5-266 Toyota Engines 3K-C 4 CYLINDER ENGINE CODING ENGINE IDENTIFICATION Engine serial number and code is stomped on right side of block above oil iter. First series of digits (3K) indicotes engine code Application Code 1166¢e Engine (1200 Model) aKC ENGINE, CYLINDER HEAD & MANIFOLDS = Following general procedures may not apply to all vehicles with 3K-C engine installed. ENGINE Removal ~ 1) Disconnect ond remove battery. Drain cooling system and remove radiator with cooling fon assembly. Hood may be removed to provide greater access to engine ond in creased clearance when removing engine. Remove air cleaner fend disconnect carburetor linkage. Disconnect fuel line ot pump, 2) Disconnect exhaust pipe from manifold, Disconnect oll fengine-to-chossis electrical connections ot engine. Remove {rive shaft and insert suitable plug in ear of transmission to prevent fluid loss, Disconnect transmission linkage, wiring and speedometer cable. 3) Attoch suitable hoist to engine hangers. Support transmis: Sion and remove crossmember. With haist supporting engine, remove engine mounting bolts and/or nuts. Lift engine ond transmission assembly up and out toward front of vehicle Installation ~ To install, reverse removol procedure, assuring thot all fluid levels and adjustments are checked prior to sorting engine, MANIFOLDS = Aluminum intake ond cast ion exhaust manifolds are removed os an assembly Removal & Installation ~ 1) Remove oir cleaner. Disconnect fuel ond vacuum lines ot carbureter. Disconnect choke ond throttle linkage ot carburetor. 2) Remove heot insulator, PCV volve ond PCV hose. Disconnect ‘exhaust pipe at manifold” Remove manifold retaining nuts ond toke off monifold. To install, reverse removal procedure, assur- ing that mating surfaces are clean and new goskets ore used. Front engine hengeris installed on stud between number 1 in toke ond exhaust monifold, CYLINDER HEAD. Removal = 1) Drain cooling system and remove upper radiator hose. Remove manifold and carburetor assembly. See MANIFOLDS in this article. Disconnect heater hose at rear of head. Remove rocker orm cover. 2) Remove rocker shalt assembly. Remove push rods and keep. them in order for reassembly in original positions. Disconnect spark plug wires. Remove head bolts begining with ends. See Fig. TL head from engine, Installation — Ensure that mating surfaces are clean, then in stall new gasket with “front” side facing up. Continue ossembly in reverse order of removal. Tighten head bolts gradually in 2 ‘0r 3 steps os shown in Fig. I. Install push rods and rocker shaft ‘osiembly, then adjust valves, = When installing rocker shaft assembly, assure thot ‘adjusting screws are backed off about 2 turns. — Gircled numbers indicate remaval sequence. eck J dad Fig. 1 Tighten Cylinder Head in Sequence Shown (Remove in Reverse Order OThrough @) Metal Bridge (Bottom) Fig. 2. Install Cylinder Head Gasket with Metal Bridge Down (Toward Block) VALVES. VALVE ARRANGEMENT EMEELE VALVE GUIDE SERVICING 1) Check clearance between valve stem and guide. If intoke clearance exceeds .003" (.08 mm) or exhaust clearance ex- ceeds ,005" (.10 mm), replace valve guide ‘ipo 200 Rapa ema CampaToyota Engines 5-267 3K-C 4 CYLINDER (Cont.) 2) To replace volve quid, break off upper portion of guide ot Snop ring. Drive remaining portion of guide out of heed through combustion chamber with suitable driver (09201. 60010), = Cylinder head should be heated to about 212.264°F before removal or replacement of valve guide. 3) Install snap ring on guide ond install from top with suitable driver (09201-40010). Drive guide in until snap ring contacts head and ream for proper stem clearance. VALVE STEM OIL SEALS Volve stem cil seal fits over guide and stem, under spring corsembly, VALVE SPRINGS Removal ~ Use suitable compressor (09202-43011) to com: press springs ond retainers, Remove valve spring retainer locks (keepers) then remove retainer, spring, seal and washer. Mark tend remove valves and components for reassembly. Installation — lastall components in original location ond ot der. Use new seals on valve stems. Compress springs and install keepers — Some engines may have @ spring shield under retainer and "O" ring seal on valve stem above keepers Rocker we—Keopers = S——Washer Valve Fig. 3 View of Valve Train Components VALVE SPRING INSTALLED HEIGHT 1) With volve spring removed, check length under specified load (see specifications) in a spring tester. Check valve spring free length, if less thon 1.83", replace spring. 2) Check valve spring squareness with a steel square. If spring is out of square more than .063" (1.6 mm), replace spring ROCKER ARM ASSEMBLY 1) Remove valve cover ond rocker orm assembly retaining bolts, Remove rocker atm asiembly. Remove retaining clips from both ends of rocker arm shott. Remove conical springs, rocker arms, springs and support stonds 2) Thoroughly cleen and inspect all components. Check rocker ermio-shaft clearance. If clearance exceeds 003", ‘replace rocker arms or shots 0: necessary. Reface valve end of ‘rocker arm it worn. Lubricate all components before assembly 3) Assemble rocker orm assembly in reverse of removal order There are two types of rocker arms used, install rocker arm 30. that protruding side of volve end of rocker arm faces support stond. Install rocker stand s0 thot when rocker assembly isi stolled, “F mark on rocker stand faces front of engine Protruding Tips Toward Support Front Mark Fig. 4 Rocker Arms and Support Assembly Order VALVE TAPPET SERVICE 1) Check clearance between valve toppet and tappet bore in crankcase. If clearance exceeds ,004", replace tappet with erste toppet nd ream bore in eronkcose to opproprite 2) Oversize toppet cvailable is .002" over standard Cronkcase must be reamed .002" ever standard or until correct clearance is obtained. Correct clearance is .0006- 0011", VALVE CLEARANCE ADJUSTMENT With number 1 cylinder ot TOC on firing stroke, adivst clearance on valves number 1, 2, 3, and 5. Rotate eronkshatt tone revolution (360°) and set valves number 4, 6,7, and 8. Set clearances COLD to: Intake — 005" (.13 mm), Exhaust — (009" (.23 mm). If setting HOT, use following clearances: In- take =".008" (20 mm), Exhaust — .012" (.30 mm). ‘Set with No. 1 Cyl. at TDC on Firing Stroke a Set with No. 1 Gl. at TDC on Exhoust Stroke Fig. 5 Adjust Valve Clearance in Order Shown ‘ipo 200 Rapa ema CampaToyota 5-268 Engines 3K-C 4 CYLINDER (Cont.) PISTONS, PINS & RINGS on PAN = Engine must be removed to remove oil pon. 1) Remove engine os previously outlined. Drain oil from oil pan and remove oil pon retaining nuts and bolts. Remove cil pon. 2) Clean mating surtoces. Apply sealer to new gasket and in- stall gasket and oil pan. Tighten retaining nuts and screws to specifications. Install engine as previously outlined. PISTON & ROD ASSEMBLY 1) Remove engine at previously outlined. Remove cylinder head and oil pan os previously oullined. Remove connecting rod cop with bearing half and push piston and connecting rod ‘ertembly up and out through top of engine. Mark connecting rod cap to insure thot itis installed on same rod and in s ome. position. 2), Mark piston to insure that it is installed in some cylinder. To install piston and rod assembly, make sure ring gaps are in correct’ position (see illustration). Coat piston and rings with oil 3) Compress piston rings with a ring compressor ond install piston ond rod assembly in crankcase with notch in piston fac- ing front of engine, Make sure bearings ore properly seated in connecting rod and cap and apply oil to crankshatt journal. 4) Moke sure beoting in connecting rod is properly seoted ‘ogeinst crankshaft journal. Install connecting rod cap in cor rect position ond tighten nuts to specifications. Install cylinder hheod, cil pan and engine as previously outlined. No. 2 Compression No. 1 Compression Lower Side Reil Upper Expander Side Roil Fig. 6 Arrange Piston Ring Gaps as Shown PISTON PIN REPLACEMENT 1). Remove ciclips from pin hole in piston, heat piston to ap- proximately 158-176°F and drive out piston pin. Make sure Piston, pin ond connecting red are marked for assembly with ‘each other. Cipro 200 me 2) Thoroughly clean and inspect all components. Piston pin should push ft through piston with piston heated to op: proximately 158-176°F. If pin falls through piston or fit is to loose, replace piston and pin. 3) Check piston pin-to-connecting rod clearance, if more than (002', bushing must be replaced. Press bushing out and install new bushing using @ press ond o suitable driver (09222- 30010). With new bushing installed, ream to correct clearance with piston pin 4) Thoroughly lubricate all components before assembly. Position piston on connecting red with notch in piston facing in ‘some direction as mark on lower part of connecting rod (see i lustration). Heat piston to 158-176°F and instal piston pin and circlips. FITTING PISTONS 1) Check size of cylinder bore in crankcase, if size is more ‘hon .008" over standard, cylinders must be bored to next ‘oversize piston. Pistons ond rings are available in 010", 020" (030" and .040" oversize. 2) Check fit of piston in the cylinder with o feeler gauge and o spring tension gauge, A .001" to .002" feeler gouge should re Quire 22-25 lbs, measured on spring tension gauge, to ‘withdraw feeler gauge from belween piston and cylinder bore, 3) Check piston rings for wear or domage ond replace os necessary. Check piston ring gap in cylinders and piston ring side clearance in pistons (see specifications). Install rings on pistons with matks on rings up and make sure ring grooves in pistons are clean. Front Marks Fig. 7 Piston & Rod Assembly Markings CRANKSHAFT MAIN & CONNECTING ROD BEARINGS MAIN & CONNECTING ROD BEARING SERVICE 1) With engine mounted on suitable workstond, remove piston cand rod assemblies as previously outlined. Remove crankshaft pulley bolt and toke off crankshaft pulley with suitable puller (09213-31021). Remove timing chain cover and rear oil seal retainer, Remove comshalt sprocket and timing chen 2) Remove cil pump. Remove main bearing caps with bearing halves and remove crankshaft. Crankshaft timing sprocket and pilot bearing in rear of crankshaft may be removed if desired 3) Thoroughly clean and inspect crankshatt. Blow out all ci! possages with compressed air. Check crankshaft for runout byToyota Engines 5-269 3K-C 4 CYLINDER (Cont.) checking center moin bearing journal with a dial indicator. If crankshaft is bent more than .0012", replace or repair crankshaft Fig. 8 Checking Crankshaft Runout at Center 4) Check main and connecting rod bearing journals with a micrometer. If journals are more than .0003" out-of-round or undersize, crankshaft must be ground to next undersize, Undersize main ond connecting rod bearings for ground cronkshofts ore avoilable in 010", 020" and .030” undersizes, '5) Main ond connecting tod bearing clearance is checked by the Plastigage method. To check connecting rod_ bearing clearance, make sure bearing halves and crankshaft journal ‘fe thoroughly clean, Place a piece of Plastigage wire on jour- ral being checked. Install connecting rod cap on connecting rod and tighten nuts to specifications. 6) Remove connecting rod cap and check flottened wire gains! scale on back of Plastigage package to determine clearance. Main bearing clearance is checked in some manner. if rod bearing clearance is more than standard, 2.002" unde size bearing is available. If clearance with this bearing will sill exceed standard clearance, crankshaft must be ground to nex! undersize. The limit of bearing clearance on both main ond rod bearings is .004" 7) Check crankshaft end play with number 3 main bearing cop. fond eriginel thrust washers installed, Pry crankshaft back ond forth and measure clearance with « feeler gauge. Standard ‘loorance is 002-009" (.0422 mm) with @ maximum limit of (012" (.3. mm). Excessive clearance may be reduced with washers 002" (.125 mm) or .004" (.250 mm) oversize. Install thrust washers with grooves toward crankshaft, 8) Install bearing halves in cronkcose and moin beating caps. Lubricate bearings ond install crankshaft. Install main bearing ‘caps with arrows toward front and tighten cap bolts in 3, 2,4, 5,1 order, = Tighten bolts in 2 or 3 steps, checking crankshaft tur- fing resistance after each step. 9) Install remaining components in reverse order of removal. noting proper alignment af timing marks. See TIMING CHAIN REPLACEMENT. CAMSHAFT ENGINE FRONT COVER OIL SEAL To replace front cover cil seal, remove crankshaft pulley, then pul out old seal with suitable too! (09308-10010). Install new seal with driver (09223-22010). Lubricate seal lips ond install cronkshaft pulley. TIMING CHAIN REPLACEMENT 1). With timing chain installed on engine, attach a spring ten sion gauge fo chain and pull out on chain with a pressure of 22 Ibs" ond check distance between choin tensioner plunger ond tensioner body, Spring Tension Gouge Fig. 9 Checking Timing Chain Elongation 2) If clearence exceeds 532", chain ond sprockets must be removed ond checked. Remove comshalt sprocket bolt and remove sprocke! and chain. Pull crankshatt sprocket from crankshot 3) Secure one link of timing chain and attach spring tension {gauge to opposite end (se illustration). With 11 lbs. tension Spplied to chain, distance "A" should be no more than 10.7" Replace chain if distance is more 4) Ploce timing chain on crankshaft sprocket and measure diometer, if ess thon 2.34", replace sprocket, Measure comshaft sprocket in some manner, if less thon 4.48", replace comshaft sprocket 5) To correctly install sprockets and timing chain, install ‘ronkshott sprocket with "O" mark in line with dowel pin on comshott (se illustration), Place timing chain on sprocket with ‘mark on chain aligned with mark on sprocket 6) Align comshaft sprocket "O" mork with mark on timing chain and instll camshaft sprocket on camshatt. Tighten camshaft sprocket bolt to specification. Install choin tensioner ‘and vibration damper. Install timing chain cover as previously outlined ig. 10 Aligning Marks for Timing Chain & Sprocket Installation ‘ipo 200 Rapa ema Campa5-270 Toyota Engines 3K-C 4 CYLINDER (Cont.) TIMING CHAIN TENSIONER & DAMPER 1) Inspect surfaces of tensioner plunger and bore of tensioner body. To test clearance, lubricate plunger and insert it into plunger body. Cover two oil passages with fingers and pull plunger about halt way out. Vacuum strong enough fo return plunger should be felt. 2) Measute thickness of tensioner head ond chain domper wall. Head should be minimum 47” (12 mm) and chain damper should be minimum ,28" [7 mm), CAMSHAFT With camshaft sprocket and timing chain removed, take off camshaft thrust plate. Remove front end plate from engine block. Remove tappeis (valve lifters) and distributor if not previously removed, Pull camshalt straight out, using care not fo damage beorings or journals — A hood bol! may be serewed info end of camsha to provide gripping surface for removol. CCheck camshaft runout at number 2 journal by using Yof the lorgest difference shown by dial indicator. Maximum runout limit i012" (.03 mm), and maximum journal out-of-round or taper is 0008" (.02 mm). CAMSHAFT BEARINGS ‘Measure camshaft journal diameter ond subtract from measured diameter of bearing bore to determine clearance Bearings should be veplaced if clearance exceeds .004" (1 mmm). Journals may be ground and .005" (.125 mm) or 10 (250 mm) undersized: bearings installed if necessary. To ‘eplace bearings, remove expansion plug from rear of engine, Use bearing replacement tool (09215-22010) to remove old bearings and insert new ones. ~ Oil holes in bearings must be aligned with oil holes in cylinder block, Install new expansion plug, coated with sealer, when all bearings have been installed. CAMSHAFT END THRUST Check clearance between thrust plate and first beoring jour- nal, if clearance exceeds .012", replace thrust plate Fics: Bearing Journal Fig. 11 Measure Camshatt Thrust Clearance with Camshatt Sprocket Installed ‘ipo 0 200 a Rea DGD — if clearance is still excessive after replacing thrust plate and installing sprocket, it wll be necessary to replace the camshatt CAM LOBE UFT Totol height of camshaft lobe is 1.436:1.440" (intoke) ond 1,432-1.438" (exhaust). Check totol lobe height, if less thon 1.424" (intake) and 1,420" (exhaust), replace camshaft. ENGINE OILING 1Y = Approximately 3.7 gts. (3.5 ltr) with il Filter ~ Full low, mounted on outside of crankcase next to distibutor, Normal Oil Pressure ~ With engine of 212°F, 28.4 psi @ 300 RPM, 42.6 psi @ 3000 RPM. Pressure Regulator Valve ~ Mounted in oil pump. See Oil Pump. ENGINE OILING SYSTEM il is circulated through engine by pressure provided by @ ‘rochoid rotor type oil pump. Pump is mounted on bottom of crankcase and driven by comshalt vio distributor drive. Ol is, drawn from oil pan and circulated through a ful flow oi filter into moin oil gallery. Oil is then distributed to main ond con necting rod bearing journals ond camshaft beoring journals, Cylinders ond piston pins ore lubricated by cil squirting from hole in connecting rod. Oil's supplied to timing choin by oil from timing chain tensioner. Oil flows from number two com bearing journal to rocker arm shaft ta lubricate rocker arms Excess oll rom rocker arm shaft lubricates vohes ond valve Engine Oiling SystemToyota Engines 5-271 3K-C 4 CYLINDER (Cont.) ‘on PUMP 1) Remove oil pan os previously outlined and remove oil pimp, Remove ol srlnar pump cover and preture regulator lug from side of pump body. Remove spring, piston and foie cm ue bony ah * 2} Thoroughly cleon ond inspect al components. Check rotor fp decrance, more thon .0079", replace rotors. Check clearance between drive rotor and cover, lace a straight edge fn moting surface of pump body and inert a feler gouge between straight edge and drive rotor. If clearance exceeds 10059" replace cover pump body oF rotors ler Gouge Drive Rotor Caygy_‘Fetler Gouss Fig. 13. Checking Oil Pump Rotor Tip Clearance 3). Check cleorance between ovter rotor and pump body with (© feeler gouge. If clearance exceed .0079", replace pump body oF rotors. Check pressure regulator spring and piston for ‘wear or signs of seizure. Replace as necessary 4) To ossemble pump, reverse disassembly procedure, Install rotors with punch marks to cover. With pump assembled, sub: merge in clean motor oil and rotate drive shaft to check flow of cil from outlet port. To install pump, reverse. removal procedure and install oil pon at previously outlined. Oil Pump Specifications Application In, (mmm) Rotor Tip Clearance (002-.006 (.04..16) Limit 008 (.2) Rotor Side Clearance (001-.004 03-09) Limit 006 (.15) Roter-to:Body Clearance (004-.006 (10-16) Limi 008 (.2) ENGINE COOLING Coolant Capacity — 5.5 quorts. Thermostat ~ Begins to open as low as 177°F (80°C) and must be fully open ot 212°F (100°C), Radiator Cop — 13-15 psi WATER PUMP Drain cooling system ond loosen drive belt. Disconnect radiator and heater hoses at pump. Remove mounting bolts fond take off water pump. Clean mating surfaces, coat new gosket with sealant ond install water pump. SIE — Cooling fon is electrically driven and may run at any time the ignition is on if coolant temperature is high. It may be necessary to remove fan and shroud fo provide greater access fo the water pump, ENGINE SPECIFICATIONS GENERAL SPECIFICATIONS VALVES. (1.21.6) 047.063, (121.6) 100140026 (,035-065) {9014-0028 (040-071) 3136.3140 (79657975) 31343140 (7.960-7.975) ‘ipo 200 Rapa ema CampaToyota Engines 5-272 3K-C 4 CYLINDER (Cont.) ENGINE SPECIFICATIONS (Cont.) PISTONS, PINS, RINGS PISTONS PINS RINGS, Engine Clearance Piston Ft RodFit__| Rings | EndGap] Side Clearance| In. (mam) In, (mm) tn. (mam) In.(mm) | In. (mm) 3KC (001.002 © .9002..0003 | No.1 | .004.011| .0012..0028 (03.05) (.004008) | 10-28) | 03.04) No.2 | 004-011 .0008-\0024 (10.28) | (,02-.06) oi | 608-035 (2.9) (© ~ Push fit with piston and pin heated to 158-175°F CRANKSHAFT MAIN & CONNECTING ROD BEARINGS MAIN BEARINGS ‘CONNECTING ROD BEARINGS TIGHTENING SPECIFICATIONS Application Ft Lbs, (mkg) Cylinder Head Bolts ‘Monifold Nuts ‘Main Bearing Cap Bolts 39-48 (5.4-6.6) 14:22 (2.03.0) 39-48 (5.46.6) 29-38 (40.5.2) 2.3(3-4) 47(6-9) 39-48 (5.46.6) 33-40 (4.5-6.5) 39-48 (5.46.6) Connecting Rod Cap Nuts Oil Pan Bolts Comshoft Thrust Piote Bots Comshoft Sprocket Bolt Crankshaft Pulley Bolt Flywheel Bolts... ‘ipo 200 Rapa ema Campa Throat | Crankshah Engine | Journal Diam. | Clearance | Bearing | EndPlay | Journal Diam. | Clearance | side Ploy Tarte) | Seem) Inet) | intr)” | Tne temmy | Ine omy aK 1968-1969 | 0006-006 | wo.3 | 002.009 | 1.53:1.454 | c009.0019] 004. 008 (49.976:50000) | (016-040) (04-22) | 41'976-42000)| (024-048) | (11-20) CAMSHAFT Engine] Journal Diam. | Clearance | tobe lif VALVE SPRINGS. Inetmmm) | ine (emm) |e. (mim) Free PRESSURE _ | Length tbr @ In Engine | ‘na (pgm Journal (03-07) Not | 1701-1702 no.2 | “Véor-1e92 2964298) Nos | ‘iei-1ce2 wera) nos | Veriere ateuta ds)