Toyota 2F Operating instructions

..
2F ENGINE
REPAIR MANUAL
Au g.,1 980
TOYOTA MOTOR CORPORATION
Pub. No. 38104E

TOYOTA
2F ENGINE
REPAIR MANUAL
t .. ,..,,_U.V<'Y«Y=v , ,,_ • o/ft~mH«Y<'Y<U<
Aug .. 1980
T1 0YOTA MO TOR CORPORAT ION
Pub . No. 3610 1\ E

SECTION INDEX
NAME
INTRODUCTION
ENGINE TUNE-UP
ENGINE SERVICE
LUBRICATION SYSTEM
COOLING SYSTEM
FUEL SYSTEM
STARTING SYSTEM
@ NITION SYSTEM
~ RGING SYSTEM
SST & SERVICE SPECIFICATIONS

INTRODUCTION
Page
GENERAL REPAIR INSTRUCTIONS .. .... .. .. 1-2
ABBREVIATIONS USED IN
TOYOTA REPAIR
MANUALS ....... 1 -3
HOW TO USE THIS MANUAL .. .... .. ......... 1-4
SYMBOLS .. .. ...... .. ............. .. .................... 1-6

1- 2 INTRODUCTION - G
en eral R ep air Ins tr uc ti ons
GENERAL REPAIR INSTRUCTIONS
1. Use fender, seat and fl oor covers to keop the car clean and prevent damage.
2. During disassembly, keep parts in order to facilitate reassembly .
3. Before per f orming electrica l work, disconnect the cable from the battery terminal.
4. Always replace cotter pins. gaskets and 0 rings with new ones.
5. When necessary. use a sealer on gaskets to prevent leaks.
6. Carefully observe all specifications for bolt tightening torques. Always use a tor-
que wrench.
7. Use genuine Toyo ta parts.
8. When replacing fu ses, bo sure tho new f use is the correct amperage . DO NOT
exceed the fuse amp rating or use one of a lower rating.
9. If the vehicle is to be jacked up only at the front or rear end. be sure to block the
wheels in order to ensure safety .
1 O. After the vehicle is jacked up, be sure to support it on stands . It is extremely
dangerous to do any work on the vehicle raised on a jock alone. even for a small
job that can be finished quickly .
11 . Use of a special service tool (SST) may be required . depending on the nature of t he
repair . Be sure to use SST where s1>eclfied and follow the proper work procoduro.
A fist of SST ca n be found at the back of this manual.
INTRODUCTION - Ab bre v ia tions Used InToyotaRepairM anuals
ABBREVIATIONS USED IN TOYOTA REPAIR MANUALS
For convenren ce. lhe following abbrovia1ions are used on T oyo1a repair manuals
Abbrevia 1i on
Term
Abbrevia 11 on
Term
---
A/T
Au1oma1ic Transmission OIS
Ovors120
BDC
Bo11om Dead Cenior
RH
Righi· hand
BTDC
Before Top Dead Conier
RHO
R1gh1 ·hand Drtve
--
EX
Exhau s1
SST
Spe c ial Service T 001
IN
lniake
STD
Standard
--
LH
Lofl- hand
T
T1gh1en1ng Torque
LHD
Loft· hand D rt ve
TDC
Top Dead Cen1or
--
MP
Mul 1ip u rpose
UIS
Undo r size
M IT
M anua l Transm is sion
WI
W 11 h
._
--
OPT
Op lion WIO
Wl1hou 1
3
I
·I
I

1 - 4
IN TRODUCTION How To Use This M anual
HOW TO USE TH IS MANUAL
1. OVERVIEW ILLUS T RAT ION
Many se rvi ce opera ti ons begin w11h an overv iew 1 llustrauon as a g one r al guide.
@
@
3- 16 ENGINE SERVICE - C- Ho>d
Fl91 . 3· 46
5 ------
6 ----
ASSEMBLY
A.UM bM lht Pil" n I~ ""'Mf!flC'• i Ol'di!f
Shl:Wrrtt . ,, the" r.q .....
... ~ · -- @ -
>••
-- - 2. ,..., ..
,•.,
The bold nu mbers ond1cato 1h eordor on which th ework is 10 be done
The figure numbersr
efer you tomoredetailed rnstruc11ons and spccrhca11ons.
INTRODUCTION - How To Use This Man ual
1 -5
2. ILLUSTRATED INSTRUCTIONS
©
@
®
®
All 1mpart an 1st eps1n ev ery ser vice JOb are 1 llus11at od Obvious s te ps aro omitted to s av os pac o
Expener>eed tcchnrcrans ma y only need to glance al the overview 1llustratron and/ or spce1hca
11on s.
-~~ ...
lf t"··· ,- T
,..
ENGINE SERVICE - C--
,_,,
...
C<-iat tNI v•lve Slf'ffl.l with e1-o roe Ot i
l
t>Stl I llwt tOfllPW) tNf itf"Cf tiN' •• nth $Sf
SST 109,01 - 310101
Drive In dl•tll'!Ce:
• .• - 10.2 "''"
- Nol • -
{O, Jll - 0.4 02 ,., _J __ - - -- 1-- - - @
1 A tlit'W cNI •• ., ahoulO be vsM when · - -l l- -- -{ F
ever Ifie w11Vt I• di:1Jtstembled.
2. Co•I tho o il lttl llp whh engine oil _ - ©
r::'f Comp.ns lhe v.s ,... lf)t •ng w11h SST ane1 ms.rt- -11- -- ®
t:.:J lhl soru'O tc11•1r.ef tocks
SSt f09102 43011 1
Altl!f tMt..i.ng 1"9 tOnng,. "Oht)y t. thfo
t't'M t!!l'ldt ~fld alt "-I the ~ 1"9S to '4ftllil!
(.IO wn snVQ1't
T he p1cturesg1vc basic 1nformat1onon what todo in each step
A symbol•Softenused toexplain theactron
reQu1ted
The 1ex1explai ns how to pertorm 1h estop
Spec1hca11ons. Notes and Cau11ons are given in bold type so you w on· 1miss them.

I
I
1 6
IN TRODUCTI ON -Symbols
SYMBOLS
The following symbols have been adopted fo r simpl ici ty and quick 1ecognl 11 on.
l •• I REMOVE or DISASSEMBLE
l• •I INSTAL L or ASSEMBLE
l lf'5 1 INSPECT
l ~ I MEASURE
l ~ I TIGHTEN
1 .-:i l CLEAN
.&. IMPORTANT
ENGINE TUNE-UP
Page
ENGINE TUNE -UP I TEMS ........................ 2-2
DRIVE BELT ............................................ 2-4
BATTERY
...................................... .......... 2-5
ENGINE OIL ...... .. .......... ........... ....... ........ 2-6
COOLING SYSTEM .............. ....... ............. 2-7
AIR CLEANER ......................................... 2-8
HOT AIR I NTAKE ................... ................. 2-9
SPARK PLUGS ..... .. ........... .. ... .. .. .. .... ....... 2-9
HIGH TENSION CORD ..................... ........ 2- 10
DISTRIBUTOR ......................................... 2-11
IGNITION TIM ING .... ... .. .... . .. ..... .. ...... ...... 2- 12
VALVE CLEARANCE . .. . ............. . .............. 2- 14
CARBURETOR .................................. ....... 2- 15
IDLE SPEED ADJUSTMENT (USA) .......... 2- 17
IDLE SPEED & IDLE M IXTURE
ADJUSTMENT (except USA) ...... 2- 18
FAST IDLE SPEED
ADJUSTMENT ( USA ) ........ ...... .... 2- 20
FAST IDLE SPEED
ADJUSTMENT (Others) ...... ....... .. 2-21
THROTTLE POSITION
ER .......................... 2-22
COMPRESSION PRESSURE ...................... 2- 23

2 -2
1
2
3
4
ENGINE TU NE -UP - EngineTu ne -u pItems
ENGINE TUNE-UP I TEMS
IT EM
DRIVE BELT TENS
ION
(General destinat ions)
Deflection wit h 10 kg (22 lb) force
Fan - Alternator
N. S.W . & Victor ia states
Other australian states
ex. Australia
Fan - Air pump
N ew be lt
Used belt
N.S. W. & Victoria states
(USA & Canada)
Borroughs be lt tension gauge No . BT-33 -73F
Air con. N ew belt
Used bell
Others
New belt
Used belt
BATTERY
Specific grav i ty
Elec tr olyte level
ENGINE O IL
Oil l evel check
Oil re1> lenish ment
Oil capacity
Ory fill
Drain & refill
USA
ECE
Others
w/ o il filter change
w
/o oi l filter change
Oil filter replacement
COOLI NG SYSTEM
Cool
ant level
Coolant quali ty , leakage
Radiator cap valve opening pressure
STD
Lin1it
REMARKS
13 - 15 mm
7 - 10 mm
0.51 - 0.59 in.
0. 28 - 0.39 in .
7 - 9 mm
9 - 12 mm
0. 28 - 0. 35 in
0.35 - 0 47 in .
7 - 10 mm
0.28 - 0.39 in.
100 - 160 lbs
60 - 80 lbs
120 - 170 lbs
80 - 120 lb s
1. 26 - 1.27
(w hen fu l ly charged ait 20 °C (68 °F ll
Correct level
F line
API service SE or better
API service SD. SE or better
API service SC. SD. SE or better
8.0 l iters 8.5 US q~ 7.0 Im p. qt
7.8 lit ers 8.2 US qt
7.0 liters 7.4 US qt
SST [09228-440 1O]
Full
li ne
0.75 - 1.05 kg / cm
2
(10.7 - 14 .9 i >si)
0.6 kg / cm
2 8.6
psi
6.9 lm1 >. qt
6.2 lm1> . qt
Coolant capacity w/ heater or air conditioner
FJ40 , 43, 45 ser ies
FJ60 series
16.0 liters 16.9 US qt 14.1 Imp . qt
16 .5 li ters 17.4 US qt 14 .5 Imp. qt
25.0 liters 26.4 US qt 22 .0 Imp . qt
FA series
5 AIR CL EA N ER
Correc t l evel
Clean element
O il capacity (Oil bath type)
ENG IN E TU N E-UP Engine Tu ne- up It ems 2 3
ITEM
6 HOT AIR INTA KE
Operational check
7 SPARK PLUGS
Visual check, Cleaning
Gap
8 HIGH TENSION CORD
9 DISTRIBUTOR
Di str ibut or cap
Air gap (USA)
Rubbi ng block gap (excep t USA)
Governor advancer. Vacuum advancer
10 IGNI TI ON TIMING
Dwell angle (except USA)
Igniti on timing
11 VALVE CLEARANCE HOT
12 CARBURETOR
Intake
Ex hau st
Choke . Choke breaker. Choke opener
Float l evel. Acceleration pump
13 IDLE SPEED ADJUSTMENT (USA)
Idle speed
14 IDLE SPEED & ID LE MIXTURE ADJUSTMEN T
(
except USA) Idl e speed
Idle mixture s11eed
15 FAST IDLE SPEED ADJUSTMENT
Fast idle speed USA
N.S. W. & Vic toria states
Others
16 THROTTLE POSITIONER
Th r ott le positloner sett ing speed
N.S. W. & Victoria states
Others
17 COMPRESSION PRESSURE at 250 rpm
STD
li mi t
Pressure dif-ference between each cyli nd er
REMARKS
0.8 mm 0. 031 in.
less than 26 k !l per cord
0.2 - 0.4 mm
0.3 mm
41°
0. 008 - 0. 016 in .
0. 012 in.
7° BTDC/ M ax. 950 rpm
0.20 mm 0. 008 in .
0.35 mm 0.014 i n.
650 r pm
650 r1>m
690 rpm
1, 8 00 rpm
lw / EGR and EVAP systems OFF
and vacuum advanc er OFF}
1.8 00 rpm
(w / EGR & EVAP syste ms OFFI
1,
800 rpm
1, 200 rpm (w/ EG R & EVAP systems
OFF)
1, 000 rpm
10 .5 kg / cm
2
149 psi
8.0 k g/c m' 114 psi
Less
than 1.0 kg / cm ' (14 psi)

2-4
Fig. 2-1
Fig. 2-2
Fig. 2-3
N.S.W.
AJternal6f
I ~:~:
L '
Fig. 2-4
ENGI NE TUNE-U P - Dr iv e Belt
A
,.
&!
~I
I 11
I
... I
-··
Others
A
F•n 6:9.
Puuov
AJt•NIOf
Cr•nk
Pu lley
On\1 Bell
---
J
DRIVE BELT
VISUAL CHECK
Cheek for
1 Crack s. de1enora11on. s1ro1chtng or wear
2. Adherence of 0 11 or grease
Improper beh-10-puHov contact.
CHECK & ADJUST BELT TENSION
General de s tlnotlons
Wnh 10 kg (22 lbl of force. press on the belts
01 the poonls ondocated tn the figure. Tile bells
should deflect 1he amount specof1 ed
Drive be ll delloc 1ion
""'
NSW &
-0 1tlCt
8'CCPI
VtetOllol avsu1h1n
Al,lStraha
t11tes
/\
New 7 9
13- 16 7 - 10
1)28-0 ....
mm
(061-0ed» 1028-0300
9 - 17
( 1n > Usoo
l03S
04)1
B 7 -
tO
mm
!028-0391
-- - -
bl\l
USA
Vs1ng a Borroughs belt 1ons1 on gauge BT-33·
73F. adjust as follows.
Dr i ve be lt tension:
Air co n.
Now belt
Used belt
Oth ers
100 - 150 lbs
60 - 80 lbs
New b el t 12 0 - 170 lb s
Us ed belt 80 - 1 20 lb s
Fig. 2 -6
ENGINE TUN E-UP Battery
BATTERY
VI SUAL CHECK
Cheek for
I Rusted bauery
suppon
2.
3. Looso
1ormina1 connoc11ons.
Rusted or deteriora1od ter minals .
4. Damaged or leakong bauery
2-5
r ··
MEASURE SPECIFIC GRAVITY
Fig. 2-7
I TRANSLUCENT ~RY
1 ~ 2
Upf)e• lovel I
lOw61' l.ovcJ
L
_J
Fig. 2-8
r
BlACK ~£RY (5 I
~ TopVotw ~
nu
low
Chock the spec1 f1c gravity of tho e1ec -
1ro l y1e w 11h a hydrometer .
Specific gravity (w h en fully
c harged at 2o •c ( 68 °F)J:
1.25 - 1.27
Check 1ho elec 1r o1v1e Quami 1y of each cell
11 insulfocient refoll w11h distilled water .

2 6 E
NGINE TU N E-UP - En gine O il
Fig. 2-9
Fig. 2- 10
Fig. 2· 12
~-
ENG IN E OIL
CHECK OIL LEV EL
The 011 level should be between the L and F
marks.If low. check !or leakage and add
oi l up
10 the F mark.
Use 1 he engine oil indicated below.
USA - -AP! se rv ice SE or belier
ECE - - API service SO. SE or belier
Others-AP! servi
ce SC. SD. SE or belier
CHECK OIL QUALITY
Check for:
1. Oe t e11oration .
2. Entry ol water.
3 01scolora t1on or th 1 nn1ng .
REPLACE OIL FILTEA
1. Remove the 011
hllc r with SST
SST
[09228-4401 OJ
2 Install a new filler and tighten 11 firmly by
hand .
- Note -
Do not tighte n with SST or a wrench.
3. Start the engine and check for oil leakage.
4 St op the engine and recheck t he oil level.
Fig. 2-13
Fig. 2· 15
Fig. 2-16
ENGI NE TUNE -UP - C oo ling Sy st em
COOLING SYSTEM
CH E CK COOLA NT LEVEL
If low. fill reservoir to FULL hne
- Note -
2- 7
To ma intain freeze protection, use a recom·
mended anti-freeze.
CHECK COOLA NT QUALITY
Check for:
I. Coolant cleanliness.
2. Rust or scale deposits around the radiator
cap and filler neck.
3 Entry of oil.
CHECK COOLI NG SYSTEM PARTS
CMck for :
I. Damaged or deteriorated radiator and
water hoses.
2 Loose hose clamps.
3. Damaged or corroded radiator core.
4. Leakage fr om the water pump. radiator
core or loose water drain cock.
~ 5 .
Fau lt y operation of radiator cap.
Inspect the spring 1ens1on and seating
condilion of lhe radiator cap vacuum
valves. If th e va l ve opens al a pr essu re
below specification or is otherwise defec·
ti
ve. replace th e radiator cap.
Valve opening pressure:
STD 0. 75 - 1. 05 kg/ cm
2
(10.7 - 14 .9 psi)
Limit 0.6 kg /c m2
(8.6 psil

2- 8 ENG
INE TUNE -UP Air Cl eane r
Fig. 2- 17
Fig. 2- 18
Fig. 2- 19
C le an
Cle an
Cue
AIR CLEANER
1 1 ~ 1 [Paper Element Typ e]
CLEAN EL E MENT
Remove 1he air cleaner
- N ot e -
Use care to
preve nt di rt or o th er foreign
mo tt er from entering into the carburetor.
2. Remove 1he element and bl ow coi n·
prossed air from 1ns1de .
3 Replace the element w ith a new one 11
to1n or excess ively dirty
VISUA L CHECK
Check for·
I Damaged. worn or deteriorated gaskets
2. Damaged or worn seal washer
IN STALL AIR CL EA NE R
1 Install the gaskets.
2 Finger
119h1en lhe brackets
3 Aher 1nstall1ng the etement.119hton tho au
clcane1cap wit h t he clips.
4 Tighten
1he w1 1\9 nut and brackets
[ Oil Bath Type ]
CLE AN E LEM EN T
1 Remove the a
ir cleaner and elemen1
2. Cl ean the element and case with kerosene
and dry them thoroughly
EN GI NE TU NE- UP - Air Clea ne r, Hot Air Intake. Spa rkP lu gs 2 9
Fig. 2- 20
r Refill
Ce so
Fig. 2-21
I CO LD
Saturate
El emen 1
lllC Volvo 1
IN STALL AIR CLEA NER
Refill the case
up to tho 1ndrcated level
with clean engine 011
2 Saturate the element w11h clean engine
otl
3. Install the cap and clement
4. T tQhten the air cleaner on the a11 cleaner
suppetl
HOT A IR IN TAKE
~ (USA, N.S .W . &
s er ies)
IN SPECTION
1 Rerroove 1he a11 cleaner cap
ECE FJ
2. Cool the HIC volvo by blowing com·
pressed au on 1t
3 Check that the a11 conuolvolvo closes the
cool air passage al 1dlo
Fig. 2 - 2 _ -' 2 '-----~--
HOT
] ~ 4.
5.
Reinstall th e air cleaner cop and w ar m up
the engine.
Check
th at 1h o air control va l ve opens th e
cool air passage al idl
e.
Fig. 2- 23
Atmosphenc
P0tl IOpenl
J
SPARK PLUGS
VISU AL CHECK
Check for
1. Cracks or ot h er dam age on the threads
and insulator
2. Electrode wear
3. Damaged or do1
e11ora1od gaskets
4 Burntelectrode
or excess carbon depos11s .

2 10
Fig. 2- 24
Fig. 2· 25
ENGI NE TUNE - UP -SparkPlugs.HighTension Cord
CLEAN SPARK PLUGS
~ 1 .
Do no1 u se 1h e spark pl ug cleaner any
longer than necessary.
2. Thoroughly bl ow o ll the cleaning co m-
pound and carb on on th e threads w11h
compressed au
3. Cl ean ofl the d irt from theouter surface of
insulator and threads.
ADJUST SPARK PLUG GAP
Check each plug gap with a spark ptug gap
gauge.
If necessary. adjust by bending th e
pro1rud1ng (o ut er) elecirode.
Spark plug gap: 0.8 mm
(0. 03 1 in.l
HIGH TENSION CORD
& CHECK RESISTA NCE
- Note -
When pulling the cord off the spark plug,
always grip the end of the cord.
Fig. 2·
27 __________ _
._.'I ,. l ~
Check the cord resistance.
Resistance:
less than 25 k C! per cord
Fig, 2·
28
Fig. 2- 29
Fig. 2- 30
Oirty, Co rr · os.ion. Burn t ng
Spring Action
Air Ga.P
Rubbing Block Gap
ENG IN E TU NE- UP Distributor 2 11
DIS TR IBUTOR
CHECK DI STRIBUTOR CAP
Clean 11 1e distributor cap and check 1he cap
and rotor f
or :
I. Cracks. damage. corrosion.burning or clir·
ty cord hol e.
2 Burn! electrode terminal.
3 Weak cent er piece spri ng ac11on .
ADJUST GAP
1 ~ 1
Adjust th e air gap. (USA)
Air gap: 0.2 - 0.4 mm
(0. 008 - 0. 016 i n.)
Ad1us1 t he rubbing block gap. (Others)
Rubbing block gap:
0.3 mm
(0. 012 In.)
CHECK GOVERNOR OPERA T IO N
~ I.
Tu rn lh e ro t or clockwise and release 1L
The rotor should return qu ickly.
2. Check th e ro1or for looseness.

•
I•
I
I
2 12
Fig. 2·32
Fio. 2-
33
USA
N.S.W.
Others
Fig. 2- 34
ENGINE TUNE-UP - Ol attibu101 ,lgnalonTiming
~ 3 .
S1art 1 he eng il\e artd di$COnneet t he
v~cuurn hoses horn the cistrib.utor. The
timing mark sho uld vary with the e~ine
rpm.
CHECK VACUUM ADVANC ER
!iiii1 OPERATION
l.!!:J Apply vacuum to the dlaphngm and cheek
that the vacuum advancer r11oves 1n acCOf·
danc• with the vacuum
IGNITION TIMING
CHECK DWELL ANGLE (except USA)
Us ing a dwelJ ang1e testM . check the dwell
angle at tdle soeed before fd)usting tile igni·
1ion t1m ino
nwell anole: 41 •
1r the angle does: not meet specirication. ad iost
1h0 rubbing blOC k g•P as f<llows;
More than 42•- Decrease the gap .
less 1he.n 4Q- - Increase the g.ap.
I
I
L
r 2-37
Met'\ o" ll yw1'941 7• I TOC _J
E NGIN E TUNE -UP Igniti on Timing 2- 13
CHECK IGNITION TIMING
~ Con n ec1 a 1schome1cr and riming t,g ll t.
- Note -
1. Oo not keep the Ignition switch ON for
more than 10 minutes if the engine will
not start .
2. As some tachometers are not compatl ·
ble with t his Ignition 5ystem . it is
recommended that you consult with the
m•nufactur · er.
3. NEVER allow the i gn i tion coll ter mi nals
to touch groUfld as it could result In
damage to th e igniter and/or isiiltJon
coll.
Do not disconnect th e battery when the
eng ine is runn ing.
6. M ake sure that the i gn i ter is preper· ty
grounded to the body .
2. Warm tJP the engine
3 O•$Connec1 lhe vacuum hoses from the
d1stribu1or and plug t he ends ol thEm
6
6
Check the ignition 1 1m 1ng wuh tho ~ng1ne
idling,
Ignition tim ing:
7• BTDC/ Max . 950 rpm
(w/ Vacuum advance cu t)
11 1l-Occssa1y, l oose n the d~St rt butor boll
and turn lhe diS1ributor to align 1he marks
Aocheclt the timing af1er tigh1en1rg the
dJS ll1bu1or

2 - 14
EN GI N E TU NE- UP -Valve Clearance
flg .~O
fig. 2· 42
,,.,
L_
VALVE CLEARANCE
ADJUSTMENT
2
3
Warm up tho engine to normal operaung
temperature
Stop the engine andreughtenthe cylinder
head bolts. the rocker suppOrt blots and
nuts Tightening torque:
Cylinder head
bolts
11 .6 - 13 .6 kg ·m
(84 - 97 ft ·lb)
Rocker support l>olls and nuts
1O mm boll 3.0 - 4.5 kg ·m
(22 - 32 It-lb)
8 mm bolt 2.0 - 3.0 kg·m
1 16 -21 ft-lb)
Adiust the valve clearance.
(I) Set the engine at idle speed. and
check the valve clearance
(21
(31
Ad1ust 11 necessary
Valve clearance:
Intake 0. 20 mm
(0. 008 In.I
Exhaust 0 . 36 mm
(0.014 In.I
Ret
igh ien the lock nuts socuroly
after
ad1ustmen1.
Recheck the valve clearance.
Fig. 2·44
Fig. 2-45
------
Cho ko B1 eu k1•
Olnph1aurn
VTV
5 - '5 ffCOnd•
E NG IN E TU N E-UP -Carburetor 2- 15
CARBURETOR
1 1!'5 1 CHOKE
I Pull out the choke k no b all the way and
check to see that the choke valve is fully
closed
~ 2 .
Chock 10 soo Ihat tho choko valve 1s fully
open when tho choke knob has been
returned
CHOKE BREAKER (USA)
~ 1.
2. Stan
th e ongi no .
Disconnect 1h o vacuum h ose between the
carburetor and tho VTV al the carburetor
side.
3 Check that mo choke breaker hnkage
returns quickly by sprong 1ons1on .
Reconnect tho hose
Check
th at tho choko breaker link age rs
pulled into lhO doaptuogm wrthon 5 - 15
seconds niter r ecom1oc11119 1h e hose.

I
t
2- 16 ENGINE TUNE-UP -Cerbu
ra tor
CHOKE BREAKER
lii1ii\ l.FJ except General and USA)
~ l S1art 1he engtne
2. 01sconncct tht hOS8 from the ttwott'8
posi\Jontr dtaphtagm ancl chee k 1ha1 the
cho ko hnkago toturos
3. R e<;onnee1 lhoO hoso to 11\e L hrot t '• p0si
tionor Chaphrogn' end check that the
cho\<o lin k age Is putted b'I the diaphragn '\.
- Note -
The choke bfe&ktr 1v1ttm utilizes the
th r ottl • po sl tioner dlapl\tegm.
fl~2~8 ~~ ~ ~~--~~~---, lii1ii\ CHOKE OPENER (USA )
~ 1. The coo\ant tempe<atUft shOuk:f be betow
s•c 1•1•fl
CO LD
··.:· .. /
•••
R.cont1ect
HOf
-
------- -- --
2. Sta r• tho ong1M and disconnect the hOSO
from tno chOko openf1" diaphregrn and
fCCOnflCCl \1 ,
3. Ch•C k tl>&l 11\0 ChO ke tinl<a ga doos not
movo .
ll l<li l4 W<lh the •"II•"" w•rm ""' odlong. doocon
U noel the ~ from t he choice Q9«!Nf
di aplvagm and chCCl that the chOko
hnK~O rOU>rl'IS
5. Aeconnoct 1ho nose and chcc.k lhst tho
chOko llnkage \s pulled bY tho chOl<o
opcf\01 d1ophregm,
f ig . 2- 50
-----
-CHECK FUEL LEVEL
l l lJlli l Cheek the luollovcl whole the engone os odhng
I
I
__ _J
fl . 2-51
€ ••• · · ·-·
Ft9. 2 62
fi g. 2· 53
Fig . 2· 54
ENGINE T UN E-UP Carburetor. Idle Spe ed Adjustment 2
17
CH ECK ACCELERATION PUMP
1 1.fE Il Chod:: thl tccele1a11on pump ooerauon
Casohne should shOOt ou1 w11h toa ffom
the Jfi1 when 1hc thro10e vatve 15 opened.
2 Cheek ow thro111e valve opening. TM
1hro1tlt valvo shOufcf be fully operi when
the acco1 ora 1or pedal t$ fullv depressed
Accelerotlon pump stroke :
9.S mm
(0 . 374 In.I
IDLE SPEED
&. ADJUSTMENT ( USA )
1. Ch<lc k lhe fo11ow;ng otems beforehand
(I) Al( cleaner tns1allcd
(2) Normal operating coolan 1 tern·
po r a1u 10
13) Choko f ull y open
(4) A ll accessorios swi tched o tr
(6) A ll vocuum lines connected
(6t Ignition 11m1ng so t corrcc11V
<
7
~ Transmission in neu1rat
{8) Fuel lovtl $h0utd be abou1 even whh
lhl COfrec1 '8vel in 1.he s.ghl gtass
BreaIt lhe tdlo l1m1tor cap on the idfe speed
8d1ushng wow. II one is 1ns1alled
Ad1ust the odle speed by tum;ng too odle
spoed 1d1us11ng screw.
Idle •P••d: 650 ,-pm

2--16
ENGINE TUNE . UP - IdleSp e&d Ad iustment.IdleSpee d& IdleM ix tureAdju st me nt
Fig. 2·66
Fig. 2·56
SEE
FUEL SYSTEM SECTION
Fig. 6·163 to 6· 175
Fig. 2· 67
fuei l.,..ol
Fig. 2·58
©
Install a l'l.ev ' li1ru t 1?:r cap on th& idle speed
adjusting screw.
\t one was insta ll ed.
- Note -
For the idle mixture adjustment . the idle
mixture adjusting screw is adjusted and
plugged with e stetl plug by the manufac·
turer .
If necessary . remove the plug and follow
th& proc&dure described In FUEL SYSTEM
section .
IDLE SPEED & IDLE MIX -
.&.. TURE ADJUSTMENT
(excep t USA )
1. Check
ihe fo ll owing items beforelland.
(!) Air cle3n<f ins1alled
(2)
No f mel opera1 i11g
coolant
tam·
per::uure
(31
Choke tuly open
(4)
AU accessories $witched oH
[5)
All vacuum lioes connect&d
(6)
Ignition timir't} s&t co1 i ee1ly
m Transmission
i11 oou1ral
El
(8) Fuel levelshould
be about oven with
the co rr ect tove1 in the si ght gl .ass..
2. 8feak
lh.t1 idle Imiter c.ap on 1he id le speed
adjusting scre\v, U
one ts insta ll ed.
Fig. 2· 59
Fig. 2 · 60 _
Fig. 2·61
Fi • 2· 62
ENGINE TUNE·UP -Id le Speed & Idle M ix ture Adjustm ent
2 19
EcE __ _
r::J 3.
~
(N, S.w . & Vic t or ia stat es)
01soonnoct 1he air hose hom t he ABV and
plug the hose ond. (At system OFfl
4, Siar 1 thP. engulQ.
5. Set to thP. 'nax1n1um speed by turning the
tdle m 1 x1u1~ ad 1usung screw w 1: h SST
(ECE) or ti screwdriver (othersl.
SST [ 09243 ·000201
~ 6. Sot to lhe idle mixt u re spQO(I by turning
~ t he 1 dkt s1 >eed a<1 1 vs1 1ng screv,.
Idle mix t ure speed : 690 rpm
- Note -
Before moving to th e next step. continue
adju8t'fnents 6
and 6 above. until th• max ·
imum speed w il l not rise any further no
matter how much the ID LE MIXTURE
ADJUSTING SCREW is adjusted .
~ 7
Set to the id!e speed by sc.-ew1ng in the
idle mixture adjusung scre\v with SST
iECE) or o screw driver (other s) .
SST[09243.00020 l
Idle speed: 660 rp1n
- N ote -
This is the LEAN DROP MEiHOO ti>r set •
ting id le speed and m;)[ture .

ldlo Spoed & IdleM l• turo Adlustmont.
2-20
ENG IN E TUNE · UP Fast Id leSpeedAdjustment
Fig. 2· 63
--- -I
_J
Fig . 2·64 -------- - ·-,
{NS W & Voetorie states\
R oc:onr'IOC t Iha air hOSe to the ASV
lnstoll 1 new hn11er cap on me tdte speed
adtusttng scrrt. 1f one was 1nstaUed
- N ott -
After comptetln9 1c1!iustment . per·form a
• O• d t••t to m•k• certAln enoine perfOJ·
m1t1c• h•• not changed.
FA ST IDLE SPEED
& ADJU S TMENT ( USA )
1 Warm up the engine and then stop 1l.
'J. Remove t he a 11 cleaner cover.
3 Fu lly pull out tile chOke knob
Fig. 2· 67
r
Fig . 2· 68
·-
fig. 2 ·~ 66 ::_ ________ _ _
·~ ( ·
l l ••l 4
01,coonec1 lhe vKuum hOses from the
d1stribu1or Jnd plvg lhe hose ends
Naeuun1 od\aocor OFF)
..
..
: • Plug
I •
I
I
I
I
fig . 2- 70
O:sconnect tho vecuum M:$El'.$ :fom pot t S r
of tho VCV °' EVAP. and EGR valve. and
plug the ho>e end• .....,_ "!'
IEVAP svsum ono EGR sv>t••" Off)
ENG I NE TUNE - UP - Festldle SpeedAdjustment
2-21
I ~ I6 AdJUSt the fast idle speed by turring l he
~ I fost Kite adJUBhng screw
Fut Idle opoed: 1 .800 rpm
7 Whon lho chOte knob tS pushed '" all the
way , 1he engine speed should return 10
kilo speed
8 Ae1M1at1 1he ew cleaner cover
FA ST IDLE SPEED
ADJU S TMENT (Ot her s)
1, Woun up lho engine and Chen step il
"J Aomovo 1he oh cteaner oover.
3. Fvttv pu ll ou1 tha chOke kflOb.
(NS W & Victor.o sto te sl
(1) Pinch shut t ile vacuum hoSE 10 the
chorcool conlster {EVAP sys tem
OFF)
121 OIK.O f'toec.1 1he waocuum ltOt& ffom
lho EGR valve and plug ""' hose
end ICGR system OFF)

2- 22 ENGINE TUNE-UP - FostldleSPHdAd1usonen~ ThfottloP0$11io""'
fig. 2· 71
i-""'-=-- ;..;.._-----------,
J
I
I
I
I
I
I
~ s
1
I
f ll!;._ 2·7 !_ __ _ _
- -- __ _ _ .J
-- - -- - ,
J
I
J
I
I
I
I
- -- --- ---
_J
Fig. 2 · 74
- --- --
------·
5. Open tho cho'8 va 1ve w1Jh a screwdlwer
and stat l the cnguie
b AOJUSI UM: fd>I l(fl_: .1pcod by 1urn11'9 lhe
las1 td lc ad1u si.ng screw.
Fast idle speed : 1, 800 rpm
7. When the ct\o4(e knob l.S oushed "'au 100
wov. tho engine: spo ed shou\d re1u1 n to
Idle
SPH<1
8 (N.$.W & Viclon• SIOIGsl
Re lease 1ne pn ltbed hQse and rccof'u\cct
the vacuum hose 10 tl'le EGR valve
9 Reinsta ll t he tu1cteanor eovo•,
THROTTLE PO SITIONER
IU"5 1( Au s tr a lia & ECE FJ series)
CHECK THROTTLE POSITIONER OP E·
RAT I ON
1 Warm up 1.he trg1ne
2 Ch ec k the idk> sr>ee d ond ad 1 us1 it n cce s~
WV
3 Ctieck niat 1na 1h1v1t1e po,,111onic1 ~e.
1 oteas.c.o 01 id le.
~ 4 .
01sconrKtC1 the ... acuum hose trom the
1hrot1lo positioner diop11ragm and pt ug
1he nose end
5 Race the engine and 1 hcn re1ea10 the
accelerator pe(,ol
6. At th•• umo. 1h e 1 hto 1uc oos1tvoner ad
josting screw sh ould t Hr i ko the th ro ttl e
lever so 1ha1 the engine runs laster than
idle RPM (T h ro 11 tc pos1tion.er •s set)
Fig . 2.75
Fig. 2· 76
...__ --
I
L
ENGINE TUNE-UP -Throllle Positioner. Comj)<ession Pressure
2- 23
~ ~ CHECK THROTTLE POSITIONER SET-
& T ING SPEED
l (NS W & Vicloroo s 1a1 eo)
(1) Pinch shul the vacuum hose 10 1hc
cha rcoal co nis1 01. IEVAP syste in
Orfl
f hf" otl l• Poaiboo o,
Adiu1 1 ~ s c,. w
El
3
4
{2) Disconnect the Y<lCUUM hose from
lhe (GR valve and 1 >l u9 l f'le h ose
end IEG R svs1em Off)
W11h lhe 1hro1tte pos11ioner scL ctieck lhe
engine spoed
Throttle po1 ltJoner totting 1Pff'd ·:
N.S. W. & Victor le ttates
1.200 rpm
Oth a-rs 1.000 rpm
If no1 a1 sp ocit icd speed. a djus 1 wllh th o
1hro11'8 pos1tt0ner adjusting SetO\v.
Reroo.5e the p1ncne<1 tK>so ano rtcun n 11el
the vocuum hoses 10 the pr op er loca1ions.
• El COMPRESS ION PRE S SURE
~ •• 1 Warm vp lh o cnglr\fl
2 Remove all spa rk plugs.
3. 015C o nnec r the h igh IE1ns 1 on co rd from the
ignition co11 to c ut o fl tho seeoni:t.ery ci r·
eu11

J
2 24 ENGINE TUNE ·UP -Compre••ion Pre •s ure
Fig . 2· 79 lllserta oomp<ession gauge 1n1 0 lhe spark
plug hO le an.d folly open the thcou te valve.
Wh1•e cranl(lflQ the engi ne . rr.easure the
comp;res.s 10l'I pressure.
Compression pressure
l at 250 rpm }:
STD More than 10 .6 kg/ cm "
(1 49 psi!
limit 8.0 k t/cm '
( 114 psil
Pressure dif fetence between each
cyllndor: Les5 than 1.0 k g/c m"
11 4 ps i!
- Note -
Atwev• use a futty chaeged battery .
ENGINE SERVICE
Page
CUTAWAY VIEW 3-2
CYLINDER HEAD .............. ................ ...... 3-4
T IM ING GEAR ...................... ................... 3-21
CYLIN DER BLOCK ........ .... ....................... 3-32

3-2
ENGINE SERVICE Cu1awayView ENGINE SERVICE Cutaway Vlew
3-3
CU TAWAY V IEW
Fig. 3·2
Fig. 3·1