Toyota 5R 1969 Operating instructions

5R, 3R-B & 3R-C ENGINE
REPAIR MANUAL
TOYOTA MOTOR SALES CO., LTD.
EXPORT - TECHNICAL DIVISION

FOREWORD
This manual has been prepared to provide the
Service-men with complete information for proper
servicin of the 5R, 3R-B and 3R-C en ines
equipped on Toyota Crown, Corona, Li ht Stout,
Stout, Dyna and Li ht Bus series.
It covers all the service procedures in detail and
will serve as a ready reference book in service
trainin of the less experienced men and also in
work supervisin of the fully qualified men.
The section index on the title pa e enables the
user to quickly locate any desired section. At the
be innin of each section is a title pa e which lists
each main subjects in the section.
The service procedures on these en ines are almost
similar, however, there are some major or minor
differences between each model en ines.
In this manual, every repair process is detailed
respectively to cover the models thorou hly.
If the service procedures are the same, the repair
process and the fi ures are described basin on
the 5R en ine.
All the information and the specifications contained
herein are the most up-to-date at the time of
publication, and we reserve the ri ht to chan e
them without further notice and without incurrin
obli ation.

SECTION INDEX
GROUP INDEX SECT
GENERAL INFORMATION |
ENGINE TUNE-UP #
A
ENGINE E
EXHAUST SYSTEM A
FUEL SYSTEM E
LUBRICATING SYSTEM i
COOLING SYSTEM ■ 1
CHARGING SYSTEM E
STARTING SYSTEM K
IGNITION SYSTEM B

GENERAL INFORMATION
G E N E R A L ......................................................... 1-1
GENERAL SPECIFICATION .................... 1-5
RECOMMENDED S . S .T ............................ 1-9
MEMORANDUM .................................. .. ......... 1-10

GENERAL INFORMATION - General 1-1
GENERAL
The 5R model en ine is desi ned based on the 3R model en ine with the various
different features such as increased displacement, modified combustion chambers
and manifold ports, raised power and torque, to ether with improved durability
and reliability. This en ine is equipped on the Toyota Grown, Stout, Dyna and
Li ht Bus series.
The 3R-B model en ine was also developed from the 3R model en ine by im
provin the reliability.
The 3R-C model en ine is incorporated with the crankcase ventilation and the
exhaust emission control systems on the 3R-B model en ine.
These en ines are equipped on the Toyota Corona series.
The construction of all en ines is the same basically, but their specification are
sli htly different from each other. Therefore, the eneral information is described
in accordance to the 5R model en ine, and different features only will be des
cribed for the 3R-B and 3R-C model en ines.
The 5R, 3R-B and 3R-C model en ines are of four-cylinder in-line, overhead
valve, water-cooled type.
The cylinder head is of a cast iron, and incorporates a bath-tub type combustion
chambers.
The cylinder block is also of durable cast iron, and incorporates the oil passa e
within the cylinder block front at the ri ht side to lubricate the valve rocker arm
mechanism.
The pistons are of a low-expansion type which is of aluminum silicone alloy with
excentric finished sli htly lar er at the ri ht an le to the piston pin bore. More
over, these pistons are cast in with a steel rin under the oil rin roove to
minimize the heat expansion of the piston.
The piston rin s are of two compression rin s and one oil rin for each piston ,
and both rin s are chrome-plated for durability.
The piston pin is off-sett 1.0 mm (0.039M) towards the camshaft side which
contributes to smooth en ine operation, and is secured onto the piston with snap
rin s at both ends of the piston pin.
The connectin rods are of for ed steel with "H" beam section, and bronze
piston pin bushin s are installed at the small ends.
The connectin rod of the 5R model en ine is provided with the lubrication hole
at the ri ht side of the lar er end upper, and the piston pin bushin is lubricated
throu h this hole by pressure dischar e.
Also, the lubrication hole is drilled within the connectin rod from the lar e end
to the small end on the 3R-B and 3R-C model en ines.
The crankshaft is of carbon steel, and the bearin journals are induction hard
ened .
The crankshaft main bearin s and the connectin rod bearin s are of micro pre
cision type, and are composed of tri-metal; lead overlay, kelmet seam, and
steel back plate for smoothness and durability.

1-2 GENERAL INFORMATION - General
Y6177
Fiq.1-1 Cross Sectional View of 5R Model En ine Y5973

GENERAL INFORMATION - General 1-3
G3422
Fi . 1-2 Cross Sectional View of 3R-C Model En ine G3423

1-4 GENERAL INFORMATION - General
The crankshaft thrust bearin s are located at the center main bearin , and are
of steel backed babbit metal •
The camshaft is of chilled castin , and the camshaft timin ear is of bakelite.
The camshaft is supported by five bearin s, and these bearin s are of steel
backed white metal.
The exhaust valve head is of austenite heat resistin steel, and dual valve sprin s
are utilized for both intake and exhaust valves.
The sprin s are made with irre ular pitch to prevent the valve sur in .
The valve lifters are installed with off-set from the center of the cam to serve the
lubrication of the lifter and to prevent the uneven wear of the lifter.
The push rods are made of steel pipe with the diameter of 9 mm (0.31 '*) , and
both ends of the pipe are welded to the steel balls by butt weldin .
Precauition
Whenever any work is performed on the car, special care should be taken to
prevent scratchin the body, fenders or spoilin the seats. To perform a satis
factory work, fender covers or seat covers must be used durin the operation.
The use of Service Special Tools must be emphasized as these tools are so
desi ned to prevent dama in of the components, and also will quicken the work.
Durin disassemblin any components, it is essential that parts disassembled
from the car or main components should be placed in sequence to facilitate the
final inspection, and assembly. Certain matin parts should be marked before
disassemblin from the main assembly to identify the matin position or for baP
ancin with the main assembly.
Service Torque Specification should be adhered whenever ti htenin the bolts
or nuts.

GENERAL SPECIFICATION
GENERAL INFORMATION - General Specification 1-5
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GENERAL INFORMATION - General & Specification 1-7
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1-8 GENERAL INFORMATION - General Specification
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GENERAL INFORMATION - Recommended S .S .T . 1-9
RECOMMENDED S .S .T .
En ine
09303-
09213-
09201-
09222-
09222-
09210-
09215-
09505-
09214-
09304-
09301-
35010
60013
40010
30010
40011
31010
40010
20010
60010
30012
36010
Imput Shaft Front Bearin Puller
Crankshaft Pulley & Gear Puller
Valve Guide Bushin Remover & Replacer
Connectin Rod Bushin Remover & Replacer
Connectin Rod Bushin Remover & Replacer
Timin Gear Tool Set
Camshaft Bearin Remover & Replacer
Differential Side Bearin Replacer
Crankshaft Pulley & Gear Replacer
Imput Shaft Front Bearin Replacer
Clutch Guide Tool
Carburetor
09860-11010 Carburetor Screwdriver Set
09240-44010 Carburetor Adjust Kit (for R S , RT series)
09240-40021 Carburetor Adjust Kit (for RK series)
Water Pump
09239-40010 Water Pump Rotor Puller
09238-40010 Water Pump Bearin Remover & Replacer
Alternator
09286-46011
09325-12010 Injection Pump Spline Shaft Puller
Transmission Oil Plu

1-10
o .
MEMORANDUM
MEMO * 4

ENGINE TUNE-UP
G E N E R A L .................................. 2-1
INSPECTION & A D JU S T M E N T ................ 2-1
Battery
...................................................... 2-1
En ine Oil .......................................... 2-1
Coolant .................................. 2-1
Pan Belt ............. . 2-1
Fuel Filter ..................................................... 2-2
Air Cleaner ...................... 2-2
Distributor .................................................. 2-2
Spark Plu
........... 2-2
I nition Timin ............................................... 2-3
Octane Selector ................................ 2-3
Valve Clearance .................................. 2-4
Carburetor .......................... 2-4
Compression T es t ......................................... 2-5
MEMORANDUM 2-6

ENGINE TUNE-UP 2-1
General
In order to maintain the full performance ori inally built in the en ine, aperiodic
en ine tune-up is essential. If any deficiency is encountered durin operation of
the car, it must be dia nosed immediately, and proper care should be taken by
tunin up the en ine. The pro ress of modern en ineerin standard has been
developed so quickly that it necessitates the use of proper instrument, and well
trained mechanics. The compression ratio has increased, also incorporates a
numerous electrical equipment, and other components which can only be taken
bare with special knowled e and proper care. In order to accomplish the work
correctly, and properly, a reliable tune-up equipment are necessary. The pro
cedures decribed in the followin orders should be carefully studied.
Inspection & Adjustment
Battery
1. Check the electrolyte level in the
battery cells.
Normal electrolyte level should be
about 10 mm (0.411) above the
plates. If necessary, replenish the
cells with distilled water.
2. The specific ravity of a fully
char ed battery should be 1.260
at 20°C (68°F) .
If the specific ravity is below
1.200, or the difference of the
specific ravity between each cell
is above 0.025, the battery should
be' char ed by disconnectin the
battery round cable.-
If the difference exceeds 0.025
after fully char in the battery,
the battery should be. inspected
at a battery service station.
3 . Clean the terminals and top of the
battery*
4. Check the battery terminals, and
ti hten them if necessary. '
Check the battery case for cracks
or other dama es.
Apply rease onto the terminals
to retard further corrosion.
En ine Oil
1. Check the en ine oil level, and
replenish if necessary.
Oil pan capacity:
RS50, 56, RT43L, 52L, RK171,
176 series:
4.0 liters (4.2 US qts.,
3 , 5 Imp. qts. )
RK44, 101 series:
4.5 liters (4.7 US qts.,
4.0 Imp . qts. )
Oil filter capacity:
0.8 liter (0.9 US qt. ,
0 . 8 Imp . qt. )
2. Check the oil for deterioration.
Check if the coolant or asoline
is present within the oil.
Replace the oil if necessary.
C oolant
1. Check the coolin system for leak,
weak hoses, loose hose clamps
and correct coolant level.
Replenish with drinkable water if
necessary.
Coolin system capacity:
RS50, 56 series:
7.5 liters (7.9 US qts.,
6 . 6 Imp. qts. )
RT43L, 52L series:
8.5 liters (9.0 US qts.,
7 . 5 Imp . qts . )
RK44, 101 series:
9.1 liters (9.6 US qts.,
8 .0 Imp . qts. )
RK171, 176 series:
9.5 liters (10.0 US qts.
8 .4 Imp . qts . )
2. Use a reliable brand anti-freeze
in cold weather.
Fan Belt
1 . The fan belt deflection should be
13 ~ 20 mm (0.50 ~ 0.7511) when
11 k (24 lbs) pressure is applied.