Toyota 2F Operating instructions

2F ENGINE

REPAIR

MANUAL

g.,1

980

TOYOTA

MOTOR

CORPORATION

Pub. No. 38104E

TOYOTA

2F ENGINE

REPAIR

MANUAL

,..,,_U.V<'Y«Y=v

,,_

•

o/ft~mH«Y<'Y<U<

Aug

1980

0YOTA

TOR

CORPORAT

ION

Pub

. No.

3610

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

USE

THIS

MANUAL

....

......... 1-4

SYMBOLS

.. ..

......

.............

.................... 1-6

1- 2 INTRODUCTION - G

eral R

air

Ins

ons

GENERAL REPAIR INSTRUCTIONS

Use

fender,

seat

and

oor

covers

keop

the

car

clean

and

prevent

damage.

During

disassembly,

keep

parts

order

facilitate

reassembly

Before

per

orming

electrica

work,

disconnect

the

cable

from

the

battery

terminal.

Always

replace

cotter

pins.

gaskets

and

0 rings

with

new

ones.

When

necessary.

use a

sealer

gaskets

prevent

leaks.

Carefully

observe

all

specifications

for

bolt

tightening

torques.

Always

use a

tor-

que

wrench.

Use

genuine

Toyo

parts.

When

replacing

ses,

sure

tho

new

use

the

correct

amperage

. DO NOT

exceed

the

fuse

amp

rating

use

one

lower

rating.

the

vehicle

jacked

only

the

front

rear end. be sure

block

the

wheels

order

ensure

safety

After

the

vehicle

jacked

up,

sure

support

stands

extremely

dangerous

any

work

the

vehicle

raised

jock

alone.

even

for

small

job

that

can

finished

quickly

Use

special

service

tool

(SST)

may

required

depending

the

nature

repair

sure

use

SST

where

s1>eclfied

and

the

proper

work

procoduro.

fist

SST

found

the

back

this

manual.

INTRODUCTION - Ab

bre

tions

Used

InToyotaRepairM

anuals

ABBREVIATIONS USED IN TOYOTA REPAIR

MANUALS

For

convenren

ce. lhe following

abbrovia1ions

are

used

oyo1a

repair

manuals

Abbrevia

Term

Abbrevia

Term

---

A/T

Au1oma1ic

Transmission OIS

Ovors120

BDC

Bo11om

Dead

Cenior

Righi·

hand

BTDC

Before

Top

Dead

Conier

RHO

R1gh1

·hand

Drtve

Exhau

SST

Spe

ial

Service T

001

lniake

STD

Standard

Lofl-

hand

T1gh1en1ng

Torque

LHD

Loft·

hand

TDC

Top

Dead

Cen1or

Mul

1ip

rpose

UIS

Undo

size

anua

Transm

sion

OPT

lion WIO

Wl1hou

·I

1 - 4

TRODUCTION How To

Use

This M

anual

HOW

TO USE

MANUAL

OVERVIEW

ILLUS

RAT

ION

Many

rvi

opera

ons

begin

w11h

overv

iew 1

llustrauon

a g

one

guide.

ENGINE SERVICE -

C-

Ho>d

Fl91

. 3·

------

----

ASSEMBLY

A.UM

lht

Pil"

""'Mf!flC'•

Ol'di!f

Shl:Wrrtt

the"

r.q

.....

...

>••

,...,

,•.,

The

bold

mbers

ond1cato

eordor

which

ework is 10

done

The figure numbersr

efer

you tomoredetailed

rnstruc11ons

and

spccrhca11ons.

INTRODUCTION -

How

Use

This Man

ual

-5

ILLUSTRATED

INSTRUCTIONS

All 1mpart

1st

eps1n

ery

ser

vice

JOb

are

llus11at

Obvious s

aro

omitted

pac

Expener>eed

tcchnrcrans

y only need to glance

the overview 1llustratron and/ or

spce1hca

11on

-~~

...

t"···

,..

ENGINE SERVICE -

C--

,_,,

...

C<-iat

tNI

v•lve

Slf'ffl.l

with

e1-o

roe

t>Stl

llwt

tOfllPW)

tNf

itf"Cf

tiN'

••

nth

$Sf

SST

109,01

310101

Drive

dl•tll'!Ce:

• .• - 10.2

"''"

Nol

• -

{O,

Jll

- 0.4

,.,

- -

1-- - - @

1 A

tlit'W

cNI

••

ahoulO

vsM

when

· -

-l

ever

Ifie

w11Vt

I•

di:1Jtstembled.

2. Co•I tho o

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

Altl!f

tMt..i.ng

1"9 tOnng,. "Oht)y

thfo

t't'M

t!!l'ldt

~fld

alt

"-I

the

1"9S

'4ftllil!

(.IO

snVQ1't

p1cturesg1vc

basic 1nformat1onon what todo

each

step

A symbol•Softenused toexplain theactron

reQu1ted

The 1ex1explai

how

pertorm

estop

Spec1hca11ons.

Notes

and

Cau11ons

are

given

bold type

you w

on·

1miss

them.

1 6

TRODUCTI

-Symbols

SYMBOLS

The following symbols have been adopted

r simpl

ici

ty and quick 1ecognl

on.

••

I REMOVE

DISASSEMBLE

l•

•I

INSTAL

ASSEMBLE

lf'5

1 INSPECT

MEASURE

TIGHTEN

.-: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-

DISTRIBUTOR

.........................................

2-11

IGNITION TIM ING

....

...

.. ....

.....

......

...... 2-

VALVE

CLEARANCE .

.............

..............

CARBURETOR

..................................

.......

IDLE SPEED

ADJUSTMENT

(USA) .......... 2-

IDLE SPEED & IDLE M IXTURE

ADJUSTMENT

(except

USA) ...... 2-

FAST IDLE SPEED

ADJUSTMENT

(

USA

) ........

......

.... 2-

FAST IDLE SPEED

ADJUSTMENT

(Others)

......

.......

2-21

THROTTLE POSITION

..........................

2-22

COMPRESSION PRESSURE

......................

-2

ENGINE

-UP

- EngineTu

-u

pItems

ENGINE TUNE-UP I

TEMS

DRIVE BELT TENS

ION

(General

destinat

ions)

Deflection

wit

h 10 kg

(22

lb)

force

Fan -

Alternator

S.W

. &

Victor

states

Other australian states

ex. Australia

Fan -

Air

pump

Used

belt

N.S.

& Victoria states

(USA & Canada)

Borroughs

lt tension gauge

BT-33

-73F

Air

con. N

belt

Used

bell

Others

New

belt

Used

belt

BATTERY

Specific

grav

Elec

olyte

level

ENGINE O

Oil l

evel

check

Oil

re1>

lenish

ment

Oil

capacity

Ory

fill

Drain

refill

USA

ECE

Others

w/ o

filter

change

filter

change

Oil

filter

replacement

COOLI

SYSTEM

Cool

ant

level

Coolant

quali

leakage

Radiator cap valve opening pressure

STD

Lin1it

REMARKS

7 -

0.51 -

0.59

in.

0.39

7 - 9

9 -

- 0.

0.35

- 0

7 -

0.28

0.39

in.

100

160

lbs

120

170

lbs

120

1.27

(w hen

charged ait

°C

(68

°F

Correct

level

line

API

service

better

API

service

SD.

better

API

service

SC. SD. SE

better

8.0 l

iters

8.5

7.0

7.8

lit

ers

8.2 US

7.0

liters

7.4 US

SST

[09228-440

1O]

Full

0.75

1.05

(10.7

.9 i

>si)

0.6

2 8.6

psi

6.9

lm1

>. qt

6.2

lm1>

Coolant capacity w/ heater

air conditioner

FJ40

43,

ser

ies

FJ60

series

16.0

liters

16.9 US

14.1

Imp

.5 li

ters

17.4

Imp.

25.0

liters

26.4

Imp

series

5 AIR CL

Correc

t l

evel

Clean

element

capacity

(Oil

bath

type)

ENG

E-UP

Engine

ne-

ems 2 3

ITEM

HOT

AIR

INTA

Operational

check

7 SPARK PLUGS

Visual

check,

Cleaning

Gap

8 HIGH TENSION CORD

9 DISTRIBUTOR

str

ibut

or cap

Air

gap (USA)

Rubbi

block

gap

(excep

t USA)

Governor advancer. Vacuum advancer

IGNI

TIMING

Dwell

angle

(except

USA)

Igniti

timing

VALVE

CLEARANCE HOT

CARBURETOR

Intake

hau

Choke

breaker.

Choke

opener

Float l

evel.

Acceleration

pump

IDLE SPEED

ADJUSTMENT

(USA)

Idle speed

14 IDLE SPEED &

MIXTURE

ADJUSTMEN

(

except

USA)

Idl

e speed

Idle

mixture

s11eed

FAST

IDLE SPEED

ADJUSTMENT

Fast

idle

speed

USA

N.S.

Vic

toria

states

Others

THROTTLE POSITIONER

ott

positloner

sett

ing speed

N.S.

Victoria

states

Others

COMPRESSION PRESSURE

250

rpm

STD

Pressure dif-ference

between

each

cyli

REMARKS

0.8

031

in.

less

than 26 k

per

cord

0.2

- 0.4

0.3

41°

008

- 0.

016

012

in.

7° BTDC/ M

ax.

950

rpm

0.20

008

0.35

0.014

650

r1>m

690

rpm

EGR

and EVAP

systems

OFF

and

vacuum

advanc

OFF}

1.8

rpm

EGR

& EVAP

syste

OFFI

800

rpm

200

rpm

(w/

R & EVAP

systems

OFF)

000

rpm

149

psi

8.0 k

g/c

114

psi

Less

than

1.0

(14

psi)

2-4

Fig. 2-1

Fig. 2-2

Fig. 2-3

N.S.W.

AJternal6f

~:~:

L '

Fig. 2-4

ENGI

TUNE-U

P -

Belt

...

-··

Others

F•n

6:9.

Puuov

AJt•NIOf

Cr•nk

lley

On\1 Bell

---

DRIVE BELT

VISUAL

CHECK

Cheek for

1 Crack

de1enora11on.

s1ro1chtng or wear

2. Adherence

grease

Improper beh-10-puHov contact.

CHECK &

ADJUST

BELT TENSION

General

tlnotlons

Wnh

10 kg

(22

lbl

force. press

the

belts

the poonls

ondocated

tn the figure. Tile bells

should deflect

1he

amount

specof1

Drive

delloc

1ion

""'

NSW

-0

1tlCt

8'CCPI

VtetOllol avsu1h1n

Al,lStraha

t11tes

New 7 9

13-

16 7 - 10

1)28-0

....

(061-0ed»

1028-0300

9 - 17

(

Usoo

l03S

04)1

B 7 -

!028-0391

- -

bl\l

USA

Vs1ng

a Borroughs belt 1ons1

gauge BT-33·

73F. adjust as follows.

lt tension:

Air

Now

belt

Used

belt

Oth

ers

100

150

lbs

New b

0 -

170

belt

80 - 1

Fig. 2 -6

ENGINE

TUN

E-UP Battery

BATTERY

SUAL

CHECK

Cheek for

I Rusted bauery

suppon

3. Looso

1ormina1

connoc11ons.

Rusted

deteriora1od ter

minals

4. Damaged

leakong

bauery

2-5

··

MEASURE

SPECIFIC

GRAVITY

Fig. 2-7

TRANSLUCENT

~RY

Upf)e•

lovel

lOw61'

l.ovcJ

Fig. 2-8

BlACK

~£RY

TopVotw

low

Chock the spec1

f1c

gravity

tho

e1ec

1ro

y1e

11h

hydrometer

Specific

gravity

(w h

fully

harged

•c (

°F)J:

1.25 -

1.27

Check 1ho elec

o1v1e

Quami

each cell

insulfocient refoll

w11h

distilled

water

2 6 E

NGINE

E-UP

gine O

Fig.

2-9

Fig. 2-

Fig. 2·

ENG

E OIL

CHECK

OIL

LEV

The

011

level should be between the L and F

marks.If low. check !or leakage and add

l up

the F mark.

Use

engine

oil

indicated below.

USA -

-AP!

ice

belier

ECE

- - API service

SO.

belier

Others-AP! servi

SC. SD.

belier

CHECK

OIL

QUALITY

Check for:

e11oration

2. Entry

water.

01scolora

t1on

nn1ng

REPLACE

OIL

FILTEA

1. Remove the 011

hllc

with

SST

[09228-4401

2 Install a new filler and tighten

firmly by

hand

Note

not

tighte

with

SST or a wrench.

Start the engine and check for oil leakage.

4 St

the engine and recheck t

oil

level.

Fig. 2-13

Fig. 2·

Fig.

2-16

ENGI

TUNE

-UP - C

ling

COOLING

SYSTEM

COOLA

LEVEL

If low.

fill

reservoir

FULL

hne

Note

intain freeze protection, use a recom·

mended anti-freeze.

CHECK

COOLA

QUALITY

Check for:

I. Coolant cleanliness.

2. Rust

scale deposits around the radiator

cap and filler neck.

3 Entry of oil.

CHECK

COOLI

SYSTEM

PARTS

CMck

for

I. Damaged or deteriorated radiator and

water hoses.

2 Loose

hose

clamps.

3. Damaged

corroded radiator core.

4. Leakage

the water pump. radiator

core

loose

water

drain

cock.

Fau

y operation of radiator cap.

Inspect the spring 1ens1on and seating

condilion

lhe radiator cap vacuum

valves.

opens al a pr

essu

below

specification

is otherwise defec·

ve.

replace

e radiator cap.

Valve

opening pressure:

STD 0.

- 1.

kg/

(10.7 -

.9 psi)

Limit 0.6 kg

(8.6

psil

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