (4) supplies the
fuel mixture during the operation
with the valve partially to fully
opened position.
Passin g through the primary main
jet ( 1 ) , the fuel mixes with the F i g . 5-5 P r im a ry High G1736
air from the main air bleeder ( 2 ) , S peed System
and flows up the main n ozzle.
H e r e , the mixture is atomized, and is mixed with the air stream flowing
through the air horn.
4. S econdary high speed system
The more the engine p o w e r is de

sired , the m ore of air-fuel mix
ture is required. T h e secondary
high speed system is so deviced
to meet this requirement, and con
sists of the secondary main jet (1) ,
main air bleeder (2 ) , main nozzle
( 3 ) , small venturi ( 4 ) , secondary
throttle valve (5) , high speed valve
( 6 ) , secondary b o r e ’ (7) and the
high speed weight le v e r ( 8 ) .
F ig . 5-6 S eco n d ary High Y6714
T h e high speed valve is installed S peed System
with a balancing weight ( 9 ) , and
is retained with a nut at the end of the shaft. A s the a ccele ra to r pedal is
dep ressed, and the prim ary throttle valve opens approximately 6 0 °, the
linkage opens the secondary throttle va lve, and also both valves a r e fully
opened at the same time.
H o w e v e r , while the engine revolution is not high enough, the high speed valve
remains closed even though both valves a re fully open ed, and the secondary
high speed system remains inactive. T h is causes the air flow through the
primary venturi to quicken accomplishing a complete atomization of the fuel
and uniform distribution of the air-fuel mixture to the cylinders.
A s 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.
Low sp e e d 5 0 0 —3 2 0 0 rpm O v e r 3 2 0 0 rpm

G1356
F ig . 5-7 High Speed V alve Operation G1357, G1358
5. P o w e r system
Both systems just previously men

tioned a r e designed to deliver the
most economical air-fuel mixture .
H o w e v e r , at w ide-open throttle,
w h e re full engine p o w e r is d e
s ired , and in crease of rich fuel
mixture is requ ired. T o o b ta in th is
rich mixture, and the full engine
p o w e r , an additional device is in
corporated in this ca rb u reto r. 3 2
A t light load when the manifold v a F ig . 5-8 P o w e r System Y6715

cuum is high, the manifold vacuum
pulls up the p o w e r piston (1 ) to close the p o w e r valve ( 2 ) . A s the primary
throttle valve is opened fully, the manifold vacuum drops, and the p o w e r pis
ton is pushed down by the spring tension which opens the p o w e r v a lv e . When
the p o w e r valve opens, the fuel
flow s down being controlled through
the p o w e r jet ( 3 ) , and joints with
the fuel from the main jet. Thus
extra fuel can be discharged from
the main nozzle ( 5 ) . to V e n tu r i
6 . A c c e le ra tin g system
When the throttle valve is suddenly

opened from the closed position,
a momentary out-of-balance con fro m F lo a t
C ham ber
dition o c c u rs in the ca rb u reto r.
F ig . 5-9 A ccelera tin g G1737
To obtain an immediate engine System
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. Th is sudden change of air flow , plus
the need fo r a momentary richness of fu el, results inadequate supply of fuel
fo r acceleration from the main nozzle. T o o v e rc o m e this momentary lapse,
which could cause "flat spot" o r engine lugging, and accelerating system is
incorporated in this carburetor.
When the accelerator pedal is depressed fo r quick acceleration, the plunger

(1 ) connected to the throttle valve is pushed down into the fuel in the pump
cylinder ( 2 ) . Thus the inlet side steel ball (3) is closed, and the fuel pushes
the outlet side steel ball and the discharge weight (4) , then flows out from
the pump jet (5) to supply the rich mixture n ecessary fo r acceleration.
When the throttle is closed, the pump plunger is pulled upward so that the
pump cylinder becomes refilled with fuel, ready fo r the next acceleration
period. A ls o when the accelerator pedal is fully d ep ress ed , the p o w e r valve
opens, and the fuel is also supplied from the p o w e r system.
7. Automatic choke system
Th e automatic choke system ope

rates by the exhaust-manifold temp
erature, intake-manifold vacuum
and the air velocity with the air
h o rn .
a. Starting cold engine
T h e choke valve is adjusted to

close fully at 25 C (77 F ) , th ere
fo r e , below this temperature, the
choJ<e valve will be closed com F ig . 5-10 Automatic Choke GO 90 9
pletely . System
A s the choke valve is located in
the air horn above the primary b a rr e l, when closed, crea te s a high vacuum.
T h e vacuum causes the fuel to flow from the main fuel system, and also from
the idle and low speed system. T h is supplies a v e r y rich fuel mixture ne
c e s s a ry to operate a cold engine.
F u lly c lo s e d D u r in g w a rm in g - u p F u lly o p en ed
F ig . 5-11 Automatic Choke Operation G0910 , G 09H , G0912

5-10 FUEL SYSTEM - « 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.
b . A ft e r engine starts
A ft e r the engine starts, the vacuum acting on the vacuum piston, and the air
intake p r e s s u re exerted on the choke valve in crea se, and the choke valve
tends to open further until p ro p e r engine revolution is obtained, balancing
with the tension of the thermostatic spring.
c . A ft e r engine w a rm s up
A s the engine w a rm s up, air entering into the thermostat case is heated by
the exhaust manifold causing the thermostatic spring to expand, and d ec re a s e s
the spring tension until the choke valve opens completely.
If the throttle valve is opened suddenly during warm -up of the engine, the
choke valve will close momentarily due to d e c re a s e of vacuum in the intake
manifold to maintain a smooth acceleration of the engine.
d. Fast idle
When the carb u retor is in choked

position, the fast idle cam fo llow er
(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 r e v o
lution becom es slightly higher.
Even though the engine w a rm s up,
and the choke valve is fully opened
the fast idling is still in operation,
and in o r d e r to obtain a normal F ig . 5-12 Fast Idle G1364
idling, d ep ress the a ccele ra tor
pedal slightly to return the cam to its original position. A ls o when starting
a cold engine, it is n ecess a ry to d e p re s s the accelera tor pedal slightly to
operate the cam.
e. U nloader
When starting to drive with a cold

engine without w arm ing up the en
gine, and trying to a ccele ra te, the
choke valve has to open to a c e r
tain position, o th erw is e, the engine
wi 11 stall.
T o avoid engine from stalling, the
choke valve is so designed that it
will open 20 mechanically from
the fully closed position.
When the a c c e le ra to r pedal 'i s
d e p re s s e d , the choke shaft (3 ) F i g . 5-13 Unloader G1365
is rotated by the cam fo llo w e r (2 )
located at the sliding rod (1 ) to open the choke valve fo rce d ly .
FUEL 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 as in summer H one
season, with slow cruising, the
fuel will evaporate rapidly. Con
sequently, engine stalling, impro
p er idling and hard starting of the
engine may result. This thermo-,
static valve system eliminates these
deficiencies. Th e thermostatic valve
starts to open at 60°C (140 F ) , to C a r b u r e t o r
FI a n g e
and allows the air flow into the
intake manifold directly with full F ig . 5-14 Thermostatic G1738
opening at 75 °C (168 ° F ) . V a lv e
1. C o il h o u s in g 13 Pump a rm s ec u rin g s c r e w 25. Pump c o n n e ctin g lin k

2. C o il h ou s in g re ta in e r 14 Pum p c o n n e c t i n g li n k 26. Pow er p iston sp rin g
3. T h e r m o s t a t b im eta l 15 U n io n f it t in g 27. P o w e r p iston
4. C o il h o u sin g g a s k e t 16 S tra in er 28. A i r horn gask et
5. C o il h o u s in g p late 17 S lid in g ro d 29. N e e d le v a lv e seat
6. C h o k e shaft 18 Boot 30. N e e d le v a lv e
7. T h erm osta t case 19 C o n n ec tin g lin k 31. N e e d le v a lv e push sp rin g
8. F a s t id le c a m 20 P i s t o n p in 32. N e e d le v a lv e push p in
9. C a s e gasket 21 F a s t id le c a m s p r in g 33. F lo a t
10. P u m p le v e r 22 P iston c o n n e c to r 34. F lo a t le v e r p in
11. C h o k e va lv e 23 V a c u u m p iston
12. A ir horn 24 C o m p re s s io n s p rin g
F i g . 5-15 C a rbu retor Components on R S S e rie s N o . l Y6717

——i 2l----- F U E L SYSTEM - Carburetor
1. B od y 18. S to p p e r le v e r s e cu rin g 35. Pum p damping sprin g

2. S e c o n d a r y sm all venturi screw 36. D is c h a r g e check v a lv e
3. P r im a r y main a ir b le e d e r 19. T h ro ttle adjusting s c r e w reta in e r
4. Pum p je t s c r e w 20. T h ro ttle adjusting sp rin g 37. S te e l ball
5. P o w e r v a lv e 21. High sp eed v a lv e 38. L e v e l g a u g e gasket
6. S lo w p a s s a g e plug 22. R e ta in e r ring 39. L e v e l gau ge g la s s
7. Pum p p lu n ger 23. S e c o n d a ry throttle le v e r 40. L e v e l gau ge clamp
8. S lo w je t 24. T h ro ttle shaft link 41. Pum p je t
9. P lu n g e r guide 25. S e c o n d a ry throttle return 42. Pum p d is c h a r g e w eight
10. " O " rin g sp rin g 43. S te e l ball
11. T h e rm o s ta tic v a lv e 26. P r im a r y throttle shaft arm 44. S e c o n d a ry main jet
12. T h e r m o s ta tic v a lv e c o v e r 27. T h ro ttle le v e r c o lla r 45. P r im a r y main jet
13. " O " rin g 28. F a s t idle le v e r 46. Main p a s s a g e plug
14. High sp eed v a lv e shaft 29. F a s t idle adjusting sprin g 47. B od y flan ge gasket
15. H igh sp eed v a lv e stop p er 30. F a s t idle adjusting le v e r 4 8. S e c o n d a ry throttle shaft
le v e r 31. S e c o n d a r y throttle v a lv e 4 9. P r im a r y throttle shaft
16. H igh s p ee d v a lv e stop p er 32. P r im a r y throttle v a lv e 50. Idle adjusting s c r e w
l e v e r sp rin g 33. F la n g e
17. 11E " ring 34. Idle adjusting s c r e w sp rin g
F i g . 5-16 C a rb u re to r Components on R S S e rie s N o. 2 Y6718

Removal solvent. These removal parts

should be kept in a clean container
1. Rem ove the air clean er assembly . to facilitate the assem bly.
2. L o osen the automatic choke stove 1. R em ove the connecting link ( 1 ) .

outlet union bolt, and rem ove the
outlet from the carburetor. 2. Disconnect the connection of the
pump connecting link (2 ) and the
3 . Disconnect the carburetor fuel pipe pump le v e r ( 3 ) , then rem o ve the
and the vacuum pipe. pump connecting link.
4. Rem ove the accelerator torque rod 3. R em ove the pump arm securing
on the R S s e r ie s and the a c c e le s c r e w ( 4 ) , and then rem o ve the
rator connecting rod on the R T pump connecting link (5) with the
s e rie s . pump le v e r .
5. Disconnect the throttle link con

necting rod (only on c a r equipped
with the T oyoglide Autom atic).
6. Rem ove the four carb u retor at

taching nuts, then rem ove the c a r
buretor from the manifold.
7. Rem ove the heat insulator if ne

c e s s a ry .
Disassembly
F ig . 5-18 Removing Con- B0348
F o r disassembling and assembling the necting Links
carb u retor, the C a rb u reto r Adjust
Kit 09240-44010 on R S s e r ie s , and 4. R em ove the six securing s c r e w s ,
09240-44010 and 09240-60030 on the then rem o ve the air horn straight
R T 4 3 L and 52L s e r ie s together with upward from the body without dam
the C arbu retor S c r e w d r i v e r S et aging the float.
09860-11010 should always be utilized. S ix s c r e w s securing the air horn
P r o p e r w ren ch es with c o r r e c t sizes onto the ca rb u retor body of which
should also be used, and the rem oved one s c r e w installed above the th er
parts must be thoroughly washed with mostatic valve is sh orter than the
clean gasoline o r carb u retor cleaning other five s c r e w s , th e refo re , this
s c r e w must be installed in the same
location upon assem bly.
Main Body
I I
Ii 1I 5. Pull out the pump plunger, and

I rem o ve the pump damping spring.
I j
I 6. L o o s e n the pump jet s c r e w s ( 1 ) ,
and re m o ve the pump jet (2 ) . In
v e r t the c a rb u re to r, and re m o ve
( 0 9 2 4 0 - 4 4 0 10 ) ( 0 9 8 6 0 - 1 10 10 1
the pump discharge weight (3 ) and
the steel ball (4 ) .
F ig . 5-17 C a rbu retor Adjust B0347
Kit & S c r e w d r iv e S et 7. R em ove the two prim ary and s e -
Pow er V a lve Wrench 09860-

11010.
10. Rem ove the p o w e r jet from the

p o w e r va lve.
11. R em ove the thermostatic valve

c o v e r , and rem ove the thermo
static valve (1) and the 110 11 ring.
Do not disassemble the thermo
static v a l v e .
F ig . 5-19 Rem oving Pump B0349

Jet
condary main air bleeders ( 1 ) ,

and rem o ve the prim ary small ven
turi (2 ) and the secondary small
venturi (3 ) .
if llliI
F ig . 5-22 Removing B0352

Thermostatic V a lv e
12. Rem ove the three flange retaining

s c r e w s , and separate the body
from the flange.
One retaining s c r e w is installed
from the flange lo w e r side.
F ig . 5-20 Removing Small B0350 13. Rem ove the prim ary and secon
Venturi dary main passage plugs ( 1 ) , and
rem ove the primary and secon
8. R em ove the slow passage plug, dary main jets (2 ) with the ga s
and re m o ve the slow jet. kets .
9. R em ov e the p o w e r valve using the
F i g . 5-23 Removing Main B0353

Jet
F i g . 5-21 Rem oving P o w e r B0351
V a lv e 14. Re m ov e the discharge check valve
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.
16. Drill the calked portion of the high

speed valve securing s c r e w s (2)
with a 3 mm (0 .1 2 M) drill, and
rem ove the high speed valve by
removing these s c r e w s as shown F ig . 5-25 Disassembling B0356
in figure 5-24. Flange
17. Remove the retainer ring (3 ) , and 21. Rem ove the fast idle adjusting bolt,
rem ove the high speed valve shaft and disassemble the fast idle le v e r
(4 ). and the spring.
22. Rem ove the retainer ring, primary

throttle va lv e , then rem o ve the
throttle shaft.
A s the throttle valve securing
s c r e w s a re calked, rem ove them
after filing the calked portions of
the s c r e w s with a file.
23. Rem ove the secondary throttle le v

e r retaining nut, and re m o ve the
secondary throttle le v e r .
R em ove the secondary throttle
F ig . 5-24 Removing High B0354 valve and the shaft in the same
Speed V a lv e B0355 manner as the prim ary side.
Shaft
A i r Horn
18. Rem ove the level gauge clamp,
level gauge glass and the level 24. Pull out the float le v e r pin (1 ) ,
gauge gasket located at the float and rem ove the float (2) , valve
chamber side. push pin ( 3 ) , needle valve push
Flange
19. R em ove the idle adjusting s c r e w

(1 ) and the throttle adjusting s c r e w
( 2 ).
20. R em ove the throttle shaft link r e

taining ring (3) and the throttle
le v e r retaining nut, and then r e
move the primary throttle shaft arm
( 5 ) , fast idle le v e r , fast idle ad
justing le v e r and the throttle le v e r
collar from the throttle shaft.
spring (4) and the needle valve necting s c r e w , and rem ove the
( 5 ) , then rem o ve the needle valve choke valve and shaft in the same
seat ( 6 ) . manner as the primary throttle
v a lv e .
25. R em ove the p o w e r piston stopper
( 1 ) , then rem ove the p o w e r pis
ton (2 ) and the piston spring ( 3 ) .
F ig . 5-29 Removing Choke V4772

Shaft
F i g . 5-27 Removing P o w e r V5381 30. R em ove the fast idle cam with the
Piston spring from the choke shaft.
26 . R em ove the strainer and the union 31. T a k e out the vacuum piston with
fitting. the piston connector
Automatic Choke 32. Pull out the piston pin, and dis
assemble the vacuum piston and
27. R em ov e the three coil housing r e the connector.
taining s c r e w s , and rem ove the
coil housing, gasket and the hous 33. R em ove the thermostat ca se r e
ing plate. taining s c r e w s , and rem o ve the
When rem oving the coil housing, case and the gasket from the air
do not deform the thermostatic bi horn.
metal .
Inspection
28. R em ove the fast idle cam fo llow er
(1 ) and the sliding rod ( 2 ) . Wash all the disassembled parts tho
roughly in clean gasoline, blow the
fuel passages and the jets with com-
F i g . 5-28 Removing Sliding V4771

Rod
F i g .5-30 Cleaning Fuel B0358
29. Re m o v e the vacuum piston con- Passage
p ressed a ir, and rem ove the dirt. defective tab, and also check for
Wash the die-cast parts with a soft w e a r o r deformation of the float
brush, and wash and clean the c a r le v e r pin hole, bracket and the
bon deposits around the throttle valve. le v e r pin.
N e v e r use a w ir e fo r cleaning the
jets. 6. Check the needle valve and valve
seat fo r p r o p e r seating.
A i r Horn
7. Check the strainer fo r clog and
1. Check theair horn fo r cra c k s, rust.
s c o r e s , damaged threads and worn
shaft b o re. Main Body
2. Check the choke valve fo r defor 1. Check the body fo r c r a c k s , dam

mation, and the choke shaft fo r age on the fitting s u r fa c e s , defec
bend, twist and w e a r . tive threads and jet fitting su rfaces.
3. Check the angle between the cut 2 . Check the jets fo r defective threads
(1 ) of the coil housing and the and slot.
thermostat bimetal ( 2 ) .
A n gle specification: 84.25 at 25 C 3. Check the p o w e r valve fo r p ro p e r
(77 °C ) operation, defective threads and
If the angle is not to the above other defects.
specification, make a new cut on
the housing. 4. Check the pump plunger fo r w e a r
of the sliding surface, defective
leather and weak spring.
Flange
1. Check the flange fo r c r a c k s , dam

age of the fitting surface and d e
fective threads, and also check fo r
w e a r of the throttle shaft b o re and
damage of the idle adjusting s c r e w
seat.
2. Check fo r w e a r and deformation

F i g . 5-31 Checking V0017 of the throttle v a l v e , and check fo r
Thermostat Bimetal w e a r , bend , twist and p r o p e r ope
ration in the housing of the throttle
N e v e r bend o r length the bimetal shaft..
with a pliers.
T h e embossed mark (3) on the 3. Check the idle adjusting s c r e w fo r
coil housing does not indicate the damage of the threads and tapered
installing position but the installing portion.
direction.
A ssem bly
4. Check the p o w e r piston fo r w e a r
and for p ro p e r operation in the B e fo r e assem bly, clean each part with
housing b o re. gasoline, and always replace the g a s
A ls o check the p o w e r piston spring kets and the packings.
fo r w e a r and deformation. A ll sliding o r rotating portions should
be coated with engine oil, and be sure
5. Check the float fo r deformation and to check fo r p ro p e r operation after
a ssem b ly.
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 .
the gasket onto the air horn . T w o
crow n head and one flat head 6. Install the sliding rod into the ther
s c r e w s a r e utilized, and the flat mostat c a s e , and assemble the
head s c r e w is installed above the fast idle cam fo llow er.
vacuum piston b o re .
2. A s s e m b le the piston connector (2)

onto the vacuum piston (1 ) with
the pin ( 3 ) , and install the piston
assembly into the thermostat case
b ore.
F i g . 5-34 Assem bling V4773

Thermostat C a se &
Related P a rts
7. A ssem b le the coil housing plate,

gasket and the coil housing onto
the thermostat c a se.
F ig . 5-32 Assem bling V4004 Check the choke valve operation
Vacuum Piston V4003 b efore tightening the coil housing
retaining s c r e w . T h e choke valve
3. A s s e m b le the fast idle cam (2 ) and must be closed from the fully-open
cam spring (3 ) onto the choke ed position when the coil housing
shaft (1) , and coat engine oil onto is turned counterclockwise.
the choke shaft, then install it onto Do not damage the thermostat bi
the air horn. metal .
Align the center graduation on the
thermostat case with the cut on the
coil housing.
F i g . 5-33 A ssem blin g V4005

Choke .Shaft
4. Install the choke valve onto the F ig . 5-35 A ssem bling Coil V4774
choke shaft, and after checking for Housing
p r o p e r operation , calk the securing
s c r e w ends.
A i r Horn of the prim ary throttle va lv e .
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.
10. Install the needle valve gasket and

the needle valve seat.
11. Install the needle valve , valve push

spring and the push pin, then a s
semble the float with the le v e r pin. F i g . 5-37 Assem bling V4775
S eco n d ary Throttle Shaft
12. Adjust the float level using the
Carbu retor Adjust Kit. 14. A ssem b le the prim ary throttle shaft
T h e float raised position should onto the flange, and check the
be 9.3 mm (0 .3 6 6 11) , and the shaft thrust play which should be
low ered position should be 22 mm less than 0 .2 mm ( 0 . 0 0 8 " ) .
• (0 .8 6 7 "). If the play exceeds the above value,
select the p ro p e r shim/s as listed
b e lo w , and install the shim/s at
one and/or both side/s of the p r i
mary throttle shaft as shown in
figure 5-38.
Throttle shaft sh ims:
P a r t Number 21581-21010:
Thickness 0 .2 mm (0 .0 0 7 " )
P a r t Number 21582-21010:
Thickness 0.3 mm (0 .0 1 2 " )
P a r t Number 21583-21010:
Thickness 0.6 mm (0 .0 2 4 " )
P a r t Num ber 21584-21010:
F ig . 5-36 Adjusting Float B0359 Thickness 1.0 mm (0 .0 3 9 " )
Level
Flange
shim Shim S t°PPer
13. A ssem ble the secondary throttle
return spring onto the flan ge, then
install the secondary throttle shaft,
secondary throttle le v e r , throttle
shaft link and the secondary throt
tle va lve.
A ft e r installing the throttle va lve,
check the throttle valve fo r p rop e r
operation, then calk the throttle
valve retaining s c r e w ends. F ig . 5-38 Assem bling Shaft G1739
T h e secondary throttle valve is Shim
thicker than the prim ary throttle
v a lv e . 15. Install the prim ary throttle valve
T h e secondary throttle valve r e onto the shaft, and check fo r p r o
taining s c r e w s a r e longer than that p e r operation of the throttle v a l v e ,
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. A s s emble the fast idle adjusting with the fin gers, then sc re w it out
spring ( 2 ) , fast idle le v e r ( 3 ) , counterclockwise three turns.
s c r e w (4 ) and the throttle le v e r Do not s c r e w in the idle adjusting
collar (5) onto the fast idle ad s c r e w securely.
justing le v e r ( 1 ) .
5 2 3 1 4
F ig . 5-41 Assem bling Flange B0356
F ig . 5-39 Assem blin g Fast V4776 & Related P a rts
Idle
Main Body
17. A s s e m b le the fast idle adjusting
le v e r and the prim ary throttle shaft 21. A ss e m b le the level gauge gasket,
arm onto the prim ary throttle shaft. level gauge glass and the glass
A ft e r assembling, make sure that clamp onto the b o d y .
both throttle va lves open fully at
the same time. 22. Install the high speed shaft ( 1 ) ,
retainer ring (3 ) and the high
18. A djust the initial opening angle of speed valve (2 ) onto the body.
the secon dary throttle valve with
the throttle shaft link so that the
secon d a ry throttle valve starts to
open when the prim a ry throttle
valve is opened to 60 .
F ig . 5-42 Installing High B0361

S p eed Shaft
23. Adjust the installation of the high

speed valve to obtain the clearance
F i g . 5-40 S eco n d a ry Throttle G1740 between the valve and the b o re to
V a lv e Adjustment be 0.1 ~ 0.3 m m ( 0 . 004 ~ 0 .0 1 2 ")
at fully closed position by loosening
19. Install the throttle adjusting s c r e w . the high speed valve retaining
screw s.
A fte r adjusting the valve, check 28. Install the body onto the flange with
if the operation of the valve is the gasket.
smooth, then calk the retaining One longer bolt among the three
s c r e w ends. bolts should be installed from under
the flange.
24. Install the thermostatic va lve.
29. A ss e m b le the p o w e r jet onto the
25. A ssem b le the high speed valve p o w e r va lve, and install it into the
stopper le v e r and the stopper lev float chamber.
e r spring.
30. Install the slow jet, then install the
slow passage plug with the pack
ing.
31. Install the prim ary and the secon

dary small venturies, and secure
them with both the prim ary and the
secondary main a ir b lee d ers .
32. Insert the steel ball and the pump

discharge weight, then install the
pump jet with the packings.
F ig . 5-43 Assem bling B0362 33. Install the pump damping spring,
Stopper L e v e r plunger and the plunger guide.
26. A ssem ble both the prim ary and 34. A ss e m b le the air horn onto the
the secondary main jets with the body with the gasket.
gaskets, and install the main p a ss
age plugs. 35. A ssem b le the pump le v e r , pump
P r im a ry main jet diameter: connecting link and the fast idle
1.06 mm on R S series connecting link.
1.08 mm on R T 4 3 L , 52L s e ries T h e pump stroke can be controlled
S econdary main jet diameter: by changing the position of the pump
1.45 mm on R S s e ries connecting link in the pump l e v e r .
1.55 mm on R T 4 3 L , 52L se rie s T h e upper hole in the connecting
link is fo r normal climatic condition
27. Install the steel ball and the dis and the lo w e r hole is fo r cold cli
charge valve retainer into the pump matic condition.
cylinder using a pincers.
Adjustment
Float L e v e l
T h e float level adjustment is perform ed

by bending the float tabs, but it should
be checked by the level line of the
level gauge glass during the engine
operating at the final inspection.
1 . Raised position
Check the distance between the

F ig . 5-44 Installing Retainer B0363 end of the float and the a ir horn
with the Adjust Guage when
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.
T h is distance should be 22 mm
(0 .8 6 7 ").
T o obtain a c o rre c t clearance,
bend the tab as shown in fiqure
5-45.
S econdary Throttle V a lve

Initial Opening A n gle
F ig . 5-45 Float T a b s B0364 Hold the primary throttle valve (1)

at 30 before full-opened position us
the float is lo w e red by inverting ing the A n g le Gauge.
the air horn. A t this time, check if the throttle shaft
T h is distance should be 9.3 mm link (2) touches the extreme end of
(0 .3 6 6 "). the g r o o v e of the throttle shaft arm
T o obtain a c o r r e c t distance , bend (3) as shown in figure 5-48, and if
the tab as shown in figure 5-45. n ecessary , bend the throttle shaft link
(2 ) .
Th e secondary throttle valve (4)
[0 9 2 4 0 -4 4 0 I 0 )
should not open when this checking
is perform ed.
A ft e r adjusting the link, check the link
motion fo r smooth operation.
F ig . 5-46 Checking Raised B0359

Position
2. L o w e r e d position
Check the distance between the

F ig . 5-48 Adjusting Initial G1741
Opening A n g le
High S p eed V a lv e Stopper L e v e r
Check the clearance between the high

speed valve stopper (1 ) and the stop
p e r le v e r (2 ) when the secondary
throttle valve starts to open. ( P r i
mary throttle valve angle is at 30
[0 9 2 4 0 - 4 4 0 I 0 ) before full-opened position) .
T h e clearance should be about 0.5
mm ( 0 . 0 2 " ) .
F ig . 5-47 Checking L o w e r e d B0365 T o obtain a c o r r e c t clea ran ce, bend
Position the lip of the stopper le v e r ( 2 ) .
Gauge onto the choke v a l v e .

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
fo llo w e r (2 ) o r the choke shaft lip
(3 ) .
F ig . 5-49 Stopper L e v e r G1742

Adjustment
Fast Idle
Positioning the choke valve at fully-

closed position, adjust the fast idle
adjusting sc re w (2 ) to obtain the
clearance between the primary throttle F i g . 5-51 Unloader G1367
valve (1) and the b ore to be 0.55 Adjustment
mm (0 .0 2 2 ") on 5R model engine
using a w ire gauge which is furnished Automatic Choke
in the Carburetor Adjust Kit 09240-
44010, and on the 3 R - B , 3 R - C model T h e automatic choke should be ad
engines, this should be 1.0 mm justed to supply adequate fuel and air
(0 .040" ) with the w ir e gauge furnish mixture fo r engine starting in a c c o r d
ed in the C arbu retor Adjust Kit 09240- ance with the climatic condition.
60030 o r a suitable w ir e gauge. Th e variation of the one graduation
A t this time, the throttle valve will on the thermostat ca se is equal to
be opened at 10 on 5R model and 4 °C (7 . 2 ° F ) .
12 on 3 R - B , 3 R - C model from the T o adjust the fuel and air mixture,
fully-opened position. turn the coil housing counterclockwise
to richen the mixture, and turn the
coil housing clockw ise to lean the mix
ture .
Mark
F i g . 5-50 Fast Idle B0360

Adjustment
U nloader F ig . 5-52 Automatic Choke B0366

Adjustment
Hold the throttle valve at fully -opened
position, and install the 50° A ngle
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 .
is installed onto the engine, but fo r
pre-adjustment, s c r e w in the idle ad 2. A fter the eng.ne is warmed up,
justing s c r e w until it slightly seats, check the float level and fo r fuel
and s c r e w it out about three turns. leak, then perform the idle adju st
Do not s c r e w in the sc re w securely. ment re ferrin g to Engine Tu n e-U p
If the tapered end of the idle adju sting section. /
sc re w is damaged, a smooth idling
operation and the vacuum a r e not ob 3. If the c a r is equipped with the
tainable . Toyoglide Automatic, adjust the
throttle link connecting rod if ne
c e s s a ry by re ferrin g to the T o
yoglide Automatic R ep air Manual
96014 for R T 4 3 L 6/ R T 5 2 L series.
CARBURETOR - 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 and the components. This carburetor does not incorporate the
automatic choke system and the thermostatic valve system.
The choke system is of a manual type mechanism. When the choke valve is fully
closed, the primary throttle valve is mechanically opened to 12 from the closed
position by the starting connecting link.
B y this operation, the engine can be w arm ed up adequately without stalling.
1. N eed le valve 13. P r im a r y air bleeder

2. Float 14. S lo w jet
3. P o w e r valve 15. P o w e r piston
4. P r im a r y main jet 16. S e c o n d a r y small venturi
5. Idle adjusting s c r e w 17. S e c o n d a r y main nozzle
6. P r im a ry throttle valve 18. S e c o n d a r y main air bleeder
7. Pump jet 19. A i r vent
8. Choke valve 20. Pump valve
9. P r im a r y main nozzle 21. Pump plunger
0. P r im a r y small venturi 22. S e c o n d a r y main jet
1. P r im a r y main air bleeder 23. High speed valve
2. A i r vent 24. S e c o n d a r y throttle valve
F i g . 5-53 C ro s s Sectional V ie w of Carburetor G3139

5-26 FUEL. 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 10 mm 0.394
S e c o n d a r y venturi inner diameter:
main 28 mm 1.103
small 10 mm 0.394
Throttle b o re diameter : prim ary 32 mm 1.261
secondary 35 mm 1.379
Main jet diameter : prim ary 1.08 mm 0.043
secon dary 1.45 mm 0.057 on R K 4 4 ,101 series
1.65 mm 0.065 on RK171 series
S lo w jet diameter 0.46 mm 0.018
S lo w air bleeder diameter: N o .l 1.0 mm 0.039
N o.2 1.8 mm 0.071
Main air bleeder d ia m eter: prim ary 0.5 mm 0.020
secondary 0.4 mm 0.016
Pump jet diameter 0.52 mm 0 . 0 2 0
P o w e r jet diameter 0.60 mm 0.024 on R K 4 4 , 101 series
0.55 mm 0.022 on RK.171 series
Main nozzle diameter : prim ary 2.8 mm 0.110
secondary 2. 8 mm 0.110
S lo w econ om izer jet diameter 1.45 mm 0.057
E m ersion hole diameter : prim ary 0.5 mm 0.020 10 pcs .
0. 6 mm 0.024 4 pcs.
secon dary 0.4 mm 0.016 4 pcs .
0.6 mm 0.024 8 pcs.
P o w e r valve operating vacuum 80 ~ 100 mmHg (3 .15 ~ 3 . 94 in H g)
A c c e le r a t o r pump stroke 4 .4 mm 0.173"; 0.8 cc
Throttle valve fully-closed angle:
prim ary 7°
secon d a ry 20 °
Choke valve fully-closed angle 10°
R em oval
1. Lift the engine c o v e r with the a s and the throttle control cable from
sistant d r iv e r 's seat, and support the carburetor on the RK171 and
it with the hook belt on the RK171 the R K 1 7 1 B s e r ie s .
s e r ie s .
R em ove the engine s e r v ic e hole 4. R em ove the fuel pipe from the c a r
c o v e r on the R K 1 7 1 B s e r ie s . buretor union fitting, and rem ove
the vacuum pipe from the carbu
2. R em o v e the inlet air connector re to r fla n ge.
from the ca rb u retor.
5 . R em ove the four nuts securing the
3. R em ov e the choke control cable, carburetor onto the minifold, and
throttle control cable and the a c rem o ve the carburetor assem bly.
c ele ra to r control cable from the Do not lose the carburetor torque
carb u retor on R K 4 4 and RK101 rod sliding pieces on the RK171
s e r ie s . and R K 1 7 1 B s e r ie s .
R em o v e the choke control cable
F U E L S Y & T E M - Carburetor 5-27
2 3 4 5 6
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. P o w e r valve
3. Snap ring 15. Pump passage plug 27. S lo w jet
4. Pump arm 16. P ump plunger 28. S lo w air bleeder jet
5. Pump arm link 17. Pump weight 29. Main air bleeder jet
6. W ire clamp 18. S teel ball 30. Small venturi
7. Union bolt 19. S tra in er clip 31. V e n t u r i gasket
8. Union 20. Pump strainer 32. Main body
9. Strainer 21. L e v e l gauge packing 33. P r im a r y main jet
0. N eedle valve seat 22. L e v e l glass 34. Main jet plug
1. N eedle seat shim 23. L e v e l gauge clamp
2. Dust c o ver 24. Gauge glass gasket
F i g . 5-54 Carburetor Components on RK101 S e r i e s N o . l Y7289

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

2. Throttle shaft link w a s h e r 18. " E " snap ring
3. Cotter pin 19. Flange gasket
4. Snap ring 20. Insulator
5. S to p p er le v e r spring 21 . Starting connecting link
6. Throttle le v e r return spring 22. Idle adjusting s c r e w
7. Snap ring 23. Flange
8. S e c o n d a r y throttle le v e r 24. Idle acfjusting s c r e w spring
9. Throttle le v e r w a s h e r 25. S lo w passage gasket
10. Throttle le v e r retaining s c r e w 26. S lo w passage plug
11. Throttle shaft link 27. Throttle adjusting s c r e w
12. P r i m a r y throttle shaft arm 28. Throttle adjusting s c r e w spring
13. Lock washer 29. Starting throttle le v e r
14. Throttle le v e r retaining nut 30. Flange retaining s c r e w
15. Pump connecting link w a s h e r 31. L o c k w a sh er
16. Pump connecting link spring 32. Pump connecting link
F i g . 5-55 C arbu retor Components on RK101 S e r i e s N o . 2 Y7290

F U E L , S Y S T E M - Carburetor 5-29
Disassembly air horn and the cable holder on

the RK101 s e r ie s and the spring
F o r disassembling and assembling the hanger on the RK171 s e r ie s .
c a rb u reto r, the Carburetor Adjust
Kit 09240-40021 and the Carburetor Main Body
S c r e w d r i v e r S e t 09860-11010 should
always be utilized. 3 . Rem ove the pump plunger by pull
P r o p e r w renches with co rrect sizes ing out upward, and then rem o ve
should be u sed, and the removed the strainer clip (1 ) , pump strain
parts must be thoroughly washed with e r ( 2 ) and the steel ball (3 ) us
clean gasoline o r carburetor cleaning ing a s c r e w d r i v e r .
solvent.
T h ese removed parts should be kept
in a clean container to facilitate the
assem bly.
09240-4002 I 09860-1 I'010
F ig . 5-58 Removing S teel V5269

Ball
R em ove the prim a ry main air

F i g . 5-56 Carburetor Adjust V5258 bleeder (1 ) and the secon d a ry
Kit & S c r e w d r iv e r S et main air bleeder ( 2 ) , and rem o ve
the prim ary small venturi (4 ) and
Disconnect the choke connecting the secondary small venturi (5 )
link ( l ) and the pump connecting by removing the retaining s c r e w s
link (2) , and rem ove the snap ring (3 ).
retaining the pump arm (3 ) , then
rem ove the pump arm with the
connecting link.
F i g . 5-59 R e m o v in g A ir V5260
B le e d e r & Small Venturi
F i g . 5-57 Removing V5259 5. R em ove the slow jet ( l ) , slow air

Connecting Link bleed jet ( 2 ) , pump valve plug
( 3 ) , weight ( 4 ) , steel ball (5 )
2. R em ove the three s c r e w s retain and the pump jet plug ( 6 ) .
ing the air horn, and rem ove the
ing the float level gauge glass

clamp, and rem ove the 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

the G ro o ved S c r e w d r i v e r , then
rem o ve the p o w er jet from the
p o w er va lve.
9. R em ove the main jet plug ( 1 ) ,

and rem ove the prim ary main jet
( 2 ) , and also rem ove the secon
F i g . 5-60 Removing Jets V5261 d a ry main jet ( 3 ) .
& Plugs
6. R em ove the union bolt (8 ) with the

gasket, union fitting ( 7 ) , strainer
(6 ) and the needle seat ( 5 ) , then
re m o ve the needle seat gasket
shims ( 4 ) , needle valve ( 3 ) , spring
(2 ) and the needle valve pushpin
( 1) .
F i g . 5-63 Removing Main V0546

Jet
10. R em ove the high speed stopper

le v e r spring ( l ) from the fla n ge,
and rem ove the three s c r e w s (2 )
retaining the main body onto the
flange, then separate the body,
insulator and the flange.
F ig . 5-61 R emoving N eedle V5262 One retaining s c r e w is installed
V a lv e & Related P a rts from the flange bottom side.
7. R em ov e the three s c r e w s retain-
11—Grooved S c re w d riv e r
F ig 5-64 Disassembling V5264

Main Body
F i g . 5-62 Removing P o w e r V5263
Va lv e 11. If necessary, re mo ve the high
F U E L S Y S T E M - Carburetor 5-31
speed v a l v e , valve shaft and the 16 . R em ove the vacuum piston by pull
high speed valve stopper lever ing out straight fo r w a r d using a
from the insulator by removing the pliers .
retaining s c r e w s and the retaining
r in g .
T h e retaining s c r e w s of the high
speed va lve, choke va lve, both
primary and secondary throttle
valves a re secured with an ad
h esive, therefore, if these s c r e w s
a re rem oved, calk the s c r e w ends
to prevent from loosening after
the valves a re assembled.
Flange
12. Rem ove the idle adjusting s c r e w F i g . 5-66 Removing Vacuum V5270
( l ) with the spring and the slow Piston
passage plug ( 2 ) .
17. If n e c e s s a r y , re m o ve the choke
valve retaining s c r e w s , and then
rem ove the choke va lve shaft and
the spring.
Inspection
Wash all the disassembled parts tho

roughly in clean gasolin e, blow the
fuel passages and the jets with com
p r essed a ir, and rem ove the dirt.
Wash the die-cast parts with a soft
brush, and wash and clean the c a r
F ig . 5-65 Disassembling V5265 bon deposits around the throttle valve .
Flange N e v e r use a w i r e fo r cleaning the
je ts .
13. Rem ove the cotter pin (3 ) retain Check the following items, and if d e
ing the throttle le v e r link, and r e fective, rep a ir o r replace as n e c e s
move the throttle shaft arm retain sary .
ing nut (4 ) , then rem ove the throt
tle shaft arm (5 ) and the starting A i r Horn
throttle le v e r ( 6 ) .
1. Check the air horn fo r c r a c k s ,
14. If n e c e s s a ry , rem ove the throttle s c o r e s and deformation.
valve retaining s c r e w s , and r e
move the prim ary throttle valve 2. Check the choke va lve fo r p ro p e r
and the shaft. operation o r e x c e s s iv e play.
15. If n e c e s s a r y , rem ove the secon 3. Check the p o w e r piston fo r w e a r

dary throttle shaft arm and the r e and fo r p roper operation.
turn spring , and rem ove the throt
tle valve retaining s c r e w s , then Main Body
rem o ve the secondary throttle valve
and the shaft. 4. Check the body fo r c r a c k s , dam
age on the fitting s u r fa c e , defective
A i r Horn threads and the jet fitting surface .
5-32 FUEL, 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 . Check the p o w e r valve fo r proper w e a r of the throttle shaft b o re and
operation, defective threads and damage of the idle adjusting s c r e w
other defects . s e a t.
11 . Check the throttle valve and shaft

for p roper operation and fo r ex
cessive play, and also check the
related links , arms and the springs
fo r w e a r and deformation.
12. Check the idle adjusting s c r e w for

damage of the threads and the
tapered end.
A ssem b ly
F ig . 5-67 P o w e r V a lv e V5266 F o llo w the disassembly procedu res

& P o w e r Piston in the r e v e r s e o r d e r .
S pecial c a re should be taken on the
7. Check the float fo r defective tab following items upon assembly and
and w o rn pin hole, and also check adjustment.
the float le v e r bracket and the float
le v e r pin fo r w e a r and deformation. 1. A lw a y s rep la ce the gaskets or
packings upon assembly.
8. Check the needle valve and the
v a lve seat fo r p ro p e r seating, and 2. B e fo r e assem bling, clean each part
also check the strainer fo r clog with gasoline.
and rust.
3. A ll sliding o r rotating portion
9. Check the pump plunger fo r de should be coated with engine oil,
fective leather and dust c o v e r , and and be checked fo r p ro p e r ope
also fo r w ea k spring. A l s o check ration after assem bly.
fo r rusty o r clogged strainer and
the steel ball fo r rust. 4. A s the prim ary and secon d a ry
main jet diameters a r e different,
n e v e r install the w ro n g o n e .
T h e prim ary main jet diameter is
sm aller than the secon d a ry main
jet, and also the sec on d a ry main
jet is plated.
5. A ls o do not install the main air

b leed er w ro n g ly .
T h e prim ary main air bleeder is
longer than the secon d a ry main
air b l e e d e r , and also the diameter
of the p rim a ry main air bleeder is
F i g . 5-68 Pump Plu n ger V5267 la r g e r than the secon d a ry main
Components air b le e d e r.
Flan ge 6 . If the ch o k e , high s p e e d , prim ary

and the secon dary throttle valves
a re r e m o v e d , check if these valves (0 . 0 3 11) by the variation of one

a re co rrectly operating after the gasket shim,
assembly, and then calk the valve
retaining s c r e w ends to prevent
them from loosening.
Adjustment
Float L e v e l
Check the float level at lo w e red posi

tion with the Adjust Kit Gauge as
F i g . 5-71 Adjusting Fuel V5271

Level
S e c o n d a r y Throttle V a lv e
Initial Opening A n g le
Position the prim a ry throttle valve at

30° before fully-opened position using
the A n g le Gauge. A t this time , check
if the throttle shaft link end ( a ) touches
the extreme end of the g r o o v e (b )
F i g . 5-69 Checking Float G3140 as shown in figure 5-72, and if n e
at L o w e r e d Position c e s s a r y , bend the throttle shaft link.
T h e secon d a ry throttle va lve should
If n e c e s s a r y , adjust the float level by not open when this checking is p e r
bending the float tabs as shown in fo rm ed .
figure 5-70.
A n g le G auge
a b
F i g . 5-72 Adjusting Initial G3141

F i g . 5-70 Adjusting Float V5268 Opening A n g le
T abs
Fa st Idle
T h e adjustment of the fuel level is
perform ed in relation to the fuel level S et the prim ary throttle va lve so that
in the float chamber with the level it starts to open by the throttle valve
gauge line alignment, by adding o r adjusting s c r e w , and then position the
decreasing the needle seat gasket choke valve at fully—closed position.
shims . A t this tim e, the throttle va lve should
T h e fuel level will v a r y about 0. 7 mm be opened to 12° from fu lly-closed
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, and if n ecess a ry , Check if the high speed valve stopper
adjust the throttle valve opening le v e r begins detaching the high speed
angle by bending o r extending the valve shaft just before the start of the
starting connecting link ( 1 ) . secondary throttle valve opening.
If n e c e s s a r y , adjust the detaching
motion of the high speed valve stopper
le v e r by bending the lip of the primary
throttle arm .
Idle Adjusting S c r e w
T h e idle adjusting sc re w should be

co rrectly adjusted after the carburetor
is installed onto the engine, but as
pre-adjustment, sc re w in the idle ad
justing s c r e w with the fin gers until it
slightly seats, and sc re w out about
F i g . 5-73 Adjusting Fast G3142 two and a half turns.
Idle Do not screw in the sc re w securely.
If the tapered end of the adjusting
High Speed V a lv e sc r e w is damaged, a smooth idling
speed and a c o r r e c t vacuum connot
Install the insulator with the high speed be obtained.
valve onto the flange.
Adjust the installation of the high speed In stallation
va lve to obtain the clearan ce between
the va lve and the b o re to be 0.6 mm 1 . Follow the removal p roce d u res in
( 0 . 0 2 4 " ) using the W ire Gauge by the r e v e r s e o r d e r .
loosening the high speed valve retain
ing s c r e w s . 2. A ft e r the engine is w arm ed up,
A ft e r adjusting the va lv e , check if the check the float level and fo r fuel
operation of the va lve is smooth, then leak, then perform the idle adju st-
calk the retaining s c r e w ends. ment re fe rr in g to Engine Tu ne-U p
section.
W ir e G a u g e
0-6 m m (0 0 2 4 ")
F ig . 5-74 Adjusting High Y7294

S peed V a lv e
FUEL S Y S T E M - Fuel Filter. 5-35
FUEL F IL T E R
F ig . 5-75 C r o s s Sectional V ie w of Fuel Filter G1733
Description
T h e fuel filter s e r v e s to prevent the carb uretor from clogging and rusting by
filtering the particles of dirt o r w ater which may be contained within the fuel.
T h is filter is a replaceable type, and consists of a filter body, glass bowl and
the element.
Th e glass bowl is provided to settle heavy dirt and w a te r, while the filter e le
ment filters the light particles 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 perform a n ces
will be impaired.
A t frequent intervals, disassemble, and rem ove the element, then clean with
clean gasoline.
Removal Lo osen the filter bowl bail nut, and

rem o ve the filter bow l, spring, e le
1 . Disconnect the inlet and outlet hoses ment and the gasket.
from the union fitting of the filter.
In spection
2. Rem ove the fuel filter assembly
from the support by removing the Wash all the parts with clean gasoline.
filter retaining nut.
1. If the element is defective o r e x
Disassembly cessively dirty, replace the e le
ment .
5~36 FUEL SYSTEM - 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
reverse order.
A ssembly A ft e r installation, operate the engine,
and check fo r fuel leak.
Position the new gasket, element and
the spring c o rr e c tly , and assemble
the bowl and the bowl bail, then tight
en the bail nut s e c u r e ly .
FUEL PUM P
I n l e t V a lv e
O u t l e t V a lv e
fro m F u e l to C a rb u re to r
S tra in e r
D ia p h ra g m
P ul I R od
R o c k e r A rm
F ig . 5-76 C r o s s Sectional V ie w of Fuel Pump G1774
Description
T h e fuel pump is of a diaphragm type, and is composed of the inlet and outlet
v a lv e s , diaphragm, r o c k e r a rm , upper and lo w e r bodies.
T h e rotational motion of the camshaft actuates the r o c k e r arm which m turn con
v e r t s into the reciprocation of the diaphragm.
T h is diaphragm movement d r a w s the fuel into the pump, and also delivers out
the fuel with specified p r e s s u re and volume to meet the requirement of the en
gine through the ca rb u reto r.
T h e operation and the construction of the fuel pump on 3 R - B , 3 R - C and 5R
model engines a r e the same, but the components a r e slightly different. Th e fuel
pump on the 3 R - B and 3 R - C is not provided with the manual le v e r .
FUEL SYSTEM - Fuel Pump 5-37
Specification:
T yp e Diaphragm
D elivery capacity at 2,500 rpm 1.6 liters/min (1 .7 U S qts/min.,
of cam shaft 1.4 Imp. qts/min.)
D elivery pressu re 0 .2 ~ 0.3 kg/cm2 (2.84 ~ 4 . 27 psi)
Vacuum -400 mmHg (15.7 inHg)
1. Fuel pump c o v e r
2. Fuel pump c o v e r gasket
3. Pump upper body
4. Fitting
5. V a lv e packing
6. V alve
7. V a lv e retainer
8. Diaphragm
9. Diaphragm spring
10. Oil seal spring retainer
11 . Oil seal packing
12. Oil seal packing retainer
13. Pump lo w e r body
14. R o c k e r arm spring
15. R o c k e r arm
16. R o c k e r arm pin
17. R o c k e r arm link
18. Insulator
F ig . 5-77 Fuel Pump Components on 5R Y6711

5-38 FUEL SYSTEM - 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. Check the spring fo r weakness
and co rrosio n .
2. R em ove the pump retaining bolts,
then rem o ve the pump assembly. 5. Check the ro c k e r arm , link and
the pin fo r w e a r .
Di sa ssembly
A ssembly
1 . R em ove the upper body retaining
s c r e w s , and rem ove the upper A l w a y s replace the gaskets with the
body from the lo w e r body. new gaskets upon assembly.
2. R em ove the valve retainer retain 1 . P la c e the ro ck er arm and the link
ing s c r e w s , and rem ove the r e into the lo w e r body , and hold them
tainer, va lves and the packings. in place.
3 . R em ove the pump c o v e r retaining 2. Install the ro c k e r arm pin from the
s c r e w s , and rem ove the pump none-serration side of the pin , and
c o v e r and the gasket from the up install the ro c k e r arm spring onto
p e r body. the ro c k e r arm locator on the
ro c k e r arm .
4. P r e s s down the diaphragm into the
pump lo w e r body , and unhook the 3. In stall the oil seal packing retainer ,
diaphragm rod from the ro c k e r oil seal packing, oil seal spring
arm link, then rem ove the dia retainer on 5R only and the dia
phragm from the lo w e r body. phragm spring onto the lo w e r body.
5. R em ov e the spring, oil seal spring 4. Install the diaphragm and hold it
retainer on the 5R o n ly , oil seal in the pump lo w e r body , then hook
packing and the oil seal packing the diaphragm rod onto the ro ck e r
r e t a in e r . arm link.
6. D r iv e out the r o c k e r arm pin to 5. Install the c o v e r with the gasket
w a r d s the serration using a blunt onto the upper body.
punch, then re m o ve the ro ck e r
a rm , link and the r o c k e r arm 6. Install the packing and the valves
s p rin g . co rrectly into the upper body as
shown in figure 5-78 , and secure
In spection
Wash all the parts in clean gasoline,

and blow the p a ssa g e with com
p re s s e d a ir.
Check the following items, and if d e
fec tiv e, rep la ce a s n e c e s s a r y .
1. C heck the c o v e r and the body fo r

c r a c k s , defective threads and worn
pin h oles.
2. Check the diaphragm fo r tear and

w orn pull rod . F i g . 5-78 Positioning Inlet V4768
Outlet V a lv e s
FUEL SYSTEM - 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,
7. A ssem ble the upper body onto the and connect a p ressu re gauge onto
lo w er body insuring that all se the pump outlet fitting.
curing s c r e w s pass through the
holes in the diaphragm without
tearing the fabric, then tighten the
s c r e w s evenly and securely.
8. Check the pump fo r p rop e r ope

ration .
In stallation
Follow the removal p roce d u res in the

reverse order.
A lw a y s replace the gaskets with the
new gaskets. F ig . 5-79 Testing D e liv e ry V4769
A fte r installation, operate the engine, Pressu re
and check fo r fuel and oil leaks.
2. Operate the engine, and m easure
the pump delivery p r e s s u r e .
If the p re s s u re does not meet the
specified p r e s s u r e , replace the
diaphragm spring.
D elivery pressu re:
0 . 2~0.3 kg/cm2 (2 .8 4 -4 .2 7 psi)
5-40 FUEL SYSTEM - Fuel Tank & Fuel Pipe
FUEL TANK & FUEL P IP E
1 . Fuel hose
2 . Fuel pipe
3 . Fuel tank set packing
4
5
6
7
8
F ig . 5-80 Fuel Tank & Fuel Pipe Components on R S 5 0 S e r ie s G3125
1. Fuel hose
2. Fuel pipe
3. Fuel sender gauge
4. B r e a th e r tube
5. Tank vent chamber
6. Fuel tank
7. Drain plug
8 . Tank silencer pad
9. Tank set packing
10. Inlet joint hose
11. Inlet upper pipe
12. Fuel tank cap
F i g . 5-81 Fuel Tank & Fuel Pipe Components on RS 56 S e r i e s Y7291

FUEL SYSTEM - Fuel Tank &Fuel Pipe 5-41
1. Fuel front pipe

2. Joint hose
3. Fuel r e a r pipe
4. Fuel pipe protector
6. Drain plug
7. Fuel tank
8. Cap chain
9. Fuel tank cap
Y 7292
F ig . 5-82 Fuel Tank & Fuel Pipe Components on R T 4 3 L & R T 5 2 L S e i r e s
3 4 5 6
1 Fuel hose
.
2; Tank bracket 7. Drain plug
3. Union bolt 8. Fuel tank
4. Fuel tank cap 9. Tank bracket
5. B reather hose
F i g .5-83 Fuel Tank & Pipe Components on RK101 G3126

5-42 FUEL SYSTEM - Fuel Tank & Fuel Pipe
1. Fuel hose 7. Tank upper band

2. Fuel tank 8. Plug gasket
3. Fuel sender gauge 9. Drain plug
4. Fuel sender gauge gasket 10. Fuel tank cap
5. Union bolt 11. B reather hose
6. Tank bracket 12. Tank lo w e r band
F ig . 5-84 Fuel Tank & Fuel Tank Components on RK171 Y7293
Fuel Tank Removal 2. R em ove the spare tire.
On R S 5 0 S e r i e s 3. Rem ove the fuel tank drain plug,

and drain the fuel, then rem ove
1 . R em ove the fuel tank sender gauge the inlet joint hose retaining plate.
c o v e r , and disconnect the gauge
w ire . 4. R em ov e the fuel sender gauge
c o v e r , and disconnect the gauge
2. R em ove the fuel tank c a p . w ire .
3. R em ove the drain plug, and drain 5. Disconnect the fuel hose from the
the fuel from the fuel tank, then tank, and disconnect the breather
disconnect the fuel hose from the lo w e r tubes from the breather pipe
tank. of the body side.
4 . R em ove the fuel tank band retain 6. Disconnect the exhaust pipe sup
ing nuts, and rem o ve the fuel tank port N o . 3 from the fram e, then
bands, then re m o v e the fuel tank rem o ve the fuel tank assembly
assembly . from the b o d y .
On R S 56 S e rie s On R T 4 3 L & R T 5 2 L S e r i e s
1 . R em o v e the r e a r body inside c o v 1 . R em ove the drain plug from the

e r L H , and disconnect the inlet tank, and drain the fuel.
joint hose from the fuel suction
pipe. 2. Disconnect the fuel hose from the
FUEL SYSTEM - Fuel Tank &1 Fuel Pipe 5-43
tank. 2. Rem ove the fuel hose union bolt

with the gaskets, and disconnect
3. Rem ove the fuel sender gauge the sender gauge w ir e from the
c o v e r , and disconnect the gauge gauge.
w ire .
3. Rem ove the fuel tank band retain
4. Rem ove the tank c a p , and rem ove ing bolts, and rem ove the fuel tank
the inlet pipe shield from the tank a ssem b ly.
suction pipe.
In spection
5. Rem ove the fuel tank retaining
bolts, and rem ove the fuel tank 1. Inspect the fuel tank fo r c r a c k s ,
a ssem bly. corrosion and leak.
If any defect is present, rep a ir o r
NOTE: replace as n e c e s s a r y .
A s the fuel tank upper panel acts
as a floor of the c a r , also use a 2. Check the fuel hose o r pipe and
sealer with w a ter resistance, non unions, and if defective, replace
drying qualities between the body as n e c e s s a ry .
and the installing surface of the
tank to prevent w a ter entering into 3. Water and dust accumulation in the
the r e a r compartment. fuel tank will cause malfunction of
the ca rb u retor, fuel filter o r the
On RK101 S e r ie s fuel pump.
If the accumulation of sediment in
1. Rem ove the drain plug from the the fuel tank and the fuel filter is
tank, and drain the fuel. e x c e s s iv e , the fuel tank should be
removed and flushed, and the fuel
2. Rem ove the fuel hose union bolt pipe should be blown out.
with the gaskets, and disconnect
the sender gauge w ire from the Installation On A ll Models
gauge.
Follow the removal p ro c e d u re s in the
3. Rem ove the fuel tank retaining reverse order.
bolts from the bracket, and r e Fuel lines must be securely fastened
move the fuel tank assembly. in position with the clamps, and all
connections should be tightened se
On RK171 S e r i e s curely .
T o prevent fuel leak, use a liquid
1. Rem ove the drain plug from the sealer with fuel-proof qualitie,® fo r the
tank, and drain the fuel. installing surface of the sender gauge
if n e c e s s a r y .
5-44 FUEL SYSTEM - A i r Cleen^r
A IR 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.
Th e air cleaner element equipped on the R S and R T s e ries is of the felt element
type, and the element equipped on the R K s e ries is of a paper element type
which a re treated with special resin.
T h e felt element is made up of a rough meshed material filter fo r the outside

and with a fine meshed material fo r the inner side, th erefore, the dust will be
accumulated not only <by the outside material, but also by the inner material.
T h is filteration efficiency is increased compared with the conventional filter typ e,
and at the same time, the draft resistance against the dust accumulation is not
affected. M o r e o v e r , as the filter material is made of synthetic fiber, the element
is washable with soft soap and clean water o r clean gasoline.
T o maintain p r o p e r operation of the engine and the efficiency of the air c le a n e r,

it is essential that the air cleaner is cleaned, and the element is replaced at
regu lar intervals. T h e air cleaner should be cleaned at e v e ry 5,000 kilos o r
3,000 miles on all models, and the element should be replaced at ev e ry 30,000
kilos o r 18,000 miles on the felt element type and 20,000 kilos o r 12,000 miles
on the paper element type.
T h e construction of these air clea n ers a re as shown in the following illustrations.

Disassem bly of the air cleaner is self-explanatory, and the assembly p rocedu res
a r e equally simple.
Instruction T ip s on Felt Element T y p e
1. F o r cleaning the element with com pressed a ir, blow out from the inside to
w a r d s the outside with low p re s s u re a ir.
2. If the element is spoiled with oil o r fat, washwith a soft soap o r clean ga so
line, and dry it thoroughly.
It is recommended that the washing of the element should be perform ed only
t h r ic e .
3. N e v e r w ash the element with a cleaning solvent except with clean gasoline.
4. If the element is w ashed, it may discolor, but the filteration efficiency will
not be affected.
. „ I
Instruction T i p s on P a p e r Element T y p e
1.
n ■
F o r cleaning the element with com pressed a ir, follow the sa me p roced u res
on the felt element type a s p rescrib ed above.
2. D o not wash the element with any solvent o r soap and w a te r.

If the element is ex cess ively dirty, replace the element.
FUEL SYSTEM - A ir Cleaner 5-45
1. Wing nut
2. S e a l w a sh er
3. A i r cleaner cap
4. Cap gasket
5. Element gasket
6. A i r cleaner element
7. A i r cleaner case
8. Case gasket
9. Clamp
10. Clamp bolt
F ig . 5-85 A ir Cleaner Components on R S S e r ie s G3127
1. Wing nut
2. S e a l w a sh er
4. Element gasket
5. Cap gasket
8. Case gasket
9. Clamp
10. Clamp bolt
9 10
F i g . 5-86 A i r Cleaner Components on R T 4 3 L & R T 5 2 L S e r i e s G3128
5-46 FUEL SYSTEM - A i r Cleaner
2. A i r cleaner hose
3. Intake air connector
4. Clamp
5. Connector gasket
6. C lamp bolt
7. Cap gasket
8. Element gasket
F ig . 5-87 A i r C lean er Components on RK101 S e r i e s G3129
1. Connector Gasket
2. Clamp
3. Clamp bolt
4. Intake air connector
5. A i r clea n er hose
6. A i r clea n er cap
7. Cap gasket
8. A i r clean er element
9. Element gasket
10. A i r clean er ca se
11. C le a n er hose N o . 2
12. C le a n er inlet N o . 2
F i g . 5-88 A i r Cle aner Components on RK171 S e r i e s G3130

LU BRICATING SYSTEM
D E S C R I P T I O N ............................................. . 6-1
O IL P U M P ........................................................ 6-2
Description ..................................................... 6-2

R e m o v a l .......................................................... 6-3
Disassembly ................................................ 6-4
Inspection & R e p a i r ...................................... 6-4
A s s e m b l y ........................................................ 6-5
Installation ................ 6-5
O IL F I L T E R .................................................... 6-5
Description .................................................... 6-6

R e m o v a l ...................... j ................................... 6-7
Disassembly ................................................... 6-7
Inspection......................................................... 6-7
A s s e m b l y ......................................................... 6-7
Installation ....................................................... 6-7
Oil Filter Element R e p la c e m e n t .................. 6-8
LU BRICATING SYSTEM - Description 6-1
D E S C R IP T IO 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
cating circuit is as shown in the above illustration.
T h e high p ressu re oil discharged from the oil pump enters into the oil filter,
and the oil is delivered into the oil hole within the cylinder after the oil is fully
filtered by the oil cleaner element.
Th e oil reaching the oil hole separates into three different w a y s ; engine front,
center and r e a r sections, and the oil flows separately into two w a ys again fo r
lubricating the crankshaft bearings and the camshaft b e a r in g s .
Th e 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 connecting rod fo r the 3 R - B and 3 R - C , a
lubrication hole is provided inside the connecting rod from the bearing end to
the piston pin e n d .
A part of the oil which lubricated the camshaft N o . l bearing is d elivered to the
camshaft N o . 2 bearing. Th e rest of the oil travels through theoil hole in the cyl
inder block and the cylinder head to the valve ro c k e r support N o . l , which lu
bricates the valve ro c k e r shaft, and then flow s out of the r o c k e r a rm s.
6-2 L U B R IC A T IN G SYSTEM - 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
is engaged with the camshaft. T h e r e fo r e , the d elivery quantity of the oil pump
will in crea se in proportion to the engine revolution.
When the engine is running at high revolution, the oil p ressu re will increase
above the specified p r e s s u re . F o r this re a s o n , the oil pump is provided witfK
a relief va lve in the oil pump c o v e r to regulate the oil p re s s u re .
F i g . 6-3 Relief V a lv e Operation G1705

LU BRICATING S Y S T E M - Oil Pump 6-3
The construction of the oil pump andthe operation of the relief valve a re as
shown in the illustration figure 6-2 and 6-3.
The oil drawn in from the strainer is delivered to the oil filter by the a r r o w
mark shown in the figure.
The delivery pressu re becomes to 3.7 4.3 kg/cm2 (52.8 — 61.4 psi) in r e
lation to the increase of the engine revolution, which opens the relief v a l v e , and
the oil will be by-passed from the outlet side into the inlet side to keep the above
specified p r e s s u r e .
Specification :
Type T rochoid
D elivery quantity: More than 2 liters (2 .1 U S q ts . , or
at oil temperature 100° C (212° F ) 1.7 Imp. qts) per minute at 300 rpm
at oil pressu re 2.8 ~ 3.2 kg/cm2 M ore than 22 liters (2 3 .3 U S q t s . ,
(40 — 50 psi) or 19.4 Imp. qts) per minute at
Testing oil S A E 30 2,500 rpm
Relief valve operating pressu re : Starts to open at 3.7 ~ 4.3 kg/cm2
at oil temperature 100° C (212° F ) (5 2 .8 ~ 61.4 p s i )
at 2,500 rpm D elivery quantity z e r o at 5.5 ~ 6.5
kg/cm2 (78.1 ~ 92.3 psi)
1. Plane w a sh er
2. Oil pump body
3. Oil pump c o ver gasket
4. Oil pump shaft
5. Oil pump drive rotor
6. Oil pump drive rotor pin
7. Oil pump driven rotor
8. Oil pump c o v e r
9. Oil strainer
10. Relief valve plug
11. Relief valve gasket
12. R elief valve spring
13. Relief valve
14. Union
15. Ball sleeve
16. Union nut
17. Oil pump outlet pipe
F i g . 6-4 Oil Pump Components Y6172
Removal 2. R em ove the oil pan.
1. Drain the engine oil. 3. Disconnect the oil pump outlet pipe .
L=4 L U BRICATIN G SYSTF.M - Oil P,.™p
4. R em ov e the oil pump assembly 0.12 mm (0.0026 ~ 0 .0047" ) , and

with the strainer. if the clearance exceeds 0.2 mm
( 0 . 0 0 8 " ) , replace the rotors as
Disassembly a set.
1. R em ove the oil s tr a in e r .
2. R em ove the relief valve plug from

the oil pump c o v e r , then takeout
the spring and the relief va lve.
3. R em ove the oil pump c o v e r .
4. R em ove the driven rotor ( l ) and

the oil pump shaft (2 ) with the
drive rotor (3 ) .
F i g . 6-6 Checking T ip V4658

Clearance
4. Inspect the side clearance between

the rotor and the installing surface
of the c o v e r .
T h e clearance should be 0.03 to
0.07 mm (0.0012 ~ 0 .0 0 2 7 " ).
( 0 . 0 0 6 " ) , replace the rotor and/
o r the c o v e r .
F i g . 6-5 Disassembling Oil V4657

Pump
Inspection & Rep air
Wash all parts in cleaning solvent, L im it 0 . 15mm

and check the following items. (0 -00 6 )
1 . Check the oil pump shaft fo r e x

c e s s iv e w e a r and s c o r e s .
If n e c e s s a r y , replace the shaft.
2. Check the drive rotor and the F i g . 6-7 Checking S id e V4659

driven rotor fo r e x c e s s iv e w e a r Clearance
and s c o r e s . If defective, replace
the ro to rs as a set. 5 . Inspect the body clearance between
D r iv e ro to r diameter is 29.70 to the driven rotor (1 ) and the body
29.74 mm (1.1 69 ~ 1 . 1 7 1 " ) . ( 2 ).
D riven ro to r diameter is 40.53 to T h e clearance should be 0.10 to
40.56 mm (1.595 - 1 .5 9 7 ") . 0.16 mm (.0.004 ~ 0 . 0 0 6 " ) .
3. Inspect the tip clearan ce between ( 0 . 0 0 8 " ) , replace the body o r the
the d rive ro tor (1 ) and the driven rotor s e t .
ro to r (2 ) .
T h e clearan ce should be 0.07 to 6 . Check the relief valve fo r proper
LUBRICATING S Y S T E M - Oil Pump, Oil Filter 6=5
7. 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.
A ssem bly
Follow the disassembly procedu res

in the r e v e r s e o r d e r .
L im it 0.2mm Installation
(0 .0 0 8 )
1. Install the oil pump into the cyl
F i g . 6-8 Checking Body V4660 inder block, and tighten the bolt
Clearance to 1.5 — 2.0 m-kg (11.0 ~ 15.0
ft-lb) torque.
fit, oil passage fo r clog, and the
sliding surface for s c o r e s . If de 2. Connect the outlet pipe, and tighten
fective , replace the relief v a l v e . the union nut sec u rely .
A ls o check the valve spring for
weakness and dam age, and r e 3. Install the oil pan with the new
place as n e c e s s a ry . gasket, and tighten the bolts to
Relief V alve Spring Specification : 0.4 - 0.6 m-kg ( 2 . 9 - 4 . 3 ft-lb)
F r e e length - 47 mm (1 . 8 5 " ) torq u e.
Installed length - 36 . 8 mm ( 1 . 4 5 " )
Installed load - 5.99 ~ 6.59 kg 4. Fill the engine oil to specified
(1 3 .2 ~ 14.6 lbs) le v e l.
O IL F I L T E R
L i f t e r V alve
Oil F i l te r C a p
In le t (fro m Oil P u m p )
O u tle t
Oil F i l te r E le m e n t
( t o C y lin d e r B lo ck Oil H ole)
Oil F i l te r C a s e
D ra in P lu g
F i g . 6-9 C ro s s Sectional V ie w of Oil Filter Y6173

6-6 LU BRICATING 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. If the element is clogged, the oil line p ressu re beyond the e le
ment will d e c re a s e by the resistance of the clogged element. T o prevent this,
the oil cleaner is provided with a lifter valve at the filter cap.
Th e difference of the oil p re s s u re between the 'element inlet side and the outlet
side becomes 0.8 ~ 1.2 kg/cm2 (1 1 .4 ~ 17.1 p s i), and the lifter valve starts
to open counteracting against the relief valve spring by the inlet side p r e s s u r e ,
which causes the oil to b y -p a ss. In this manner, the oil from the pump is de
livered to the hole within the cylinder block directly without filtering the o il, and
without decreasin g the oil line p r e s s u re .
S pecification:
Type P a p e r element
Case capacity Approximately 0 .8 liter (0.85 US
qts . , or 0.7 Imp . qts )
Filtering a re a Approximately 2,650 cm2 (410 in2 )
Lifter valve operating p r e s s u r e :
at oil temperature 70 — 75° C Starts to open at 0.8 ™ 1.2 kg/cm2
(158 ~ 167° F ) (11.4 m 17.1 p s i)
Using oil S A E 30
Oil leak L e s s than 0 .2 liter (0.21 U S q t s .,
or 0.18 Imp. qts) per minute at 0.7
kg/cm2 (9 .9 psi)
1. V a lv e retaining bolt
2. Gasket
3. Lifter valve spring
4. W asher
5. L ifter valve
6. Oil filter gasket
7. Oil filter cap
8. Oil filter body gasket
9. Cartridge guide gasket
10. Oil filter element
11. Oil filter case
12. W asher
13. Filter support spring
14. Gasket
15. Drain plug
16 . Cartridge guide gasket
17 . Cartridge guide
F i g . 6-10 Oil Filter Components Y6174

LU BRIC ATIN G SYSTEM - Oil Filter <o=l
Removal A ssem bly
Rem ove the three attaching bolts , and Follow the disassembly p rocedu res
rem ove the oil filter assembly from in the r e v e r s e o r d e r with the fo llow
the cylinder block. ing precautions.
Disassembly 1. A lw a y s replace the gasket upon

assem b ly.
1. R em ove the valve retaining bolt
(1 ) , and take out the relief valve 2. B e sure to install the body gasket
spring ( 2 ) , gasket (3 ) and the with the chamfered side upward.
lifter valve (4 ) .
F i g . 6-12 Installing B ody G1707

F i g . 6-11 Removing Lifter V4661 Gasket
V a lve
3. A ssem b le the oil filter case so
Z e r o to three w a sh e rs (5 ) are that the drain plug will be positioned
installed between the spring and in parallel with the engine block
the lifter va lve. Do not lose them and towards the r e a r .
as these w a sh ers a re to adjust the
lifter valve opening p r e s s u r e .
2. Rem ove the oil filter cartridge

guide, then disassemble the oil
filter c a p , element and the c a s e .
Inspection
Wash the disassembled parts with the

cleaning solvent. Drain Plug
1. Check the element, and replace

it if it is ex cess ively dirty o r dam F i g . 6-13 Installing Oil V4662
aged . F ilter Case
2 . Check the filter cap and the case . 4. Tighten the oil filter cartridge guide
If these are distorted o r dam aged, to specified torque of 1.0 - 1.5
replace as n e c e s s a r y . m-kg (7 .5 - 11.0 f t - lb ) .
3. Check the lifter valve fo r fitting Installation

condition and s c o r e s on the sliding
surface. Replace if damaged. 1. Install the oil filter assembly with
6-8 LU B R IC ATIN G S Y S T E M - Oil Filter
the new gasket onto the cylinder 2. Lo osen the oil filter cartridge
block, and tighten the bolts to 1.0 guide, and rem ove the filter case
to 1.5 m-kg (7 .5 ~ 11.0 ft - lb ) with the cartridge guide.
to r q u e .
3. Clean the case and the cartridge
2. Fill the engine oil up-to the speci guide, and install the new element
fied l e v e l. at c o r r e c t position , and then tighten
the cartridge guide to 1.0 ~ 1.5
3. Start the engine, and check fo r m-kg (7 .5 ~ 11.0 ft - lb ).
oil leak from the filter.
4. Fill the engine oil up-to the spe
Oil Filter Element Replacement cified level.
1 . R em o v e the drain plug from the 5. Start the engine, and check fo r
filter c a s e , and drain the engine oil leak from the filter.
o il. A ft e r checking the oil leak, check
the oil level again.
COOLING SYSTEM
D E S C R I P T I O N ................................................ 7-1
W ATER P U M P ................................................ 7-2
Description .................................................... 7-2

R e m o v a l .......................................................... 7-4
Disassembly ............ ...................................... 7-5
Fluid c o u p lin g ............................................. 7-5
Water p u m p ................................................. 7-5
Inspection........................................ .. 7-6
Fluid c o u p lin g ............................................. 7-6
Water p u m p ................................................. 7-6
A s s e m b l y ................ ........................................ 7-6
Water p u m p ................................................. 7-6
Fluid c o u p lin g ............................................ 7-7
Installation ....................................................... 7-7
THERM OSTAT ............................................... 7-8
Description ..................................................... 7-8

R e m o v a l ....................................................... 7-8
In spection ......................................................... 7-8
Installation ....................................................... 7-9
R A D IA T O R ....................................................... 7-9
Description ..................................................... 7-9

R e m o v a l ........................................ 7-10
Inspection ......................................................... 7-10
Installation ....................................................... 7-10
1 1
COOLING S Y S T E M - Description 7-1
D E S C R IP T IO N
T h e rm o sta t W a te r P u m p B y -p a ss H ose W a te r P ip e
R a d ia to r Fan R a d ia to r H o s e W a te r J a c k e t
F ig . 7-1 Engine Cooling S ystem Y6175
Th e cooling system on the 5 R , 3 R - B and 3 R - C engines is of a p ressu re fo rc e d

circulation insuring positive cooling efficiency.
Th e construction of the cooling system and the circulation of the coolant a re

shown in the above illustration.
The coolant is pumped out from the lo w e r tank of the ra d ia to r, and is fo rce d ly
circulated within the w ater jackets provided in the engine. A t this tim e, the
majority of the coolant is directly delivered to the w a ter pipe located within the
cylinder head to cool the surrounding of the combustion chambers w h e r e the
engine heats up to the highest temperature during the engine operation. T h e
balance is delivered to the cylinder block through the by-pass h ose, and is c i r
culated from the cylinder wall to the cylinder head. T h e coolant which has been
heated is returned into the upper tank of the radiator through the thermostat.
If the coolant temperature is lo w , and the thermostat is closed, the coolant is

pumped out from the thermostat chamber and the cylinder block through the b y
pass hose (this is r e v e r s e flow when the thermostat is open ed) , and is d elivered
into the w ater pipe.
——2----- C O O L I N G—b Y S T E M - Trouble Shooting. Water Pumn
Symptoms & P robable Causes Remedies
1 . Overheating
a. L a ck of coolant Replenish, and check for leaks

b. L o o s e fan belt Adjust fan belt tension
c. Oil soaked fan belt Replace fan belt '
d. Defective thermost Replace thermostat
e. Water pump inoperative Repair o r replace w ater pump
f. Clogged cooling system Clean radiator, and w ater jacket
g. In co rrect ignition timing Adjust ignition timing
h. B ra k e dragging Adjust brakes
2. O vercooling
a . Therm ostat defective Replace thermostat

b . E x trem ely s e v e r e climate C o v e r part of radiator co re
3. L o s s of coolant
a. L e a k y radiator R ep air o r replace radiator

b . L o o s e o r damaged hose Tighten connections o r replace hose
connection
c . L e a k y w a te r pump Rep air o r replace w a ter pump
d. L o o s e heater hose connection Tighten connection or replace hose
o r damaged hose
e . L e a k y cylinder head gasket Tighten bolts evenly and securely
f . C racked cylinder head o r block R ep air o r replace as n ecessary
4. N o is y cooling system
a. Defective w a ter pump bearing Replace w a ter pump bearing

b . L o o s e o r bent fan blades Tighten, rep a ir o r replace fan blades
c. Defective fan belt Replace fan belt
W ATER PUM P
Description
T h e w a te r pump equipped on 5R en

gine is of a direct driven fan type for
stable cooling effect under ex c e s s iv e
heavy load operation, but on 5R en
gine equipped with the To yo glide A u
tomatic transmission and R T 4 3 L ,
5 2 L which is equipped with 3 R - B
and 3 R - C is of a fluid coupling type
which minimizes the p o w e r loss at
high speed operation.
T h e fluid coupling consists of the coup
ling case , coupling rotor , fluid coup F ig . 7-2 D irect D riven T y p e G1708
ling bea rin g , bearing c a s e , silicone Water
oil and the pulley seat. Pump Section
COOLING S Y S T E M - Water Pump 7-3
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 seat by calking the
pulley seat end. T h e r e fo r e , the rotor
and the related parts of the fluid coup
ling cannot be disassembled.
The fluid coupling case is filled with
silicone oil, and owing to this o il, the
fan is driven almost at the same r e
volution with the pulley when the en
gine is operated at comparatively low
speed, but as the rotational resistance
of the fan increases at engine high
speed operation, the slippage occurs
in the coupling. Then the fan revolu
tion does not increase excess ively,
and this not only avoid the unnecessary F ig . 7-3 C ros s Sectional G3131
engine pow er lo s s , but also d ec rea ses V ie w of
the fan n o is e . Fluid Coupling
Th e water pump body is constructed with the thermostat ch a m ber, and the rotor
is of a centrifugal type having six blade^s. T h e advantages are as fo llo w s ; it is
compact, the delivery quantity is la rg e , and even though the outlet port is made
sm aller, the pressu re will not in crea se , th erefo re, it is quite convenient to p e r
form the temperature adjustment.
1. Water pump rotor

2. Stud bolt
3. Stud bolt
4. Thermostat guide plate
5. Water pump body
6. Water pump gasket
7. T a p e r s c r e w plug
8. Fan pulley
9. Pulley seat
10. Water pump bearing
11 . Water pump c o v e r
12. Gasket
13. Pump seal set
F ig . 7-4 Water Pump Components fo r D irect D riven T y p e Y6176
Specification:
Type Centrifugal with six blades

D elivery quantity M ore than 70 liters (18 .5 U S gals . ,
15.4 Imp. g a ls ) per minute in the lift
7-4 COOLING 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 :
Fluid Silicone oil
V i scosity
3000 cst 10,000 cst ( R T 4 3 L C - A )
Q uantity 11 - 12 cc
1. Therm ostat guide plate

2. Water pump body
3. Fluid coupling assembly
4. Water pump bearing
5. Water pump c o v e r
6. Pump seal set
7. Water pump rotor
F i g . 7-5 Water Pump Components for Fluid Coupling T y p e G3132
Rem oval bolts, and rem ove the w ater pump

a ssem b ly.
For RS s e rie s :
F o r R T 4 3 L and 52L s e r ie s :
1. Drain the coolant.
2. R em o v e the inlet and the outlet
hoses from the radiator and the b y 2. R em ove the radiator inlet and out
pass h o s e . let hoses and the by-pass hose.
3. L o o s e n the fan belt tension, and 3. R em ove the fan shroud, and r e
re m o v e the fan and the fan belt. move the fa n .
4. R em o v e the fuel pipe clamp from 4. Lo o se n the fan belt tension, and
the w a te r outlet. rem ove the belt.
5. R em o v e the w a ter pump retaining 5. Lo osen the air pump drive belt
COOLING S Y S T E M - Water Pump 7-5
tension, and rem ove the belt. T o rem ove the pulley with the fluid
coupling bearing case from the
6. Rem ove the air pump idle pulley w ater pump bearing shaft, use a
bracket. bolt with the thread diameter of
10 mm, thread length of 30 mm
7. Rem ove the water pump retaining and thread pitch of 1.25.
bolts , then rem ove the water pump S c r e w in the bolt into the pulley,
assem bly. and rem ove the pulley with the
fluid coupling bea_ring case from
F o r R K s e r ie s : the water pump bearing shaft.
1. Drain the coolant. Water Pump
2. R em ove the radiator outlet and inlet 1. Rem ove the water outlet, and r e
hoses and the by-pass h o s e . move the thermostat.
3. L oosen the fan belt tension, and 2. Rem ove the w ater pump c o v e r
rem ove the belt. from the w ater pump body fo r the
direct drive ty p e .
4. Rem ove the fan and the fan pulley.
3. Rem ove the w ater pump pulley
5. Rem ove the water pump retaining seat from the w ater pump bearing
bolts, then rem ove the w ater pump shaft using the Water Pump Rotor
assem bly. Puller 09239-40010 for the direct
drive ty p e .
Disassembly
Fluid Coupling
1. Rem ove the w ater pump c o ver

from the water pump body.
2. Rem ove the fluid coupling case

from the fluid coupling bearing
case.
3. P la c e the fluid coupling pulley in

a vise protecting the pulley with
a suitable m aterial. Do not deform F ig . 7-7 Removing Pulley V4663
the pulley when securing in a vise . Seat
D ia m e te r tOmm
L e n g th 30 mm
P itc h \ . 25
F i g . 7-6 Removing Bearing G3133 F i g . 7-8 Removing Rotor V4644

Case
7—6 CO O LING 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 the fluid coupling bearing,
and a p r e s s . bearing case and the pulley fo r w e a r
and damage, and if defective, replace
5. R em ove the hole snap ring (1) the fluid coupling assembly.
from the rotor ( 3 ) , and rem ove
the w a te r pump seal set ( 2 ) . Water Pump
1 . Inspect each part of the water

pump fo r c r a c k s , w e a r and dam
a g e . If defective, replace as ne
c e s s a ry .
Check the hole snap ring g r o o v e ,

thrust w a sh e r (1 ) and the floating
seat (2 ) . If defective, replace it
using the w ater pump rotor kit.
F i g . 7-9 Rem oving S ea l V4646
6 . Heat the w a te r pump c o v e r to ap

proximately 80 °C (176 ° F ) , then
p r e s s out the w a te r pump bearing
assembly from the c o v e r using the
Water Pump B e a rin g R e m o v e r &
R e p la c e r 09238-40010 and a press.
D o not re m o ve the bearing unless
f o r replacement.
F i g . 7-11 R o tor & Pump V0012
C o v e r Inspection
3. Check the pump c o v e r fo r defec

tive installing portion (3 ) of the
floating seat and fo r looseness of
the bearing. If defective, replace
it with the w a te r pump rotor sub-
09238-40010 assembly .
4. Check the bearing fo r w e a r , rough

n e ss, s c o r e s and abnormal n o is e .
If defective, replace the bearing.
F i g . 7-10 Rem oving B e a rin g V4645
A ssem b ly
7. R e m o v e the floating seat and the
gasket from the w a te r pump c o v e r . Water Pump
Inspection 1. Install the gasket and the floating

seat into the pump c o v e r .
Wash all parts except the fluid coup
ling, w a te r pump bearing and the 2. Heat the w a te r pump c o v e r to ap
w a te r pump shaft rubber parts in proximately 80°C (176 F ) , then
cleaning solvent. p r e s s in the bearing assembly into
C O O L I N G S Y S T E M - Water Pump 7-7
the pump c o v e r until the bearing 4. Coat the w a te r pump g r e a s e onto

end is flush with the upper end the surface of the floating seat and
of the c o v e r as shown in figure the thrust w a s h e r, and then p r e s s
7-13 using the Water Pump B e a r in the rotor onto the bearing shaft
ing R em o v er & R ep lacer 09238- until the rotor end surface and the
40010. bearing shaft end surface a r e flush.
A t this time, the measurement from
the rotor end to the c o v e r end
should be 33 mm ( 1 . 3 0 " ) .
5. Install the w ater pump pulley seat

fo r the direct driven type onto the
bearing shaft.
6. Install the w a te r pump c o v e r onto

the w a ter pump body so that the
w a ter drain hole provided on the
c o v e r will be tow ards the lo w e r
side, and confirm that the ro tor
F ig . 7-12 Installing Bearing V4647 is not contacting with the body,
If these a r e contacting, adjust the
clearance between the rotor end
surface and the body by increasing
B e a rin g
the pump c o v e r gasket.
Th e specified clea ran ce should be
0 .3 ~ 0.7 mm (0.012 - 0 . 0 2 8 " ) .
Pum p C over 8 . Install the thermostat and the w a te r

s '
outlet.
Fluid Coupling
1. P r e s s in the pulley with the fluid

F ig . 7-13 B earin g Installing GO 845 coupling bearing ca se onto the
Position bearing shaft until it sto p s.
3. Install the w ater pump seal set into 2. Install the fluid coupling ca se with
the r o t o r . the new gasket, and fill with the
silicone oil.
—
W SKMMM § mm mm
Installation
M M ■
Follow the rem oval p roced u res in the
r e v e r s e o r d e r following the described
aiMMPW precautions.
1. A l w a y s replace the gasket.
M U H H •H ■
—
Ho h m SB
2. Adjust the fan belt tension to 13
to 20 mm (0 .5 ~ 0 . 8 " ) when de
p r essed at midway of the belt with
F ig . 7-14 R otor Installing V4648 11 kg (24 l b s ) .
Measurement
3. Start the engine after installation,
and check fo r w a te r leak.
7—8 CO O LING S Y S T E M — Thermostat
THERM OSTAT
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 .
T h e thermostat is installed within the thermostat chamber of the water pump,

which restricts the coolant flow into the radiator. Th u s, the engine warm-up
period is minimized, and maintains engine economical operating temperature.
T h e w ax type thermostat has the following excellent features.
1. A s it is not affected by w a ter p r e s s u re , it ensures positive operation, and

w a te r leak is slight when the valve is closed.
2. A s the w a te r flow resistance is small on the thermostat, the w a ter flow into
the radiator is la r g e .
3. T h e construction is v e r y durable, and the life of the thermostat is prolonged

due to no valve vibration.
4. It is heat-proof, co ld -p roo f and p r e s s u re -p ro o f.
Specification:
F o r R S & R T s e r ie s F o r R K series
Type Wax Bellows
Starts to open at 80.5 ~ 8 3 . 5 °C 63.5 ~ 6 6 . 5 °C
(177 ~ 1 8 2 °F ) (146 ~ 151 ° F )
Fully opens at 95°C ( 2 0 3 ° F ) 73°C (1 9 4 ° F )
V a lv e lift 8 mm (0.315" ) 8 mm (0.315" )
S h a ft
W ax C a s e
W ax
C lo s e d G1690
F ig . 7-15 Wax T y p e Therm ostat Operation G1500
Rem oval Inspection
1. Drain the coolant, a n d rem o ve the 1., R ep lace the thermostat if the valve
w a te r pump outlet h ose. is opened at normal tem perature.
2. R em ove the w a te r outlet, and then 2. S u b m erge the thermostat into the
re m o v e the thermostat. w a te r , and raise the w a ter temp
erature gradually to check the
valve opening tem perature.
COOLING S Y S T E M - Thermostat. Radiator 7-9
T h e valve should start to open at and at 73°C (1 9 4 ° F ) fo r R K

80.5 ~ 8 3 .5 °C (177 ~ 1 8 2 °F ) fo r s e r ie s , and the valve lift is more
R S and R T s e r ie s , and at 63.5 than 8 mm (0 . 315" ) , the thermo
to 6 6 .5 °C (146 — 151 F ) f o r R K stat is satisfactory.
s e rie s .
If the valve is fully opened at 95 C Installation
(203° F ) fo r R S and R T s e r ie s .
Follow the removal p rocedu res in the
R A D IA T O R reverse order.
Description
T h e radiator equipped on R K s e r ie s is of a plate fin and tube type, and the

corrugated fin and tube type is equipped on the R S and R T s e r ie s .
On the c a r equipped with the Toyoglide Automatic transmission, an oil co ole r

is provided at the radiator lo w e r tank to cool the automatic transmission fluid.
A s the radiator is of the p r e s s u re type, the radiator cap is provided with r e

lief valves to maintain the p re s s u re of approximately 0 ~ 0.5 kg/cm 2 (0 ~ 7
p si) within the cooling system.
When the p ressu re within the radiator increases above 0.5 kg/cm2 (7 p si) the
p r e s s u re relief valve allows the p re s s u re to escape through the o v e r -flo w p ip e .
When the p r e s s u re d e c re a s e s lo w e r than atomospheric p r e s s u re as the coolant
is cooled, the vacuum relief valve allows the outside a ir to enter preventing the
formation of vacuum within the radiator.
On the p ressu re type radiator, the coolant will not boil even though the coolant
temperature reaches 100 C (212 F ) , t h e r e fo r e , to maintain this excellent cooling
efficiency, it is essential that the relief valves operate p r o p e rly .
V acuum R e lie f V a lv e O p e r a tio n P r e s s u r e R e lie f V alve O p e r a tio n
G1110
F i g . 7-16 C r o s s Sectional V ie w of Radiator Cap GIJU1
Specification:
R S s e r ie s R S 4 3 L & R T 5 2 s e r ie s
Type P r e s s u r e cooling same
C o r e type Corrugated fin & tube same
Radiation 340 Kcal/min same
V a lv e opening 0.5 kg/cm2 same
pressu re (7 psi)
Coolant capacity 2.6 liters (2.7 4 U S q t s ., 2.9 liters (3.0 5 U S qts.
2.28 Imp. q t s .) 2 .55 Imp. q ts . )
Weight 6 .4 kg (141 lbs) 5.8 kg (12.7 lbs)
7-10 COOLING S Y S T E M - Radiator
r<lv4^, lU i series R K 1 7 1 , 176 series

Type P r e s s u r e cooling same
C o r e type Plate fin & tube same
Radiation 330 Kcal/min 305 Kcal/min
V a lv e opening 0 .5 kg/cm2 same
p r e s s u re (7 psi)
Coolant capacity 3 liters (3.1 5 U S qts. 5 . liters (5.25 U S qts,
2 .64 Imp . qts. ) 4 .40 Imp . qts . )
Weight 7.8 kg (17.2 lbs) 11.0 kg (24.4 lbs)
Removal 2 . R em ove the radiator inlet and out

let hoses.
For R S, RK44 & 101 s e ries
3. Rem ove the radiator wind guide.
4. R em ove the three radiator support
2 , Disconnect the flexible hoses of the retaining bolts, and rem ove the
automatic transmission fluid oil radiator assembly with the fan
c o o le r from the radiator, (only on shroud and the radiator support
c a r equipped with T o yo glid e Auto from underneath the vehicle.
matic tran sm ission ).
5. R em ove the fan shroud and the
3 . R em ove the radiator inlet and out radiator support from the radiator.
let h oses.
Inspection
4. R em o v e the radiator assembly with
the fan sh ro u d . 1 . Inspect the radiator fo r leaks from
the upper tank, lo w e r tank and the
5. R em ov e the fan shroud from the c o r e . Rep air if n e cess a ry .
ra d ia to r.
2. Inspect the radiator c o re fin fo r
F o r R T 4 3 L & 52L s e r ie s clogging the air p a ssa ges. If ne
c e s s a r y , repair the fins.
1 . D rain the coolant.
3 . If the clog of the radiator c o re ex
2 . Disconnect the flexible hoses of the ceeds 20 percent of the entire
automatic transmission fluid oil a r e a , replace the radiator assem
c o o le r from the radiator, (only on bly .
c a r equipped with Toyoglide A u to
matic tra n sm ission ). 4. Check the radiator cap p ressu re
relief valve and the vacuum relief
3 . R em o v e the radiator inlet and out valve springs fo r p ro p e r tension,
let h oses. and also check the packing fo r
dam age. Replace if n e c e s s a r y .
4. R em o v e the fan shroud from the
radiator, and then re m o ve the r a Installation
diator a s s e m b ly .
Follow the removal p rocedu res in the
F o r R K 1 71, 176 & f7 1 B s e r ie s r e v e r s e o r d e r on the respective s e ries
and after installation, check fo r water
1. Drain the coolant. le a k .
CHARGING S Y S T E M
D E S C R I P T I O N ................................................. 8-1
A L T E R N A T O R & R E G U L A T O R .............. 8-3
Construction .................................................. 8-3

O p e r a tio n .............................. 8-5
Inspection in C a r .......................................... 8-6
ALTERNATOR ............................................... 8-8
R e m o v a l ........................................................... 8-8
Disassembly .................................................. 8-8
Inspection & R e p a i r ••• 8-10
B earing ....................................................... 8-10
Rotor ........................................................... 8-10
S t a t o r .............. ............................................ 8-10
Brush & Brush h o l d e r .............. * ............ 8-11
R e c t i f i e r ....................................................... 8-12
A s s e m b l y ......................................................... 8-12
A ltern ator Output T e s t .................. .............. 8-13
Installation .......................................................
R E G U L A T O R ......................................
R em oval,..................................................
8-14
8-14
8-14
E
Electrical Adjustment ................................... 8-14
Voltage relay ............................................. 8-14
Voltage regulator ..................................... 8-14
Regulator Circuit T e s t ................................. 8-15
Inspection & Mechanical A d ju s t m e n t .......... 8-16
Voltage relay ............................ 8-16
Voltage r e g u l a t o r ........................... 8-17
Installation ........ . .......................... 8-17
M E M O R A N D U M ............................................... 8-18
C H A R G I N G S Y S T E M - Description 8-1
D E S C R IP T IO 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

which is the sou rce of electric p o w e r , and also to supply electric p o w e r to other
electrical equipment in place of the battery when the engine is operated.
T h e charging system consists of the alternator and the alternator re gu la to r, and

the wiring diagram is as shown in the above illustration. T h e p r o p e r operation
of the charging system can be checked with the ammeter and the ch arge warning
light equipped on the R S s e r ie s , and also by the charging warning light equipped
on the R T and R K s e r ie s .
T h e alternator has the following excellent features in comparision with the con
ventional D C generator.
1. It provides a v e r y high output at cruising speeds and also at lo w e r engine

revolution.
2. Since the alternator uses the silicone diodes fo r rectification, there is no

increase of temperature due to the rectification sparks compared with the
D C gene rato r .
A ls o as the slip ring of the alternator is not used fo r rectification, the brush
life is longer in the alternator.
3. T h e maximum revolution of the alternator is rather restricted by the mecha

nical conditions of the ball bearings, centrifugal fo r c e of the rotor and the
fan belt than the electrical conditions. T h e r e fo r e , the alternator can be op
8-2 CH ARG ING 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.
4. A s the alternator has a self-limiting characteristic in limiting the output, and

by utilizing the diodes fo r rectification, current control such as a cut-out
relay and a current limiter is not required fo r the alternator.
T h e functioning of the alternator regulator in the charging system is to regulate

the alternator output voltage to a p r e -s e t value.
Symptoms & Prob a b le Causes Remedies
1. Battery discharges
a. L o o s e o r w orn fan belt Adjust o r replace fan belt

b. Shorted o r opened stator coil Replace stator
c. Opened rotor coil R eplace rotor
d. P o o r contact between brushes Clean o r replace brushes
and slip rings
e. D efective rectifier/s Replace rectifier/s
f. Regulator voltage adjusted too Adjust regulator
low
g. Burnt o r p o o r contact of r e D r e s s points o r replace regulator
gulator low speed points
h. Melted regulator high speed Replace regulator
points
i. L a c k o r insufficient electrolyte Replenish with distilled w a ter o r ad
just specific gravity
j . Shorted battery plates Replace battery
k . P o o r connection of battery Clean and tighten terminals
terminals
1. Opened o r p o or connection of R ep a ir o r replace w iring
w irin g between ignition switch
and regulator "IG " terminal
m. Burnt o r p o o r contact of fuse Replace fuse o r clean fuse holder
n. Opened o r p o o r connection of R ep a ir o r replace w irin g
w irin g between regulator 11F 11
terminal and alternator 11F 11
terminal
o . E x c e s s iv e current load Recheck current draw
2. Battery o v e r ch a rg e s
a. P o o r contact of regulator 11F " R ep air contact

terminal
b . Opened p r e s s u r e coil of voltage Replace regulator
regulator
c . Melted regulator low speed Replace regulator
points
d . P o o r contact of regulator high D r e s s points
speed points
CHARGING S Y S T E M - Trouble Shooting. Alternator & Regulator 8-3
e. Regulator voltage adjusted too high Adjust regulator

f. Opened o r poor connection of R ep air o r replace wiring
wiring between alternator " N "
terminal and regulator " N "
terminal
3. Defective actuation of charge warning light o r defective ammeter operation,
a . L o o s e fan belt Adjust fan belt tension

b. L o o s e wiring connections Tighten o r repair connections
c . Defective regulator operation Adjust o r replace regulator
4. A ltern ator noisy
a . Defective bearing/s Replace bearing/s

b . Malfunction of rectifier/s Replace rectifier/s
c . Grounded o r shorted stator coil Replace stator
ALTE R N A TO R & REGULATOR
Construction
F i g . 8-2 C r o s s Sectional V ie w of A ltern ator Y5118
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
fiers and the fra m e s .
T h e rotor consists of two s ix -fin g e r e d , cup-shaped h a lv e s , which when a ssem
bled become a 12-pole ro to r.
8-4 CHARGING S Y S T E M - Alternator &1 Regulator
A 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.
T h e stator is composed of a large number of windings assembled on the inside
of a laminated c o r e that is attached to the fram es. T h e stator coil is of a three-
phase " Y " type. A n alternating current generated at the stator coil is converted
to a direct current by the six rectifiers which a re mounted at the rectifier holders.
T h e rectifier is of a silicone diode which has a v e r y high resistance to a flow
of current in one direction, but it has a v e r y low resistance in the other d ire c
tion . T h e r e f o r e , with a p ro p e r polarity, the low resistance allows the current
to flow from the stator Coil to the battery, and the high resistance prevents a
r e v e r s e current from the battery. M o re o v e r, the stator coil has a self-limiting
characteristic in- limiting the current flow in its coil to a p r e -s e t value even the
revolution in crea ses exceedingly. F o r these reason s, a current control such as
a cut-out relay and a current limiter a re not required fo r the alternator.
T h e alternator regulator is composed of the voltage regulator and the voltage

r e l a y . T h e function of the voltage regulator in the charging system is to regu
late the generating voltage of the stator coil to a p r e -s e t value controlling the
exciting current of the rotor coil.
T h e voltage relay is provided to prevent the flickering of the headlights and the
irr e g u la r vibration of the ammeter needle when the engine is operated at idle
revolution.
Specification:
RS. R T 4 3 L . 52L & R K 171B s e r ie s
A lte rn a to r P a r t N o . 27020-21011
Voltage 12 volts
Maximum output current at 14 volts 40 am peres
under heated condition
N o load revolution at 14 volts 820 rp m
P e r m is s ib le maximum revolution 12,000 rpm
A llo w a b le surrounding temperature -40 °C ~ 80 °C (-40 ° F ~ 176 ° F )
Ground Negative
Direction of revolution C lo ck w ise as seen from pulley
Weight Approximately 4 .8 kg (10.6 lbs)
Testin g specification:
N o load revolution at normal 14 volts, z e r o am pere, at 800 + 150
temperature rpm
Output revolution at normal 14 volts, 40 am peres at less than
temperature 3,500 rpm
RK44. 101* and 171 s e r ie s
A lte rn a to r P a r t N o . 27020-22010
Voltage 12 volts
Maximum output current at 14 volts 25 am peres
N o load revolution at 14 volts 950 rpm
C H A R G I N G S Y S T E M - Alternator & Regulator 8-5
Perm issible maximum revolution 11,000 rpm

Allow able surroung temperature -40 °C ~ 80 °C (-40 ° F ~ 176 ° F )
Ground Negative
Direction of revolution Clockw ise as seen from pulley
Weight Approximately 3.5 kg (7 .7 lbs)
Testing specification:
No load revolution at normal 14 volts, z e r o am pere, at 900 + 100
temperatu re rpm
Output revolution at normal 14 volts, 25 a m peres, at less than
temperature 3 ,500 rpm
Operation
T h e alternator generating circuit fo r the R S serieis and fo r the R T and R K

s e r ie s as shown in the above illustration is slightly different. The R S s e r ie s
a re equipped with the ammeter together with the ch arge warning light, but the
R T and R K s e r ie s a re equipped only with the charge warning light deleting the
am m eter.
'W
When the ignition switch is closed, the current flows from the battery to the
voltage relay points " P o " and MP 1 M, through the ch arge warning light, therefore,
the charge warning light g lo w s. A t the same time, the exciting current from the
battery flows to the rotor coil through the fuse fo r the turn signal, voltage r e
gulator points " P L 1 11, " P L o 11, brushes and the slip rings, causing the rotor to
magnitize.
In these condition, as the rotor is rotated, the three-phase alternating current is
generated within the stator coil, and the alternating current is fully rectified into
8—6 C H ARG ING S Y S T E M — Alternator b* Regulator
direct current by the six rectifiers. This direct current voltage is actuated be
tween the 11B " terminal and the 11E " terminal. A ls o the output voltage of the
stator coil neutral point becom es higher, the pull-in fo rc e of the p ressu re coil
in the voltage relay in crea se s, and the point " P o " contacts the point " P 2 " side,
resulting the ch arge warning light to go out.
T h e s e points a re closed when the neutral point voltage reaches to 4.5 ** 5.8
volts, but the points a re closed while the engine is operated normelly •
If the alternator output voltage becom es higher than the voltage in the battery,
the output current starts flowing to the battery o r to the load. When the output
voltage in creases further, the pull-in fo r c e of the voltage coil in the voltage r e
gulator in crea se s. Due to this, the point T L o 11 opens from the low speed point
" P L 1 '!. A s the point opens, the exciting current to the rotor coil has to pass
the control resistance MR fM, and d e c r e a s e s , resulting to reduce the output volt
age at " B " terminal.
U nder light load at high revolution, the point " P L o " contacts the high speed
point " P L 2 11, and the exciting current is further decreased to control the nB n
terminal voltage to the specified voltage.
A s the output voltage is d e c re a s e d , the pull-in fo r c e of the voltage, coil dec rea ses ,
and the point MP L o M returns to the point " P L l " . T h u s, the point " P L o " repeats
the intermittent movement to control the alternator output voltage.
Inspection In C a r
1 . Precaution fo r operation with the voltage of the nN 11terminal in

altern a to r. c r e a s e s abnormally so that the
voltage relay burns.
a. T a k e c a re when connecting any If it is n ecessary to open the
test equipment onto the alter " B " terminal, disconnect the
nator as the alternator output connector plug fo r the " F n t e r
MB M terminal is connected to minal at the same time.
the battery at all times, and if F o r adjustment of the regulator,
the ignition switch c lo s e s , the make sure to disconnect the
voltage of the 11F M terminal is connector plug.
the sam e. If not, the points may be melted
b. A l w a y s pay attention to the po and the fuse may be burnt.
larity of the b a ttery, not to f. T a k e c a re not to wet the alter
connect it onto the alternator nator rectifier diodes with water
oppositely. o r steam when washing the
If connected oppositely, la rge car.
current flows from the battery N e v e r connect a condenser
to the alternator so that the onto the 11F M terminal.
rectifiers a r e da m a ged, and
sometimes the flash er unit will
b u rn . B a tte ry
A lte rn a to r
c . F o r quick charging the battery , €> © A
make su re to disconnect the R e g u la t o r T e s t e r
y
battery to starter cable.
If not, the rectifier will be dam B
aged . R e g u la t o r
d. N e v e r rotate the engine at high ' I E 99C t
T )c p cp
speed with the " B " terminal

lead w i r e disconnected. C u r r e n t C ir c u it
C u rre n t C irc u it
If disconnected, the voltage r e
V o lta g e C ir c u it
gulator cannot operate and the
F i g . 8-4 T e s t Circuit GO156
CHARGING S Y S T E M - Alternator & Regulator 8-7
2. P r e - c h e c k of this test. " F " and " E " terminals using the
regulator tester as shown in figure
a. L o o s e installation of the alter 8-5.
nator .
n. Pan belt tension.
c . Burnt-out fuse in the fuse block.
d. Charging system w irin gs.
3. Disconnect the " B " terminal lead

w ir e from the alternator, and con
nect the regulator tester as shown
in figure 8-4.
4. Ch^ck the voltage and amperage

of the alternator regulator at n o r
mal operating temperature.
Start the engine and increase the F ig . 8-5 Checking Voltage G0162
engine revolution gradually until Between 11F " & " E "
the engine revolution reaches from
700 ~ 2,300 rpm. Read the voltage T h e voltage should be 12 volts.
which should be 13 . 8 ~ 14 . 8 volts , If the reading of the voltmeter is
and the current should be less z e ro voltage o r low voltage than
than 10 am peres. the specified voltage, it indicates
A current flow considerably higher the following symptoms.
than that specified a b o v e , indicates
that the battery is discharged o r a. Opened o r poor contact of fu s e ,
the battery plates a r e shorted. regulator "IG " terminal w ir e
If the voltmeter needle vibrates, o r " F 11 terminal w ir e .
it indicates that the regulator points b . Regulator high speed points
a re rough o r improper connection melted.
of " F 11 terminal.
If the voltmeter indicates m ore than 6 . Disconnect the regulator connector
that specified above, it is the in plug, and check the resistance
dication of the following symptoms. between the regulator MIG M and
" F Mterminals with a circuit tester.
a. Voltage regulator low speed T h e r e should be no resistance.
point gap is too w ide. If there is any resistance, it in
b. Voltage regulator low speed dicates that the voltage regulator
points melted o r high p re s s u re low speed points contact p o orly.
contact.
c. Voltage regulator high speed
point gap is too w ide.
d. P o o r contact of voltage regu
lator high speed point,
e. Voltage regulator o r relay coil
circuit opened.
f. P o o r contact of voltage relay
points.
g. Defective regulator ground.
5. Stop the engine, and turn the igni

tion switch to first position to the
right. F ig . 8-6 Checking Resistance G0163
Check the voltage between the Betw een " IG " & " F "
8^8 CHARGING S Y S T E M - Alternator & Regulator. Alternator
7. Check the resistance between the ALTERNATOR

alternator " F " and " E " terminals
with a circuit tester. Removal
T h e specified resistance is ap
proximately 6 ~ 9 ohms. If this 1. Disconnect the battery to ground
resistance is less than 6 ohms, cable from the battery.
the ro tor coil o r w ir e s a re shorted.
The resistance is excessively 2. Rem ove the engine under c o v e r
higher than that specified above, fo r RK171 se r i e s .
the rotor coil o r brushes, and the
slip rings have a high resistance 3. Disconnect the wirings from the
o r a r e opened. alternator.
4. R em ove the fan belt adjusting bar

bolt, and then rem ove the fan belt.
5. Rem ove the alternator retaining

bolt, and rem ove the alternator
from the alternator bracket.
Disassembly
1. R em ove the three through bolts.
2. Insert a s c r e w d r iv e r into the

notches in the drive end fram e,
Betw een nF M & " E " and pry with the s c r e w d r iv e r to
separate the drive end frame from
8 . P e r fo r m the load test in the follow the stator.
ing manner. If n e c e s s a r y , tap lightly on the
Make the same connection as shown d rive end fram e with a mallet to
in figure 8-4, and start the en w a rd s the pulley, and then rem ove
gine, and run it at approximately the drive end fram e with the rotor.
1,100 rpm with all lights and a c
c e s s o r ie s turned on.
T h e ammeter should indicate ap
proximately 40 am peres on the
R S , R T 4 3 L , R T 5 2 L and R K
171B s e r ie s , and approximately
25 a m p eres on the R K s e r ie s
except on R K 1 71B s e r ie s with
the voltage of 13.8 ~ 14.8 volts.
If the cu rrent flow is extremely
lo w e r than the specified am pera ge,
the rectifier o r stator coil is
shorted o r opened.
If the battery is in full charged F ig . 8-8 Removing D r iv e V2195
state and the am perage reading is End F ra m e
less than the specified a m p e r a g e .
It is recommended to discharge the 3. R em ove the pulley, fan, space
battery to p erform the load test. collar and the k e y , then rem ove
Disconnect the high tension lead the ro tor from the drive end fram e
from the ignition coil, and turn the using a p r e s s .
starter fo r about 5 ~ 10 seconds
to d isch a rg e the battery. 4. R em ove the r e a r bearing from the
CHARGING S Y S T E M - Alternator & Regulator 8-9
1. Key 11. B earing

2. Alternator pulley 12. Stator
3. Alternator fan 13. Rectifier holder
4. S p a ce collar 14. Brush
5. D riv e end frame 15. Brush spring
6. Felt ring 16. Brush holder
7. Felt ring c o v e r 17. Rectifier end fram e
8. B earing 18. " B " terminal insulator
9. Bearing retainer plate 19. Bushing
10. Rotor
F ig . 8-9 Alternator Components fo r R S , R T se rie s Y6168
rotor shaft with the Injection Purrip

Spline Shaft P u ller 09286-46011.
5. Rem ove the bearing retainer from

the drive end fram e, and re m o ve
the bearing and the felt c o v e r .
6. Rem ove the rectifier holder r e

taining nuts, "B 11terminal nuts and
insulators, then separate the stator
with the rectifier holders from the
rectifier end fram e.
F ig . 8-10 Removing Rotor V1138
F ig . 8-12 Removing Stator B0039

F i g . 8-11 Removing R e a r V1139 with Rectifier H older
B earing
8-10 CH ARG ING 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.
a. R em ove the brush lead w ire s
from the holder.
b. R em ove the terminal insulators .
c . Rem ove the stator coil MN n
terminal lead from the holder.
When removing the brush holder
a ssem b ly, do not rem ove it by
cutting the " N 11 terminal lead o r
melting the solder.
F ig . 8-14 Testing Rotor Coil V2196

fo r Open & S hort Circuit
2. Connect the tester from the slip

ring to the rotor o r rotor shaft,
and check the insulation between
them.
If the tester needle m oves, the
rotor coil o r slip rings a r e d e
F i g . 8-13 Removing Brush V1141 fective .
H older T h e rotor assembly should be r e
placed .
Inspection & R epair
B e a rin g
Check the bearings fo r s c o r e s , rough

n e ss, abnormal noise o r damage.
If defective, replace the bearing/s.
R o to r
1. Check the rotor coil fo r open o r

short circuit.
Connect a circuit tester from the
slip ring to the other ring. F ig . 8-15 Testing Rotor V2197
T h e coil resistance should be 3 . 5 Coil fo r Ground
to 3.7 ohms on the R S , R T 4 3 L ,
R T 5 2 L and R K 1 71B s e r ie s , and Stator
4.1 ~ 4 .3 ohms on R K s e r ie s
except on R K 171B s e r ie s . 1. Check the stator coil fo r insulation .
If there is little o r no resistance, Connect the tester between the
the coil o r slip rings indicate a stator coil lead and the stator c o r e .
short o r ground, and considerably If the tester needle m oves, the
higher than that specified above, coil insulation is defective.
indicates an opened coil o r con R ep a ir the coil o r replace the
nection defect. stator a ssem b ly.
If the test show s that the rotor
CH ARG ING 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.
Brush & Brush H older
1. Check the brush fo r crack and

w ear.
If the brush is w orn beyond 9 mm
(0 .3 5 "), replace the brushes.
T h e brush should slide smoothly .
P ig . 8-16 Testing Stator B0041
Coil fo r Insulation
2. Check the stator coil fo r open c i r

cuit .
In o rd e r to perform this test, the
stator coil leads must be discon
nected from the rectifier leads.
T o disconnect the leads, hold the
rectifier lead with a nose pliers
to prevent the rectifier from heat
ing, and melt the soldered portions
using an electric soldering iron
of 100 n 200 watts fo r 2 seconds. F ig . 8-19 Brush Length V1143
2. If replacing the brush, install .the

new brush and the brush spring
into the brush holder, then solder
the brush lead w ir e keeping the
protruded brush length to 13 mm
(0 .5 1 ").
A ft e r soldering the brush lead,
check if the brush movement is
smooth.
F ig . 8-17 Melting S o ld e r G3364

13mm (0 51'!)'
L r
1 1 m i | | .,:'-
w
5*
wL
1
F i g . 8-20 Replacing Brush V0216

V0217
F i g . 8-18 Testing Stator Coil V1145

fo r Open Circuit
8-12 C H A R G I N G S Y S T E M - Alternator
Rectifier sistance, and 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. If the needle of
the rectifier holder and the rectifier the tester moves in either polarity,
le a d . the rectifier is shorted.
T o perform this test, the rectifier If the needle does not move in ei
holder must be separated from the ther polarity, the rectifier is open
stato r . ed , and should be replaced.
R e fe r to paragraph 2 of the Stator If any one of the negative side
Inspection & R ep air on page 8-11, rectifiers is found defective, al
w a ys replace the negative side
1. Rectifier holder positive side. rectifiers with the holder assem
Connect the tester ( + ) lead onto bly .
the rectifier holder and the ( - )
lead onto the rectifier lead as
shown in figure 8-21, and check
the resistance.
Good rectifier will indicate no r e
sistance, and if it indicates a high
resistance, the rectifier is opened.
N ext, turn the polarity of the tester
and check again. If the tester n ee
dle m oves in either polarity, the
rectifier is shorted. If the needle
does not move in either p ora lity,
the rectifier is opened, and should
be replaced.
If any one of the positive side r e c
tifiers is found defective, always Assem bly
rep la ce the positive side rectifiers
with the holder assembly. 1. Connect the brush holder onto the
stator coil nN M terminal in the fol
lowing manner.
a. Install the stator coil " N 11t e r

minal lead onto the brush h o ld e r.
b. Install the terminal insulators.
c . Position the brush lead at c o r
rect position.
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 F ig . 8-23 Assem bling Brush V1146
Holder
CHARGING S Y S T E M - Alternator 8-13
2. Position the stator with the recti the rotor shaft bearing through
fie r holder onto the rectifier end the space ring with' the T r a n s m is
fr a m e . sion Oil Plu<f'•(59325-12010.
Install the insulators onto the posi
tive side rectifier holder and onto
the MB 11 terminal at c o rre c t posi
tions, and then tighten the holder
and !'B 11 terminal retaining nuts.
F ig . 8-26 Installing D r iv e B0045

End F ra m e
6. P r e s s in the brushes against the

brush spring tensions into the
F i g . 8-24 Assembling Stator V1148 brush holder.
Coil Next, insert a w ir e through the
a ccess hole in the rectifier end
3. Install the felt ring ( 2 ) , felt c o v e r fram e, and also into the hole p r o
(3) so that the convex surface of vided in the brush holder to p r e
the c o v e r will face towards the vent the brushes from falling.
pulley side onto the drive end With the brushes positioned as a-
fram e ( 1 ) . P a ck multipurpose b o v e , assemble the drive end fram e
g r e a s e into the bearing ( 4 ) , and onto the rectifier end f r a m e , and
install the bearing. tighten them with the three retain
Next, install the bearing retainer ing bolts.
(5) with three retaining s c r e w s .
F ig . 8-27 Installing W ire V0218

F ig . 8-25 D riv e End F ra m e B0044
A ssem bly 7. Install the space co lla r, key, fan
and the pulley onto the rotor shaft,
4. Pack multipurpose g r e a s e into the and install the retaining nut.
r e a r bearing, and p r e s s in the
bearing onto the rotor shaft at the A ltern ator Output T e s t
slip ring s id e .
P e r fo r m the output test in accordan ce
5. Install the drive end frame onto
8-14 CHARGING S Y S T E M - Alternator. Regulator
with the circuit shown in the following 3. Rem ove the regulator retaining
illustration. bolts, and rem ove the regulator
assem bly.
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, re p a ir the defective p o r
tion , and repeat the electrical adjust
ment after performing the mechanical
adjustment.
A lw a y s use a fully charged battery
F ig . 8-28 Output T e s t Circuit Y 5120 to perform the electrical adjustment.
1, Turn on the switch MS 1 M only, Voltage Relay

then in crease the alternator r e v o
lution gradually with a variable Make the test circuit as shown in
motor until the voltage reading figure 8-29.
reach es 14.8 volts, and read the Operate the variable motor, and turn
alternator revolution at that time, on the switch ( S ) .
which should be 650 ~ 950 rpm. Next, in crease the alternator revolu
tion gradually, and read the voltage
2. T u rn on t-he switch " S I 1 ind when the test lamp goes out.
" S 2 11 further holding the output T h e voltage relay operating voltage
voltage at 14.8 volts with a v a r i should be 4.5 ~ 5.8 volts.
able resistance, increasing the al If the voltage is not within the speci
ternator revolution to 1,900 rpm, fied voltage, adjust it by bending the
and read the ammeter at that tim e. adjusting arm of the voltage relay.
T h e ammeter should be 30 ~ 40 L ig h t
a m p eres on R S , R T 4 3 L , R T 5 2 L A l t e r n a to r
and R K 1 7 1 B , on the R K s e r ie s X
except the R K 1 7 1 B s e r ie s this
should be 19 ~ 27 a m p eres.
Installation
Follow the rem oval p ro c e d u re s in the

r e v e r s e o r d e r . Adjust the fan belt
deflection to 13 ~ 20 mm (0.5 0 to
0 . 7 5 " ) with the fan belt pushed at 11
kg (24 lbs ) .
F i g . 8-29 Voltage Relay G0176
REGULATOR T e s t Circuit
Rem oval Voltage Regulator
1. R em ov e the windshield w a s h e r ja r Make the test circuit as shown in

on R S s e r ie s if installed. figure 8-30.
Operate the variable motor, and turn
2. Disconnect the regulator wiring on the switch ( S ) . Check the voltage
harness connector plug. and am perage by varying the alternator
revolution gradually at the time when
CHARG ING S Y S T E M - Regulator. 8-15
the ammeter needle registers maxi tact of the voltage regulator points
mum . " P L 1 " and " P L o " is poor .
Increase the alternator revolution, and P r e s s down the armature of the
read the voltage at the time when the voltage regulator, and check the
ammeter needle registers one-half of resista n ce.
maximum amperage reading. T h e resistance should be 2. 8 ohms
A ls o increase the revolution until it on the R S , R T 4 3 L , R T 5 2 L ,
reaches 3,000 rpm, and read the RK171B s e r ie s , and on R K e x
voltage. cept on RK171B s e r ie s this must
T h e regulating voltage should be with be 11 ohms.
in 13.8 ~ 14.8 volts at one-half of If the resistance is considerably
maximum amperage at 3,000 rpm of higher than the specified resistance
alternator revolution. value, the control re sistor is d e
If the regulating voltage is not within fective .
the specified voltage, adjust it by-
bending the adjusting arm of the volt 2. Connect the circuit tester between
age regulator. the »;f r i and " E 11 terminals.
T h e resistance should be z e r o .
If there is any resistance, the
contact of the voltage relay points
" P I " and " P o " is p o o r .
P r e s s down the armature of the
regulator r e l a y , and check the
resista n ce.
T h e resistance should be about
100 ohms.
If the resistance is considerably
higher than 100 ohms, the voltage
coil is opened.
If the resistance is extremely lo w
F i g . 8-30 Voltage Regulator G0177 e r than the above, the voltage r e
T e s t Circuit lay points " P I 11 and " P o " a re
melted o r the voltage coil is
Regulator Circuit T e s t shorted.
“ IG” te rm in a l “ N ” te rm in a l “ F ” te rm in a l
3. Connect the circuit tester between
the " N " and " E " terminals.
23 ohms.
relay Ooil is opened.
If the resistance is extremely lo w
e r than the above, the voltage
relay coil is shorted.
4. Connect the circuit tester between

F ig . 8-31 Regulator Wiring G3456 the " L " and " B " terminals, and
H a rn ess Connector Plug p r e s s down the armature of the
voltage re la y , then check the r e
1. Connect the circuit tester between sistance .
the "IG " and " F 11 terminals. T h e resistance should be z e r o .
T h e resistance should be z e r o . If the r e is any resistance, the
If there is any re sista n ce,the con contact of the voltage relay points
" P o " and " P 2 'V is p o o r .
8-16 CHARGING S Y S T E M - Regulator
5. Connect the circuit tester between A r m a tu re G ap

the " B " and " E " terminals.
T h e resistance should be infinite.
If the r e is any resistance, the
voltage relay points " P o " and
" P 2 " a r e melted.
P r e s s the armature of the voltage
relay , and check the resistance.
100 ohms.
coil is opened.
If the resistance is extremely lo w F i g . 8-33 Nomenclature of G0174
e r than the above, the voltage coil Voltage Regulator
is shorted.
A ft e r dressing the points, wash them
6 . Connect the circuit tester between thoroughly with cleaning solvent.
the MF n and " E " terminals. If any of the points is burnt o r pitted
T h e resistance should be infinite. e x c e s s iv e ly , replace the regulator
If there is any resistance, the a ssem b ly.
voltage regulator points " P L o " and
" P L 2 " a r e melted. Voltage Relay
P r e s s the armature of the voltage
regulator, and check the r e s is 1. P r e s s down the armature, and
tance . check the contact spring deflection
T h e resistance should be z e r o . with the fe e le r gauge.
If there is any resistance, the This deflection should be 0.20 to
contact of the regulator points 0.45 mm (0.008 ~ 0 . 0 1 8 " ) .
" P L o " and nP L 2 n is po or. If n e c e s s a r y , adjust it by bending
the point holder " A " .
Inspection Mechanical Adjustment
T h is mechanical adjustment described

h e re should be perform ed when the
specified values a re not obtained in
the regulator test.
Dirty contact points should be d ressed
with a suitable paper o r a suitable
fine em ery cloth.
A r m a tu r e G ap
F i g . 8-34 Checking S p rin g V2198

A d j u s t i n g A rm <j| A n g le G a p Deflection G0180
2. Check the point gap with the fe e le r

P o i n t (P l ) „ ... gauge.
R ) i n t( P 2 )
This point gap should be 0 .4 to
G ap 1.2 mm (0.016 ~ 0 .0 4 7 ") .
If n e c e s s a r y , adjust the gap by
bending the point holder " B ".
F ig . 8-32 Nomenclature of G0175
V oltage Relay
CHARGING S Y S T E M - Regulator 8-17
E ig .8 -3 5 Checking Point V1185 F i g . 8-37 Checking Point V2155

Gap G0181 Gap GO 182
Voltage Regulator
1. Check the armature gap with the

fe e le r gauge.
This point gap should be 0.6 to
0.8 mm (0.024 ~ 0 .0 3 2 ") .
If n ecess a ry , adjust the gap by
bending the low speed point holder
"A ",
F i g . 8-38 Checking S prin g V3105

Deflection G0183
4. P r e s s the arm ature, and check

the angle gap with the fe e le r gauge .
This gap should be m ore than 0 . 2
mm (0 .00 811) .
If not, replace the regulator.
F i g . 8-36 Checking V1186

A rm atu re Gap
2. Check the point gap with the fe e le r

gauge.
This point gap should be 0.25 'to
0.45 mm (0.010 ~ 0 .0 1 8 ") .
If n e c e s s a r y , adjust the gap by
bending the high speed point holder
" B " as shown in figure 8-37.
3. P r e s s the armature, and check F i g . 8-39 Checking A n g le V2199

the contact spring deflection with Gap
the fe e le r gauge. Installation
This deflection should be 0.2 to
0.6 mm (0.008 ~ 0 . 0 2 4 " ) . Follow the removal p roce d u res in
the r e v e r s e o r d e r .
8-18 MEMORANDUM
MEMO *
STA R TIN G S Y S T E M
D E S C R I P T I O N ................
TROUBLE S H O O T IN G .
S T A R T E R ........................
Construction ..................
O p e r a tio n ........................
R e m o v a l ..........................
Disassembly ..................
Inspection & Rep air
A r m a t u r e ....................
Field c o i l ....................
Magnetic switch ........
Brush holder & brush
S ta rte r clutch . . . . . . .
A s s e m b l y ........................
Testing A ft e r A ssem bly
Installation ......................
B A T T E R Y ........................
Inspection & Adjustment

Charging ........................
MEMORANDUM
STA R TIN G SYSTEM - Description 9-1
D E S C R IP T IO 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
bustible air-fuel mixture fo r starting the engine. T h e starting system is composed
of the starter and the battery, and its wiring diagram is as shown in the above
illustration.
T h e battery stores the energy in a chemical form , and when the connection is
made from the battery to the starter motor, a chemical action takes place inside
the battery.
T h is chemical action actuates the starter motor to convert the electrical en erg y
to mechanical e n e r g y .
T h e starter motor has the following characteristics.
It is compact and light. T h e output is la rg e , and the ■end fram es arK

e of a sealed
type to prevent the entry of dirt and dust.
T h e slippage of the over-running clutch is v e r y little, and the armature is not
over-ru n .
T h e operation of the over-running clutch and the magnetic switch enable to a c
complish a smooth, and trouble-free g e a r mesh.
T h e use of a mold commutator has increased the durability of the commutator
against the centrifugal fo r c e .
A lso the use of molds fo r the magnetic switch terminals has extremely reduced
the possibility of having short circuiting and poor insulation.
9-2 STA R TIN G SYSTEM - Trouble Shooting
Symptoms & ]Rr*olDcitale Cdusss Remedies
1i S ta rte r d oes not turn

S ta rte r spins, but does not crank the engine
a . P o o r contact of starter switch Replace ignition switch

contact points
b . Burnt o r poor contact of mag Clean contact plate o r replace mag
netic switch contact plate netic switch
c . Open magnetic switch pull-in Replace magnetic switch
coil circuit
d. Open magnetic switch holding Replace magnetic switch
coil circuit
e . P o o r contact of brush D r e s s commutator and brush
f. Burnt commutator Lathe cut commutator
9- Commutator mica too high U nder cut mica
h . Shorted field coil Replace field coil
i . Shorted armature Replace armature
j . Weak brush spring tension Replace springs
k . P o o r soldering of field coil S o ld e r
1. Worn bushings Replace bushings
m . Weak battery R ech a rg e battery
n . Shorted battery cell/s Replace battery
o . P o o r contact of battery Clean and tighten terminal/s
terminal/s
P. Open circuit between starter R epair
switch and magnetic switch
q- P o o r battery ground cable con Clean and tighten
nection
S ta r te r turns, but pinion does not mesh with ring g e a r
a . S ta r te r clutch pinion g e a r worn R eplace starter clutch

b. D efective starter clutch Replace starter clutch
c . Defective d riv e spring Replace drive spring
d. P o o r movement of clutch on Clean and c o r r e c t
splines
e . Worn starter clutch bushing Replace starter clutch
f. P o o r starter clutch pinion travel Adjust magnetic switch stud
9- Worn starter bushing/s Correct
h. Worn starter bushing/s R ep lace bushing/s
i . Ring g e a r worn Replace ring ge a r
S ta r te r motor keeps running
a. Shorted magnetic switch coil R eplace coil

b. Melted magnetic switch contact R eplace megnetic switch
plate
c. S ta r te r switch returns poorly Replace ignition switch
S T A R T I N G S Y S T E M - Starter 9-3
STARTER
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
sw itch.
T h e field coil is connected with the armature coil through the brushes and the
commutator segments in s e r ie s . T h e windings of the field coil and the armature
coil a re of a heavy copper w ir e to withstand the la rge current encountered
during the starting operation.
T h e starter clutch is engaged to the armature shaft with the helical splines. A s
the starter clutch is pushed out by the pinion d rive spring, the turning of the
pinion occu rs due to the helical splines, and this enables a smooth engagement
of the pinion with the ring g e a r .
A ls o as the starter clutch pinion is engaged with the ring g e a r , the turning fo r c e
of the armature pushes the starter clutch pinion into a complete mesh without
further fo rce of the pinion drive spring.
F o r these reason s, the pulling fo r c e of the magnetic switch is not required to
be strong, the magnetic switch, th erefore, is designed v e r y small compared
with the unit used on the conventional push-in type starter.
T h e starter clutch has an on e-w a y clutch, and it transmits the turning fo r c e of
the armature to the ring g e a r , but the armature is not turned by the ring g e a r
as soon as the engine is started.
T h e drive le v e r is provided with the pinion drive spring, and as the upper end
of this spring is hooked directly onto the magnetic switch joint, the drive spring
9-4 STA R TIN G SYSTEM - Starter
acts as 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 the commutator side surface and the brush holder plate. Th e
brake is affect by the magnetic switch return spring through the drive le v e r when
the starter clutch is returned in its original position.
A brake spring is installed at the commutator end fram e to regulate the no-load
high speed revolution when the starter is operated with no-load fo r testing.
Operation
S t a r t e r S w itc h
On closing the starter switch, the battery current flows into the hold-in coil and
also to the armature coil through the pull-in coil, field coil and the brushes.
Th en the moving c o r e of the magnetic switch is pulled in by means of the mag
netic f o r c e , and the starter clutch is slided on the armature shaft by the drive
spring and the drive le v e r to engage the starter pinion with the ring g e a r .
A t this time, the pinion is partially engaged with the ring g e a r 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 en erg izes the arm a
ture to spin creating a la rg e torque.
T h is m oves the starter clutch pinion further to completely engage with the ring
g e a r , and brings the starter into the engine cranking condition. A s the magnetic
switch is clo sed , the current does not flow to the pull-in coil, and the contact
plate is retained at the closed position by the holding coil until the engine starts
to o p erate.
With the starter switch off after the engine starting, the current flows from the
magnetic switch contact plate to the pull-in coil and the holding coil. A s these
coils a r e wound to have their attractive fo r c e s act in opposite d irection s, these
attractive f o r c e s cancel each other, and the plunger return spring retracts the
plunger moving c o r e to open the magnetic switch. A t the same time, the starter
clutch is returned to its original position, and the armature is pushed tow ards
the commutator end fram e side by the plunger return spring to effect the a rm a-
STA R TIN G S Y S T E M - Star ter 9-5
ture brake. T h en , the armature quickly stops, and b e c o m e s ready fo r the start
e r re-operation.
Specification:
Rated voltage 12 volts

Rated output p o w er 1.0 KW
Rating 30 seconds
Direction of revolution C lockw ise as seen from pinion side
Number of pinion teeth 9
Number of poles 4
Weight Approximately 5.8 kg (12.8 lbs)
Suitable battery 40 ~ 70 A H
Output characteristics:
No-load
Voltage at 11 volts
A m p era ge L e s s than 45 amperes
Revolution More than 6,000 rpm
Locked
Voltage at 7.0 volts
A m p e ra ge L e s s than 550 am peres
T orque More than 1.4 m-kg (10.1 ft-lbs)
6 78 9 10 I I
1314 15 16 17 1319202122 23 2425
1. End f r a m e c o v e r 10. Housi ng bushing 19. Brush

2. T h r o u g h bolt 11 . Bushi ng c o v e r 20. F i el d coil
3. Armature 12. Lock washer 21. Pole core
4. S t a r t e r clutch 13. B r a k e s p r ing 22. Insulator
5. Magnetic switch 14. R u b b e r ring 23. Y oke
6. Pinion stop c o l l ar 15. Commut at or end f r a m e 24. R u b b e r plate
7. Sna p ring 16. End f r a m e bushing 25. Plate
8. D rive lev er w/spring 17. B r u s h spr i ng
9. S t a r t e r d r i v e housing 18. B r u s h hol der
F i g . 9-4 Star te r Components G3137

9-6 STA R TIN G SYSTEM - 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.
3. R em ove the starter retaining nuts,

and rem o ve the starter.
Disassembly
1 . Disconnect the field coil w ir e from F ig . 9-6 Removing Brush V1808

the magnetic switch terminal. Holder
2. R em ove the two magnetic switch armature ( 3 ) , starter clutch (4)

retaining s c r e w s , and rem ove the and the drive le v e r with the drive
magnetic switch from the drive spring (5 ) .
end f r a m e .
F i g . 9-7 Removing A rm atu re V1810

F i g . 9-5 Rem oving Magnetic V1806
Switch 8. R em ove the snap ring and pinion
stop collar from the armature shaft
3. R em o v e the end fram e c o v e r , and end,then rem ove the starter clutch.
re m o ve the lock w a s h e r , brake
spring and the rubber ring.
4. R em o v e the two through bolts , and

rem ove the commutator end fram e.
5. T a k e out the brushes from the

brush holder, and rem o ve the
brush holder from the armature
shaft.
6. R em ov e the yo k e from the drive

housing.
F ig . 9-8 Removing S ta rte r B0034
7. R em o v e the drive le v e r set bolt Clutch G1249
from the d riv e housing, and r e
move the rubber ( 1 ) , plate ( 2 ) , To re mo ve the snap ring, make
S T A R T I N G S Y S T E M - Star ter 9-7
a tool similar to the one as shown T h e p ro p e r depth should be 0.5

in the illustration. to 0.8 mm (0.02 ~ 0 . 0 3 " ) .
D riv e out the pinion stop collar
towards the starter clutch side L im it 0.2mm ( 0 . 0 0 8 ' )
first using the tool, and rem ove
the snap ring.
N ext, rem ove the stop collar and
the starter clutch. C o rre ct
Inspection & Repair
Arm atu re
1. Inspect the clearance between the

In c o rre c t
armature shaft and the bushings.
T h e clearance should not exceed F ig . 9-9 Mica Depth G0151
0.2 mm (0.008" ) .
S elect a p rop e r size bushing to 4. Check the armature coil fo r ground
obtain a clearance of less than using a g r o w l e r .
0.035 ~ 0.135 mm (0.002 to Connect one test prod on the com
0 .0 0 4 "). mutator , and the other test prod
on the armature c o r e o r shaft.
A rm atu re shaft diameter: If the test lamp lights, the a rm a
12.50 mm (0 .4 7 2 " ) ture coil is grounded.
A rm atu re shaft bushing inner Rep air o r replace the armature.
diameter:
STD 12.535 ~ 12.560 mm
(0.493 I 0 .4 9 4 " )
U / S - 0 .30
12.235 ~ 12.260 mm
(0.482 ~ 0 .4 8 3 ")
U / S - 0 . 50
12.035 ~ 12.060 mm
(0.474 ~ 0 .4 7 5 ")
2. Check the commutator for rough

n ess, burnt o r scored surface.
If n e c e s s a r y , d r e s s o r cut with
a lathe just enough to rem ove stock F i g . 9-10 Testing A rm atu re V2186
to clean the surface. Coil fo r Ground
If the diameter of the commutator
is out-of-round m ore than 0.3 mm Check the armature coil fo r inter
(0 .012" ) , cut the commutator on nal short by placing the armature
a lathe. on the g r o w le r , and hold a hack
T h e out-of-round should be less saw blade o v e r the armature c o r e
than 0.1 mm ( 0 . 0 0 4 " ) . while rotating the armature.
T h e serviceable limit of the com If the hacksaw blade v ib r a te s , the
mutator is 36.8 mm ( 1 . 4 5 " ) , and armature coil is shorted.
if the limit ex c e e d s , replace the R ep air o r replace the arm ature.
arm atu re.
T h e specified commutator diameter Check the armature coil fo r open
is 3 8.8m m ( 1 . 5 3 " ) . circuit by placing the armature on
3. Check the mica depth, and file off the g r o w le r , and connect the two
commutator segments with the test
the mica if the depth is less than
p ro d s , and check the reading.
0.2 mm ( 0 . 0 0 8 " ) .
9-8 STA R TIN G SYSTEM - 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 the test fo r all adjacent field coil has a ground circuit.
segments moving one segment at Repair o r replace the field coil.
a time.
If there is inconsistent reading, it
indicates an open circuit. 8
R ep a ir o r replace the armature.
F i g . 9-14 Testing Field B0036

Coil fo r Ground
Magnetic Switch
F ig . 9-12 Testin g A rm a tu re V2188
Coil fo r Open Circuit T h e following magnetic switch tests
described in paragraphs 1 through 3
Field Coil should be perform ed with the condition
that the starter is assembled, and
1 . Check the field coil fo r open c i r with the specified voltage application.
cuit using a circuit tester. In testing, disconnect the field coil
Connect one test prod onto the lead from the magnetic switch t e r
field coil lead and the other prod minal 11F M.
onto the other field coil lead.
If the tester needle does not m o v e , 1. T e s t the pull-in coil motion of the
the field coil has an open circuit. magnetic switch.
R ep a ir o r replace the field coil. Connect the test leads onto the
"50" terminal and the " F " termi
2. Check the field coil fo r ground. nal as shown in figure 9-15.
Connect one test prod onto the T h e magnetic switch should pull
field coil lead and the other lead in the plunger strongly with 8 volts.
on the y o k e .
If the tester needle m o v e s , the 2. With the magnetic switch in pull-in
S T A R T I N G S Y S T E M - Starter 9-9
F i g . 9-15 Pull-in Coil G1265 F i g . 9-17 Plunger Return V1812

T est Test G1267
condition, connect the battery ne 4. Inspect the length of the magnetic
gative lead onto the magnetic switch switch moving stud.
body. T h e length is approximately 34 mm
Next, disconnect the test lead of (1 . 3 4 " ) from the installation su r
the battery negative side from the face of the magnetic switch to the
11F n terminal. extreme end of the moving stud
T h e plunger must be pulled in, joint hook.
and held in this position with 8 If n e c e s s a r y , adjust the moving
vo lts. stud length by loosening the lock
If held, the holding coil is satis nut to obtain the c o r r e c t position
factory . of the pinion travel as shown in
figure 9-18.
F ig . 9-16 Holding Coil T e s t G1266

F i g . 9-18 'C h eck in g Moving V1813
3. Check the plunger return motion Stud Length
by connecting the battery positive
lead onto the " F " terminal, and Brush H older & Brush
the negative lead onto the magnetic
switch b o d y . 1. Inspect the brush holder fo r insu
A ft e r pulling out the pinion until it lation using a circuit tester.
reaches to the pinion stop collar Connect the test prods onto the
with the hand, relea se the hand positive side brush holder, and
from the pinion. onto the negative side brush holder.
A t this time, if the plunger returns If the tester needle m o v e s , the
with 12 volts, the magnetic switch brush holder insulator is defective,
is satisfactory. and should be repaired o r replaced
9-10 S TA R TIN G SYSTEM - 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
ment .
If defective, replace the starter
clutch assembly.
A ssem bly
F i g . 9-19 Checking Brush V1814 When assembling each part, coat with
Holder Insulation multipurpose g r e a s e onto the sliding
surface o r moving portion of the a r
2. Check the brush length, and if the mature shaft splines, starter clutch
length is less than 12 mm (0 .4 8 11) , bushing, end fram e bushings, drive
replace the brushes. le v e r and the moving stud.
T h e specified brush length is 19
mm ( 0 . 7 5 " ) . 1. Install the starter clutch (2)', pin
ion stop collar (3 ) and the snap
3. Check the brush spring tension ring (4 ) onto the armature shaft
with a pu ll-scale. (1 ) , and then lock the stop collar
T h e reading of the tension should in place by calking at two points.
be made when the spring just
com es off the brush.
T h e specified spring tension should
be 1,050 ~ 1 .350 gram s (2 .3 to
3.0 lbs) when the new brushes
a r e installed.
If the tension is less than 600 g
(1 .3 2 lb s ) , replace the spring/s
and/or the brush/es.
F ig . 9-21 Installing S ta rte r V2191

Clutch
2. Install the drive le v e r (2 ) onto the

starter clutch (1 ) as follow s.
A lw a y s install the drive le v e r as
in the illustrated position.
If the installation is in correct, the
pinion meshing with the ring ge a r
F ig . 9-20 Checking S prin g V1816 will be im p roper.
T ension A ls o the steel w a s h e r (3) must
always be installed towards the
S ta r te r Clutch clutch side.
1 . Check the pinion teeth fo r w e a r 3. Install the armature onto the drjve
and damage. housing, and tighten the drive
S TA R TIN G SYSTEM - 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.
Th e armature shaft thrust play
should be 0.05 ~ 0 .35 mm (0 .002
to 0 . 1 3 " ) , and the thrust play
limit is 0.8 mm (0 .0 311) .
8. Pack multipurpose g r e a s e into the

end fram e c o v e r , and install it on
F ig . 9-22 Direction of D riv e V1818 to the end fram e.
L e v e r Installation
le v e r set bolt.
4 . Install the plate and the rubber plate

onto the drive housing, and then
install the yoke onto the drive
housing.
2 ,.; m m
F ig . 9-25 Installing End V1821

F ra m e C o v e r
9 . Install the magnetic switch onto the

drive housing.
A lw a y s hook the moving stud joint
onto the drive spring from the
under side of the spring as illus
F i g . 9-23 Installing Rubber V1819 trated .
Plate
5. Install the brush holder onto the

armature, and install the brushes
into the brush holders.
F i g . 9-26 Installing Magnetic G0152

Switch
10. Check the clearan ce between the

starter clutch pinion and the pinion
F ig . 9-24 Installing Brush V1808
H older
9-12 STA R TIN G S YS TE 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
the starter is operated under no at 7.0 volts producing a torque of
lo a d . 1.4 m-kg (10.1 ft—lb ) o r m ore.
Installation
Follow the removal procedu res in the

reverse order.
BATTERY
Inspection & Adjustment

1 ~ 4 mm ( 0 - 0 4 —0 .1 6 ")
1. Check the electrolyte level in each
c e ll.
A d d sufficient electrolyte to level
F i g . 9-27 Clutch Pinion G0153 lin e.
C learance A lw a y s use distilled w ater to r e
plenish the battery.
T estin g A ft e r A ssem b ly
2. Check the specific gravity of the
T h e following tests should be p e r electrolyte with a hydrometer.
form ed after assembling the starter. If the specific gravity reading is
If suitable equipment is not available, below 1.200, and the difference
at least the no-load test should be between each cell is more than
made. U s e a fully charged battery 0.025, the battery should be r e
fo r the te s ts . charged .
Electrolyte specific gravity of a
T o perfo rm the no-load test, connect fully charged battery should be
the test lead as shown in figure 9-28. 1.250 ~ 1.270 at 20°C ( 6 8 ° F ) .
The starter motor should rotate T h e specific gravity of acid solution
smoothly at a constant speed of more to be used as electrolyte, va rie s
than 6,000 rpm at 11 volts with the according to its temperatures. It
current d raw of 45 a m p eres o r l e s s . in n ecessary before adjusting the
specific gravity that it is converted
accordingly to standard tempera
ture reading of 20 C (68 F ) .
F o r conversion of temperature
pertaining to acid specific gravity ,
the following equation should be
used.
S20 = S T + 0.0007 (t-2 0 )
S20 Specific gravity at

20 °C
S T .......... Specific gravity at
F ig . 9-28 T estin g Circuit G0154 t°C
t .............. Tem p eratu re of
T o perfo rm the lock test, follow the electrolyte
instruction and p ro c e d u re s outlined 0.0007 . . T em peratu re coefficient
in the instruction manual of the tester
furnished by the manufacturer. Electrolyte specific gravity at
20 °C ( 6 8 ° F ) :
STA R TIN G SYSTEM - Starter 9-13
1.260 is 100% fully charged state H ydrogen , and oxygen gases are
1.210 is 75% fully charged state produced during normal battery ope
1.160 is 50% fully charged state ration. This gas* mixture can explode
1.110 is 25% fully charged state if flames o r sparks a re brough near
1.060 is fully discharged state the vent openings of the battery.
T h e sulphuric acid in the battery e le c
Charging trolyte can cause a serious burn if
spilled on the skin o r spattered in the
B e fo r e placing the battery on the e y e s . It should be flushed away with
c h a rg e r, clean the battery terminals , la rge quantities of clear w a te r.
check the electrolyte level, and r e F o r quick charging, make sure to
plenish with distilled w ater as n ec e s disconnect the battery to starter cable.
s a r y . Rem ove all the filler caps while If not, the alternator rectifier will
charging, and do not allow the battery be damaged.
electrolyte temperature to rise 45 C
(113 ° F ) .
9-14 MEMORANDUM
MEMO
'
fife.
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
TROUBLE S H O O T I N G ................................. 10-2
D I S T R I B U T O R ................................................. 10-2
Description ............ ........................................ 10-2

R e m o v a l ........................................................... 10-4
Disassembly ................................................... 10-4
In spection......................................................... 10-6
G o vern o r & s h a ft ....................................... 10-6
Distributor c a p ........................................... 10-7
B r e a k e r plate & stationary plate .......... 10-7
Other i t e m s ................................................. 10-8
A s s e m b l y ................ ........................................ 10-8
P erfo rm a n c e T e s t & A d ju stm en t................ 10-10
B r e a k e r point g a p ..................................... 10-10
Cam dwell angle ....................................... 10-10
A d va n ce c h a r a c t e r is tic s ........................... 10-10
C o n d e n s e r ................................................... 10-11
Installation ....................................................... 10-11
IG N IT IO N C O I L ............................................... 10-12
Description ..................................................... 10-12

R e m o v a l ........................................................... 10-13
Inspection ......................................................... 10-13
Installation .......................... 10-14
HIGH T E N S I O N W IR E S ............................... 10-14
Description ..................................................... 10-14

R e m o v a l ........................................................... 10-14
Inspection.............................................. 10-14
Installation .................... 10-14
SPARK P L U G ................................................. 10-14
R e m o v a l ........................................................... 10-14
Inspection & Adjustment ............................... 10-14
Installation ....................................................... 10-15
M E M O R A N D U M ............................................... 10-16
IG N IT I O N SYSTEM - Description 10-1
D E S C R IP T IO N
Ig nition Coil D is tr ib u to r
F ig . 10-1 Ignition System Wiring Diagram G3138
T h e ignition system produces high-voltage su rges of up-to 20,000 volts, and

d elivers them to the spark plugs in "time" with the engine.
Each high-voltage surge jumps a c ro s s the spark plug gap and ignities the com
pressed air-fuel mixture.
T h e ignition system is composed of the primary (lo w -vo lta g e) circuit and the
secondary (high-voltage) circuit, and the wiring diagram is as shown in the
above illustration.
T h e primary circuit consists of the battery , distributor b r e a k e r points , condenser
and the ignition coil primary windings.
T h e secondary circuit consists of the ignition coil secondary windings, distributor
cap, rotor, high-tension wirings and the spark plugs.
When the b rea k er points a r e closed, the prim ary current flow s from the battery
through the ignition switch to the primary windings in the coil, then to ground
through the closed b re a k e r points.
When the b re a k e r points open, the magnetic field built up in the ignition coil p r i
mary windings moves through the secondary windings of the coil producing high
voltage su rge.
T h e high voltage surge is produced each time the b re a k e r points open. T h e
high voltage flows through the coil high tension wiring to the distributor cap
w h ere the rotor distributes it to one of the spark plug wiring in the distributor
cap.
10-2 IG N I T I O N S Y S T E M - Tr ouble Shooting, Distributor
Symptoms & P robable Causes Rem edies
1. S ta rte r turns, but engine will not start

a . Weak battery R ec h a rg e battery
b. E x c e s s iv e moisture on spark Rem ove moisture, and dry
plugs o r high tension w irin gs
c . C ra ck ed o r leaky distributor Replace cap o r rotor
cap o r rotor
d. Broken w ir e in prim ary circuit Repair o r replace w ire
e . Burnt o r improperly adjusted Adjust o r replace points
b re a k e r points
f. D efective condenser Replace condenser
2. Hard starting
a . Defective spark plug/s Clean, adjust o r replace plug/s
b. D efective b r e a k e r points Replace points
c . L o o s e connection in primary Tighten o r repair
circuit
d. D efective condenser Replace condenser
e . D efective coil Replace coil
f. D efective cap o r rotor Replace cap o r rotor
3. Engine misses
a. Dirty o r defective spark plug/s Clean, adjust o r replace plug/s
b . L o o s e ignition w ire / s o r de Tighten, repair o r replace w ire/ s
fective insulation
c . C ra ck ed distributor cap Replace cap
d. Im proper b r e a k e r points ad Adjust b re a k e r points
justment
D IS T R IB U T O R
Description
R o to r
D i s t r i b u to r C a p .
P r im a r y
T e rm in a l
C o n d e n se r- C o n ta c t P o in t
B r e a k e r Arm
Oil C u p
Cam
F i g . 10-2 Sectional V i e w of Distributor Y5662

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 dvance
D riv in g P l a t e
A ngle
G o v e rn o r
Cam W eig h t
C am
D riv in g P in
W eig h t S u p p o r t P in
b e fo re A dvance A dvanced
G0185
F ig . 10-3 Operation of G overn or G0186
A dvance
A ngle
D ia p h rag m
■ Jf A dvancer
O c ta n e S e l e c t o r
b e fo r A dvance
F ig . 10-4 Operation of Vacuum A d v a n c e r
A dvanced G1273
G1274
. . . '
T h e distributor includes the b re a k e r points and the condenser which a r e con
nected in the primary circuit. It also includes the rotor and the distributor cap
which are connected in the secondary circuit.
T h e distributor is driven by the g e a r on the camshaft in "time" with the engine.
A s the spark timing va rie s according to the load and the engine revolution, the
automatic spark advance mechanism is provided in the distributor. T h e centri
fugal go v e rn o r advances the position of the cam according to the engine r e v o
lution, and also the vacuum advancer controls the position of the b r e a k e r plate
according to the load on the engine.
A ls o the octane selector is provided in the vacuum advancer, and it is n e c e s

sary to adjust the spark timing in accordance with the quality of fuel.
Specification:
P a r t N o. 19100-44010 fo r 5R 19100-40050 19100-40015

fo r 3 R - C fo r 3 R - B
Weight A p p ro x . 1 . 1 kg (2 .4 lb s )
Condenser capacity 0.20 ~ 0.24 microfarad
B r e a k e r point spring 400 ~ 550 grams
tension
B r e a k e r point gap 0 .4 ~ 0.5 mm
(0.016 ~ 0 .0 2 0 ")
Dwell angle 52°
10-4 IGNITION 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, at 130 m m H g ( 5.12 inHg)
9.1 - 13.1' at 180 mmHg ( 7.09 inHg)
12.0 ~ 16.0' at 260 mmHg (10.25 inHg)
13.8 - 17.8' at 330 mmHg (13.00 inHg)
15.0 ~ 19.0 at 390 mmHg (15.25 inHg)
F o r 3 R - B & 3 R - C Engines
Begins at 45 ~ 60 mmHg (1.77 ~ 2.36 inHg)
Tim ing advances 3.0 ~ 5.0 at 90 mmHg (3.54 inHg)
5.0 ~ 7.0 at 120 mmHg (4.73 inHg)
7.7 ~ 9.7 at 180 mmHg (7.09 inHg)
10.0 ~ 12.0 at 250 mmHg (9.84 inHg)
G o v e rn o r advance characteristics:
F o r 5R Engine
Begins at 400 ~ 600 rpm
Tim ing advances 4.0 ~ 6.0 at 1,000 rpm
13.0 ~ 1 5 .0 ° at 1,900 rpm
15.0 ~ 1 7 .0 ° at 2,500 rpm
F o r 3 R - B Engine
Tim ing advances 6.0 ~ 8 .0 ° at 1,000 rpm
8.5 ~ 1 0 .5 ° at 1,200 rpm
13.0 ~ 1 5 .0 ° at 2,500 rpm
F o r 3 R - C Engine
Tim ing advances 8.7 - 1 0 .7 ° at 1,000 rpm
12.0 ~ 1 4 .0 ° at 1,200 rpm
16.5 ~ 1 8 .5 ° at 2,500 rpm
Octane selector advance One complete turn is about O2.3

One graduation is about 5.2
Rem oval
1 . Disconnect the high tension w ir e s 3. Rem ove the vacuum pipe from the
from the spark plugs and the igni vacuum advancer.
tion coil.
A s the high tension w ir e s a re of 4. L o osen the distributor clamp
an internal resistance type ( R e - s c r e w ,a n d rem ove the distributor.
sitive c o r d ) , c a r e must be taken
that the w ir e s a r e rem oved by Disassembly
pulling on the cord insulating fittings
rather than on the w ire insulation. 1. R em ove the distributor c a p , ro tor,
dust proof c o v e r and the adjuster
2. Disconnect the primary w i r e from cover.
the distributor.
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

2. G overn or spring 11. A d ju ster c o v e r 20. B r e a k e r plate
3. G o vern o r weight 12. Housing cap spring 21. Stationary plate
4. G overn or shaft & plate 13. Oil cup 22. S p rin g set
5. Steel w a sh er 14. Distributor cap 23. Vacuum advancer
6. Bakelite w a sh er 15. Cap center piece 24. " O " ring
7. Term inal insulator 16. Rotor 25. W asher
8. Term inal bolt 17. Dust proof c o v e r 26. Spiral g e a r
9. Condenser 18. B re a k er 27. Pin
F i g . 10-5 Distributor Components G3424

10-6 IGNITION SYSTEM - Distributor
2. R em ove the b r e a k e r arm 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 the b r e a k e r
arm (2 ) with the contact point (3)
from the b r e a k e r plate.
F i g . 10-8 Removing V3678

Distributor Cam
7 . R em ove the g o v e r n o r springs and

the g o v e r n o r w eigh ts.
F i g . 10-6 Rem oving B r e a k e r V3675 8. R em ove the pin, and then rem ove
the spiral g e a r .
3 . R em o v e the vacuum adva n cer r e T o rem ove the pin, drill the r iv -
taining s c r e w ( 1 ) , adva n cer lead etted pin en d .
w i r e retaining s c r e w (2 ) and the T a k e c a r e of the 3 ~ 7 w a sh e rs
snap ring (3 ) , and then rem o ve installed on the g o v e r n o r and plate
the vacuum a d va n cer ( 4 ) . at both sides of the distributor
housing.
Inspection
Wash all the parts with the exception

of the vacuum advancer and the con
d en ser in cleaning solvent.
Inspect the following items, and r e
pair o r replace any defective p a rt/ s .
G o v e rn o r & Shaft
1. Check the shaft fo r w e a r , and

F ig . 10-7 Rem oving Vacuum V3676 check the fitness with the distri
Advancer butor housing.
4. R e m o v e the housing cap springs,
2. Inspect the shaft fo r bend which
and r e m o v e the co n d en ser and the
should not ex ceed 0.07 mm o r
terminal insulators.
0 .0 0 3 " .
5. R e m o v e the b r e a k e r plate with
stationary plate. 3. Check the fitting portions of the
g o v e r n o r weights with the support
6 . R e m o v e the distributor cam r e pins fo r binding, and check the
taining s c r e w , and re m o v e the g o v e r n o r spring fitting surfaces
distributor cam . fo r w e a r .
The g o v e r n o r weight and pin
clea ran ce is 0 .2 mm ( 0 . 0 0 8 " ) .
IG N I T I O N S Y S T E M - Distributor 10-7
0.2m m (0.008")
G o v e rn o r W eig h t
Limit 7 mm (0.27")
L_
F ig . 10-9 Checking Pin GO 190 F i g . 10-11 Checking Carbon G1275

C learance P ie c e
4. Install the distributor shaft, w ash B r e a k e r Plate &■ Stationary Plate

e r s , spiral g e a r and the pin onto
the distributor housing, and then 1. R em ove the snap ring ( 1 ) , and
inspect the thrust clearance with rem ove the w a s h e r ( 2 ) , set spring
a dial gauge o r fe e le r gauge. (3 ), balls ( 4 ) , w a s h e rs ( 5 ) ,
T h e clearan ce should be 0.15 to stationary plate (6 ) and the b re a k
0 .5 mm (0.006 ~ 0 . 1 9 7 " ) . e r plate (7 ) .
If the clearan ce ex ceed s 0.5 mm
(0 .02" ) , adjust the clearance with
the adjusting steel w a s h e r.
liiiaSF
5 3 2 1
F i g . 10-12 Disassembling V3682

Stationary & B r e a k e r Plate
F ig . 10-10 Checking Thrust V3681 2. Coat multipurpose g r e a s e onto the

C leara n ce sliding surface of the stationary
plate with the b re a k e r plate after
Distributor Cap washing, and assemble the dis
assembled parts.
Check the cap fo r c r a c k s , carbon
tracks, and the burnt o r corroded 3 . Inspect the b re a k e r plate operation
terminals, and also check the center re sista n ce.
carbon piece fo r w e a r . T h e resistance should be less than
T h e piece length is 9 mm ( 0 . 3 5 " ) , 530 gram s (18.7 o z ) .
and the limit is 7 mm ( 0 . 2 7 " ) .
10-8 IG N I T I O N SYSTEM - 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. Insert the thrust w a sh e rs ( 2 ) , (3)

and (4 ) onto the go vern o r shaft
and plate ( 1 ) , and then install the
g o v e r n o r shaft and plate onto the
housing (5 ) after lubricating the
shaft with engine oil.
F i g . 10-13 Checking G0335 T h e bakelite w a sh er should be
Operating Resistance installed between the steel w ash
ers .
4. Insert two s c r e w d r i v e r s between
the b r e a k e r plate and the station
a ry plate as shown in the figure,
and pry the s c r e w d r iv e r s .
A t this time, the clearan ce b e
tween the both plates should be less
than 0 .2 mm ( 0 . 0 0 8 " ) .
If the clea ran ce e x c e e d s , adjust
it with the w a s h e r .
D river
L e s s t h a n 0.2mm (0.008* F i g . 10-15 Assem bling V3683
G o vern o r Shaft
2. A s s e m b le the w a s h e rs ( 6 ) , spiral
g e a r (7 ) and the pin (8 ) onto the
D river shaft, and then rivet the both pin
ends..
3. A ss e m b le the go v e rn o r weights
F i g . 10-14 Checking C l e a r - G0349 (1 ) and ( 2 ) , and the go vern o r
ance between Stationary springs (3 ) and ( 4 ) .
& B r e a k e r Plate T a k e c a re of the assembling d ir e c
tion of the g o v e r n o r springs as
Other Items shown in figure 10-16.
A l s o lubricate the connections and
1. Check the b r e a k e r points fo r burnt the pins with engine oil, and check
o r pitted condition, and if n e c e s fo r smooth operation.
s a r y , clean with a point file.
4. Coat the distributor shaft with mul
2. Inspect the distributor cam lobes tipurpose g r e a s e , and install the
f o r s c o r e s and w e a r . cam onto the shaft.
Tighten the cam retaining s c r e w ,
3. Inspect the conden ser fo r capacity and fill the g r o o v e in the upper
and d e fe c ts . portion of the cam with g r e a s e .
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.
7. Install the terminal bolt and the

insulators, and tighten the nut
finger tight together with the con
den ser lead w ir e ;
8. Install the contact point and the

b re a k e r arm onto the b r e a k e r
plate with the snap ring and the
retainer s c r e w .
F i g . 10-17 Assem bling Cam V3678 Connect the b r e a k e r arm lead
w ir e onto the terminal, and tighten
5. Install the b re a k e r plate assembly the nut.
onto the housing, and secu re it Coat the cam lobes with g r e a s e .
with the retaining s c r e w s together Do not allow any oil o r g r e a s e
with the cap springs. on the point su rfaces.
A s the form of the cap spring is
different from each other, install 9. Adjust the octane selector to the
the cap spring as shown in figure normal position as follow s.
10-19. T h e setting line should be flush
with the housing thread e n d .
O ne
F i g . 10-18 Assem bling V3677

B r e a k e r Plate F ig . 10-20 Octane S e le c to r G1701
Norm al Position
10-10 IG N IT I O N SYSTEM - 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 , and

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 .
P e r fo r m a n c e T e s t &■ Adjustment
B reaker A rm S p rin g Tension
Inspect the b r e a k e r arm spring tension

with a spring tension tester by pulling F ig . 10-22 Adjusting Point V3686
at right angle of the b re a k e r arm Gap V3687
point. Read the tester just when the
points o p en . Cam Dw ell A n gle
T h e specified tension should be 400
to 550 gra m s (14.1 ~ 19.4 o z ) . Check the cam dwell angle with the
If the tension is l o w , replace the distributor tester.
b r e a k e r point assem bly. T h e angle should be 52°. T h e ad
justment can be made by adjusting
the b re a k e r point gap.
If the gap is w ide, the angle will be
sm all, and if the gap is n a r r o w , the
angle will be la rg e.
F ig . 10-21 Checking S p rin g V3688

T ension
B r e a k e r Point Gap >UT0*
Rotate the distributor shaft until the F i g . 10-23 Checking Cam V3689
b r e a k e r arm rubbing block is at the Dw ell A n g le
top of the c a m .
Check the point gap with a fe e le r A d v a n c e Characteristics
gauge, and adjust the gap to 0 .4 to
0-. 5 mm (0.015 ~ 0 . 0 2 0 " ) . Check the g o v e r n o r advance and the
T o adjust the gap, loosen the contact vacuum advance with the distributor
point retaining s c r e w , and insert a t e s t e r . When the tests a r e p e r fo rm e d ,
slot type s c r e w d r i v e r into the cut test the g o v e r n o r advance first as the
portion of the contact point plate. vacuum adva n cer is influenced by the
N e x t, p ry the s c r e w d r i v e r to obtain governor.
the c o r r e c t c le a r a n c e .
A ft e r adjusting the gap, tighten the 1. G o vern o r advancer.
retaining s c r e w s e c u r e ly . Operate the distributor in the di
rection of rotation, and adjust the
IG N IT I O N S Y S T E M - Distributor 10-11
speed to the initial rpm setting Vacuum A dvan ce Specification:

listed in the specification.
Move the protruded scale so that F o r 5R Engine
one of the flashes aligns with the
z e r o d e g re e mark. Vacuum mmHg A dvan ce angle
S low ly increase the rpm to setting (inH g)
specification fo r the first advance 70 ~ 90 A dvan ce begins
reading listed in the specification. (2.76 ~ 3.54)
If the c o r r e c t advance is not in 130 ( 5.12) 6.5 ~ 1 9 .5 °
dicated at this rpm, replace the 180 ( 7.09) 9.1 * 1 3 .1 °
g o vern o r springs. 260 (10.25) 12.0 ~ 1 6 .0 °
Operate the distributor both fo r 330 (1 3 .0 0 ) 13.8 ~ 1 7 .8 °
w a rd and r e v e r s e in the rpm 390 (1 5 .2 5 ) 15.0 ~ 1 9 .0 °
ran ges.
F o r 3 R - C & 3 R - B Engines
G o vern o r A d va n ce Specification:
Vacuu m mmHg A d va n ce angle
F o r 5R Engine (inHg)
45 ~ 60 A d va n ce begins
Distributor rpm A d va n ce angle (1.77 ~ 2.3 6)
400 ~ 600 A d va n ce begins 90 ( 3.5 4) 3.0 - 5 .0 °
1 ,0 0 0 4 .0 - 6 .0 ° 120 ( 4 .7 3 ) 5.0 ~ 7 .0 °
1,900 13.0 - 1 5 .0 ° 180 ( 7.0 9) 7.7 ~ 9 .7 °
2.500 15.0 ~ 1 7 .0 ° 250 ( 9.8 4) 10.0 m 1 2 .0 °
F o r 3R -B Engine Condenser
Distributor rpm A d va n ce angle Check the condenser fo r minimum

320 ~ 480 A d va n ce begins s e r ie s resistance, maximum insulation
1 ,000 6.0 ~ 8.0° resistance and the capacity with the
1 ,200 8.5 ~ 1 0 .5 ° distributor tester.
2.500 13.0 v 1 5 .0 ° T h e s e r ie s and the insulation r e s is
tances should be within the permissible
F o r 3 R - C Engine range on the tester.
A ls o the capacity should be 0.20 to
Distributor rpm A d va n ce angle 0.24 m icrofarad.
320 ~ 480 A d va n ce begins If defective, replace the cond en ser.
1 , 000 8.7 ~ 1 0 .7 °
1 ,2 0 0 12.0 ~ 1 4 .0 ° Installation
2.500 16.5 ~ 1 8 .5 °
1. Position the N o . 1 piston at T . D . C.
Vacuum advan cer. of the compression stroke. A t this
Connect the test set vacuum line
onto the fitting on the vacuum ad
v a n c e r.
S et the tester to 0 advance, z e r o
vacuum at the distributor 1,000
rpm .
Check the advance at the first v a
cuum setting specification in the
specification.
If n ecess a ry , replace the advancer.
F i g . 10-24 Timing Marks B0264

10-12 IGNITION 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 slightly with the starter
movable with the/fin gers. after the distributor drive g e a r is
N ext, align the timing pointer on partially engaged with the oil pump
the timing g e a r c o v e r with the tim shaft.
ing ball, and this will set the tim
ing to B . T . D . C . 8° on the 5R , 3 . Rotate the distributor housing coun
and 12 on the 3 R - B , and 5 on terclock w ise until the points are
the 3 R - C engine. Th is ball is starts to open, and tighten the
provided on the crankshaft pulley . clamp s c r e w .
2. Position the distributor into the 4. Connect the primary w ir e and the
cylinder block with the rotor at vacuum pipe.
the N o . l firing position.
Make sure that the oil pump shaft 5. Install the dust proof c o v e r , rotor
is engaged with the distributor and the distributor cap.
shaft.
6. Install the high tension w ir e s with
the firing o r d e r of 1 - 2 - 4 - 3.
7. Run the engine at 550 rpm for

5R and 3 R - B , and at 650 rpm
fo r 3 R - C , and check if the timing
pointer aligns with the timing ball
using the timing light.
If n e c e s s a r y , adjust the ignition
timing.
8. Adjust the octane selector by r e

fe rrin g to Engine Tu n e-U p s e c
F i g . 10-25 Distributor V4654 tion .
Installation Position
IG N I T I O N C O I L
Description
T erm in al
C om p o u n d I n s u la to r
C ase
P r im a ry Coil
S e c o n d a r y Coil
In s u la to r
F i g . 10-26 Sectional V i e w of Ignition Coil G0194

IGNITION 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 . By this windings, the voltage is in
c r e a s e to about 20,000 volts which is sufficient to spark a c ro s s the sparkplug
gap without any difficulty.
T h e voltage generated in the secondary winding is strongest when the prim ary
circuit is opened because of the difference of speed of movement of the magnetic
lines of fo r c e .
When the b re a k e r points a re closed, the current flows through the prim ary wind
ings causing magnetic lines of fo r c e to move away from the soft iron c o r e .
B ecau se of their attraction to the c o r e , they move relatively slow . When the
prim ary circuit is opened, the magnetic line of fo rc e snap back to the c o re b e
cause of their attraction to it.
Specifications:
P r im a ry voltage 12 volts
P r im a ry resistance 3.7 ohms
S eco n d ary resistance Approximately 9,000 ohms
S econ d ary voltage Sparking distance from center to three
negative electrodes should be m ore than 8
mm (0 .3 1 5 " ) at distributor revolution of 75
rpm and at 12 volts.
Sparking distance from center to three
-negative electrodes should be m ore than
6 mm (0 .2 3 6 " ) at distributor revolution of
3,000 rpm and at 12 volts.
Weight Approximately 0.7 kg (1 .5 lb s ) .
Rem oval If the reading is not within the

specified resistance, the coil is
1. Disconnect the w ir e s connecting opened o r shorted.
to the ignition c o il.
3. Check the insulation resistance
2. R em ove the ignition coil retaining between the case and the terminal
bolts, and then rem o ve the ignition with a 500 volts megoohm m eter.
c o il. T h e insulation resistance should
be more than 100 megohms.
Inspection
4. Check the secondary voltage with
B e fo r e testing the coil, alw ays heat a coil tester following the instruc
the coil to normal operating tem pera tion manual of the tester furnished
ture . by the manufacture.
T h e sparking distance from the
1 . Check the prim ary resistance with center to the three negative e le c
a tester. trodes should be m ore than 8 mm
T h e reading should be within 3.3 (0 .3 1 5 " ) at distributor revolution
to 4 .3 ohms. of 75 rpm and at 12 volts.
A ls o the sparking
2. Check the secondary resistance. than 6 mm (0.236*0 at distributor
T h e resistance should be within revolution of 3,000 rpm and at
8,400 ~ 9,200 ohms. 12 volts.
10-14 IGNITION 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 the rem oval p roce d u res in the w i r e , and do not make a sharp
the r e v e r s e o r d e r . bend in the w i r e .
HIGH T E N S I O N W IR E S Installation
Description Insert the w ir e securely as it w as

installed b efo re, and do not allow the
Internal resistance type spark plugs w ir e to contact any metal surface.
and ignition coil w ir e s a r e installed
on the engine high tension circuit.
T h e s e w ir e s a r e of a radio resist SPARK PLUG
ance type which the c o r e is carbon-
impregnated linen. T h e s e w i r e s a re Removal
designed to eliminate the high frequen
cy electrical impulses that a r e the Disconnect the high tension w ire s
so u rce of ignition noise in te rfe re n c e , from the spark plug terminals, and
but a r e also su perior in resistance rem o ve the spark plugs using the
to c r o s s - f i r e . T h e resistive w ir e s , S p a rk Plug Wrench.
h o w e v e r , a r e m ore easily damaged,
by c a r e le s s handling than copper Inspection & Adjustment
co re d w i r e s . F o r this reason , c a re
must be taken that the w ir e s a re 1. Check the plugs fo r cra c k s , and
rem oved by pulling on the w ir e in chips on the insulators.
sulating fittings rather than on the
w ir e insulation. 2. Check the electrodes fo r w e a r .
Rem oval 3. Check fo r ex cess ive carbon de

posit.
T o disconnect the high tension w i r e s ,
pull only on the end insulating fitting. 4. Check the porcelain fo r gla ze,
D o not pull o r je r k the w i r e b e c a u s e o r blister.
pulling on the w i r e might cause dam If carbon deposit is e x c e s s iv e , it
age to the conducting c o r e of the w ir e . is an indication of burning engine
o il.
Inspection Replace with a hot type plugs.
If the plugs a re ex cess ively white
1. Check the resistance value of each o r rapid electrode w e a r , replace
w i r e between both ends. with a cold type plugs.
T h e resistance value should be
less than 25,000 ohms, and if it
e x c e e d s the specified value, r e
place the w i r e .
2. Wipe the high tension w ir e s with

a cloth moistened with cleaning
solvent, and w ipe them d r y .
Bend the w i r e s to check fo r brittle,
c r a c k s o r loose insulation.
3. Check the condition of the w ir e

term inal.
If any terminal is c o r r o d e d , clean F i g . 10-27 S p a rk Plug V2204
it, and if it is broken o r distorted, Burned Condition
IG N IT I O N S Y S T E M - High Tension Wires 10-15
A : 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
insulation.
7. Adjust the plug gap to 0.7 ~ 0 .8

mm (0.027 ~ 0 .0 3 1 ") by bending
the ground e le c tr o d e .
Installation
Follow the removal p roce d u res in

the r e v e r s e o r d e r .
T h e specified spark plug tightening
torque is 1.0 ~ 2.5 m -kg (7 .2 ~
18.0 ft-lb) .
F i g . 10-28 Cleaning S park V2205
P lu -
10-16 MEMORANDUM
MEM O sp *
P r e p a r e d By
T O Y O T A M OTOR S A L E S C O . , LTD.
E x p o rt-T ech n ica l Division
Haruhi Plant
H aruhi-m ura, Nishikasugai-gun

.A ich i P r e f . , Japan
A p r il 1969
No. 98022
Printed in Japan

5r 1969

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5R, 3R-B & 3R-C ENGINE

TOYOTA M O TO R SALES CO., LTD.

This manual has been prepa red to provide the

T h e section index on the title page enables the

T h e s e r v ic e p rocedu res on these engines a r e almost

A ll the information and the specifications contained

RECOMMENDED S . S . T ............................ 1-9

MEMORANDUM .................................. ........... 1-10

T h e 3 R -B model engine w as also developed from the 3R model engine by im­

T h e 5 R , 3 R - B and 3 R - C model engines a r e of fou r-cylinder in -lin e, overhead

Th e cylinder head is of a cast iron, and incorporates a bath-tub type combustion

T h e pistons a r e of a low-expansion type which is of aluminum silicone alloy with

T h e piston pin is off-sett 1.0 mm (0 .0 3 9 M) towards the camshaft side which

T h e crankshaft is of carbon steel, and the bearing journals a r e induction hard­

T h e crankshaft main bearings and the connecting rod bearings a r e of micro p r e ­

Fig. 1-2 Cross Sectional View of 3R-C Model Engine G3423

T h e camshaft is of chilled casting, and the camshaft timing gear is of bakelite.

Whenever any w ork is perform ed on the c a r , special c a r e should be taken to

T h e use of S e r v i c e S pecial T o o ls must be emphasized as these tools a re so

During disassembling any components, it is essential that parts disassembled

S e r v i c e T o rq u e Specification should be adhered w h e n ev er tightening the bolts

>4 >4 >4

>3 >3 >3

09303- 35010 Imput Shaft Front B earin g Pu ller

09860-11010 C a rb u reto r S c r e w d r i v e r Set

09239-40010 Water Pump R otor P u lle r

09286-46011 Injection Pump Spline Shaft Pu ller

I N S P E C T I O N & A D J U S T M E N T ................ 2-1

In o rd er to maintain the full performance originally built in the engine, a p erio d ic

Inspection & Adjustment R K 4 4 , 101 series:

3 . Clean the terminals and top of the R T 4 3 L , 52L series:

Adjust the belt tension if n eces­ fa r as possible, then release the

4. Check the vacuum advancer me­

A i r C lean er 7. Check the tyreaker arm tension

2. Clean the ro to r , and check fo r 1. Inspect each plug individually fo r

When cleaning with the abrasive

3. Inspect each spark p l u g fo r make

Ignition Timing 4. If the engine does not ping, turn

relation with the characteristic of the 3 R - C engine, r e fe r to Emission

1. Start the engine, and check the

2. T h e adjustment of the engine idling

a. Rem ove the intake manifold

F o r detail operation and p roce d u res , 4.. On the R S , R T 4 3 L , 52 s e r ie s ,

If n e cess a ry , adjust the choke r e ­ N O T E : A lw a y s use a fully charged

3. Install the compression gauge into

TROUBLE S H O O T I N G ................................ 3-1

Symptoms & Probable Causes Rem edies

a . Incorrect valve clearance Adjust valve clearance

2. Ignition system im properly adjusted

a. Incorrect ignition timing Adjust ignition timing

a. Clogged carburetor jet Disassemble and clean carburetor

4. Insufficient carburetor air intake

a. Restricted air cleaner Clean air cleaner

a. Insufficient coolant Replenish coolant

i. B ra k es dragging Adjust brakes

a. Oil pan drain plug loose Tighten drain plug

a. Defective piston rings Replace piston rings

a. Im proper oil viscosity Change to p rop e r viscosity oil

a. Burnt distributor points Replace points

b. Points incorrectly adjusted Adjust points

a. Burnt valves Rep air o r replace valves

a. Choke operating improperly Adjust o r repair choke mechanism

Popping, Spitting and Detonation

T h e 3 R -B model engine w as also developed from the 3R model engine by im

T h e crankshaft is of carbon steel, and the bearing journals a r e induction hard

T h e crankshaft main bearings and the connecting rod bearings a r e of micro p r e

Adjust the belt tension if n eces fa r as possible, then release the

4. Check the vacuum advancer me

If n e cess a ry , adjust the choke r e N O T E : A lw a y s use a fully charged

Disassembly 10 . R em ove the engine mounting b r a c k

Wash the disassembled parts tho

1. T h e use of cylinder sleeve is r e