View source for Tech:Engine/K-Series/TRD

I'll let TRD do the talking!!!

http://www.vhtracing.com/TRD_K_ENGINE_MANUAL.pdf (Dead link)

http://www.rollaclub.com/hosted/TRD-K-Engine-Manual.pdf (Mirror, 25MB)

Link by Taz_Rx

=Transcription=



The aim of this transcription has been to faithfully reproduce a textual version of the historic TOSCO/TRD manual. Please '''DO NOT edit this''' except for correcting transcription errors. If you wish to comment or expand on sections of the TOSCO/TRD manual, please copy them to a new page and do so there.


'''People are encouraged to check any measurements or part numbers against the original manual in case of transcription errors.'''


==Stage I==
Without altering the displacement (1,166 cc), the pistons have been established to increase the compression ratio.

===Cylinder Head Gasket, Piston & Piston Rings===
====(1) Main modifications====
;a. Cylinder head gasket.
:Due to increase of compression ratio, the thickness upon assembling has been revised.
;b. Piston
:Without altering the displacement (75&empty; 1,166cc), the compression ratio has been incrased.
;c. Piston rings.

:Two compression rings with thickness of 1 mm are utilized and the oil ring is of three-piece type with the thickness of 2.5mm.



====(2) Required parts.====

{| class="wikitable"
! Description !! Qty.
|-
| Gasket,cylinder head || 1
|-
| Ring set, piston || 4
|-

| Piston w/pin || 4 
|}

====(3) Assembling standards.====

{| class="wikitable"
! Item !! Sports parts !! S. T. D
|-
| Piston clearance mm || 0.06~0.08 || 0.03~0.05
|}

{| class="wikitable" border="1"
!rowspan="3"|Item 
!colspan="3"|Sports parts 
!colspan="3"|S. T. D
|-
!colspan="2"|compression rings
!rowspan="2"|Oil ring
!colspan="2"|Compression rings
!rowspan="2"|Oil ring
|-
| No. 1 || No.2 || No.1 || No.2
|-
| Clearance between ring & ring groove (mm) || 0.02~0.04 || &larr; || 0.015~0.06 || 0.03~0.07 || 0.02~0.06 || 0.015~0.06

|-

| Gap clearance (mm) || 0.15~0.35 || &larr; || 0.20~0.90 || 0.15~0.35 || &larr; || 0.20~0.90
|}

==Stage II==

Besides the boring of the cylinder block and correction of the valve seats contacting surfaces, parts have been established which are capable for assembling almost without any modification.




===1. PISTON & PISTON RINGS===

====(1) Main modifications.====

;a. Piston

:The oversize is 3mm (78&empty;) with the displacement of 1,261 cc.

;b. Piston rings

:Two compression rings with the thickness of 1 mm are utilized.

:The oil ring is of three-piece type with the thickness of 2.5 mm.




====(2) Required parts.====

{| class="wikitable"
! Description !! Qty.
|-
| Gasket,cylinder head || 1
|-
| Ring set, piston || 4
|-

| Piston w/pin || 4 
|}

====(3) Assembling standards.====

{| class="wikitable"
! Item !! Sports parts !! S. T. D
|-
| Piston clearance mm || 0.07~0.10 || 0.03~0.05
|}

{| class="wikitable" border="1"
!rowspan="3"|Item 
!colspan="3"|Sports parts 
!colspan="3"|S. T. D
|-
!colspan="2"|compression rings
!rowspan="2"|Oil ring
!colspan="2"|Compression rings
!rowspan="2"|Oil ring
|-
| No. 1 || No.2 || No.1 || No.2
|-
| Clearance between ring & ring groove (mm) || 0.02~0.04 || &larr; || 0.015~0.06 || 0.03~0.07 || 0.02~0.06 || 0.015~0.06

|-

| Gap clearance (mm) || 0.15~0.35 || &larr; || 0.20~0.90 || 0.15~0.35 || &larr; || 0.20~0.90
|} 

===2. VALVE MECHANISM===

====(1) Main modifications.====

;a. Camshaft

:The revise the valve timing, the cam profiles are revised.

;b. Valves
:To improve the intake and exhaust efficiency, the head diameters of the intake and exhaust valves have been enlarged.
;c. Valve springs.

:To prevent surging, revised from single to dual springs and the installed load is revised.

;d. Valve spring retainer & spring seat.

:Due to the revision of the valve springs from single to dual, the retainer and seat are newly established.

====(2) Required parts.====

{| class="wikitable" border="1" 

! No. !! Part No. !! Description !! Qty. !! Remarks

|-

| 1 || 13511-KE003 || Camshaft 

|rowspan="2"| Either one || Overlap 70&deg;
|-
| || 13511-KE051 || Camshaft || Overlap 66&deg;
|-
| 2 || 13711-KE051 || Valve, intake || 4 || Head dia. 37&empty;
|-

| 3 || 13715-KE051 || Valve, exhaust || 4 || Head dia. 30&empty;

|-

| 4 || 90501-42409 || Spring, compression (outer) || 8 || "O"
|-

|5 || 90502-KE501 || Spring, compression (inner) || 8 ||

|-

|6 || 13734-KE051 || Seat, valve spring || 8||

|-

|7 || 13741-KE051 || Retainer, valve spring || 8||

|-

|8 || <!--Rollaclub.com-->90913-03005 || Lock, valve spring retainer || 16 || "O"

|}

====(3) Assembling procedures & assembling standards.====

Replace with the above parts.

===3. INTAKE & EXHAUST SYSTEMS===

====(1) Main modifications====

;a. Intake manifold.

:Matched with the carburetor throttle bore, enlarged the ports to reduce the intake resistance.

;b. Exhaust manifold.
:Revised the shape to improve the exhaust efficiency.



====(2) Required parts.====


{| class="wikitable" border="1" 

! No. !! Part No. !! Description !! Qty. !! Remarks

|-
| 1 || 17104-KP751 || Manifold sub-assy. exhaust || 1 ||
|-
| 2 || 17111-KE051 || Manifold sub-assy. intake || 1 ||

|-

|3 || 21911-TE001 || Gasket, carburetor || 8 || 40&empty;
|-
|4 || 21912-TE001 || Insulator, carburetor heat || 4 || 40&empty;
|}



====(3) Assembling procedures.====

Replace with the above parts.



=== 4. FUEL SYSTEM & ACCELERATOR LINKAGE ===

====(1) Main modifications.====

;a. Carburetor.

:Revised the throttle bore to match the specification for high speed driving.

;b. Accelerator linkage.

:Due to the revision of the carburetor, the shape of the linkage is revised.



====(2) Required parts.====

{| class="wikitable" border="1" 

! No. !! Part No. !! Description !! Qty. !! Remarks

|- 

|1 || 21001-SP001 || Carburetor set || 1 || Dellorto DHLA40 x 2

|-

|2 || 78022-KE002 || Linkage set, accelerator || 1 ||

|}



====(3) Assembling procedures.====

Replace with the above parts.

[[File:TRD Fig1.png]]

== STAGE III ==

===1. CYLINDER HEAD===

====(1) Main modifications.====
Enlarge the intake and exhaust ports to improve the intake and exhaust efficiency.
Also, due to the revision of the valves and valve springs,<!--Rollaclub.com--> machined the valve spring seats portions and inserted the valve seat rings and valve guides.

{| class="wikitable" border="1"

! Item !! Detail !! Size & etc.

|-

|Intake valve || Replaced || Head dia. 38&empty; stem dia. 6.6&empty;

|-

|Exhaust valve || " || Head dia. 33&empty; stem dia. 6.6&empty;

|-

|Valve guide bushing (IN.) || " || Bore 6.6&empty;

|-

|Valve guide bushing (EX.) || " || Bore 6.6&empty;

|-

|Valve seat ring (IN.) || " ||

|-

|Valve seat ring (EX.) || " ||

|-

|Valve spring seat portion || Machined || Recess machining

|-

|Port shape || " || Grinding for enlarging

|-

|Combustion chamber shape || " || Capacity revised

|}



;Caution:

:'''At the same time with the modification of the cylinder head, perform the surface grinding of the cylinder block top surface.'''

:'''(Refer to cylinder block paragraph.)'''

====(2) Required Parts.====
{| class="wikitable" border="1" 

! No. !! Part No. !! Description !! Qty. !! Remarks

|- 
| 1 || || Head assy, cylinder || 

|- 
| 2 || 11115-KE003 || Gasket, cylinder head || 1 

|- 
| 3 || 11131-KE002 || Seat, intake valve || 4 

|- 
| 4 || 11135-KE002 || Seat, exhaust valve || 4 

|- 
| 5 || 11121-KE001 || Bushing, valve guide (IN) || 4

|- 
| 6 || 11125-KE001 || Bushing, valve guide (EX) || 4

|- 
| 7 || 90520-12049 || Ring, shaft snap || 8 || "O"

|- 
| 8 || 90116-KE001 || Bolt, stud || 2

|- 
| 9 || 90116-KE002 || Bolt, stud || 6

|}

[[File:TRD_Fig2.png]]

====(3) Machining procedures & assembly standard.====

;a. Valve guide bushing replacement.

:Due tot he revision of the valve stem diameter, the valve guide is revised with a smaller bore (6.6&empty;) item.

:Valve guide bushing x cylinder head

:Fitting allowance - 0.018 ~ 0.035 mm (20&deg;C)
;Caution:

:'''The replacement of the valve guide bushing must accord to the repair manual procedures of the conventional engine. Also, after replacement, inspect the bushing bore and correct with a reamer if found defective.'''
;b. Valves seat ring replacement.

:Due to the revision of the valve head diameter, replace the intake and exhaust seat rings.

:Head the cylinder head to about 130&deg;C, cool the valve seat ring with dry ice to shrink and fit.

:The intake valve seat ring must protrude into the combustion chamber 1 mm more than the exhaust. (Refer to Fig. 3-a & 3-b.)

:Cylinder head x valve seat ring
:Fitting allowance - 0.07 &#177; 0.01 mm.




;Caution:

:'''Sufficent care must be taken so that there is no clearance between the ring seat and the cylinder block and also for inclination of the ring.'''




[[File:TRD_Fig3a.png]] [[File:TRD_Fig3b.png]]



{| class="wikitable" border="1"
|colspan="2" |Contact surface angle || 45&deg;
|-
|colspan="2"|Contact surface correction angles  || 15&deg; 45&deg; 65&deg;
|-
| rowspan="2" |Contact width || Intake mm || 1.2 +0.2 -0
|-
| Exhaust mm || 1.2 +0.2 -0
|}
;c. Valve spring seat portion machining.

:Machine the valve spring portion 1.3 mm for recess from the standard surface (Refer to Fig. 3-a & 3-b.)
;d. Port grinding.

:Intake.

:Perform the grinding by maintaining the standard shape.

[[File:TRD_Fig4.png]]




:Exhaust.

:Grind the oblique lines of the Fig. 3-b.




;e. Combustion chamber machining & cylinder head surface grinding.

:When revising the combustion chamber shape, surface grind the cylinder head surface to obtain the compression ratio of 11.3 ~ 11.5 at the same time.




[[File:TRD_Fig5.png]]




:Combustion chamber capacity

::As a unit - 22 ~ 23 cc

::When assembled - 31 cc




;f. Water jacket machining.

:Depending on the grinding volume of the cylinder head, warpage may be produced from heat and installation of the cylinder head.

:To countermeasure this, perform the argon welding on the water jacked before grinding the cylinder head surface (Refer to Fig. 5.)



;Caution:

:'''After machining the b, c and e, perform the water test for 5 ~ 10 minutes at 2 kg/cm&sup2;'''


;g. Replacement of rocker supporting securing bolts.

:To prevent damaging of the cylinder head threads, replace the rocker support securing bolts (90910-01005 x 6, 90116-08127 x 2) to (7), (8) stud bolts.



===2. CYLINDER BLOCK===

====(1) Main modifications.====

Increased the cylinder bore from 75&empty; to 79&empty; (displacement from 1,166 -> 1,293 cc), grind the cylinder block top surface with a surface grinder.



====(2) Required part.====




{| class="wikitable" border="1"
! No. !! Part No. !! Description !! Qty.
|-
| 1 || 11495-SP001 || Plate plug (fuel pump hole) || 1
|}




====(3) Machining procedures & assembling standards.====

;a. Surface grinding.

:Due to the revision of the dimension above the pin of the piston, surface grind the cylinder block top surface.

[[File:TRD_Fig6.png]]


:Cylinder block top surface

::Warpage allowance - 0.02 mm



;b. Boring.

:To enlarge the cylinder bore from 75&empty; to 79&empty; perform the boring and honing.

:The cylinder bore must be the minimum actual value of thrust direction in relation between 15 mm to 110 mm from the block top surface.



;Caution:

;;# The piston diameter must be the maximum actual value at 7mm above the piston skirt in thrust direction at normal temperature (20&deg;C).
;;# After machining, perform the water test for 5 ~ 10 minutes at 2kg/cm&sup2;.


;c. Chamfering of the cylinder skirt.

:Chamfer the cylinder skirt with an air grinder or file (2 ~ 3&deg;)



;d. Revise the bolts securing the oil filter and alternator bracket and thread to M10, P-1.25 to improve strength.

===3. PISTON & PISTON RINGS ===

====(1) Main modifications.====

;a. Piston

:Revised the shape to provide a flat head.

;b. Piston rings.

:Will utilize a compression ring with the thickness of 1 mm.

:The oil ring is of three piece type with the thickness of 2.5 mm.

;c. Piston pin.

:Revised the outer diameter of the piston pin from 18&empty; to 20&empty; to improve the strength.

====(2) Required parts.====



{| class="wikitable" border="1"
! No. !! Part No. || Description || Qty.
|-
| 1 || 13011-KE004 || Ring set, piston || 4

|-

| 2 || 13011-KE006 || Piston w/pin || 4

|}

[[File:TRD_Fig7.png]]






====(3) Assembling procedures & assembling standards.====

;a. Fitting of <!--Rollaclub.com--> piston with the cylinder block.

:The minimum actual value of the cylinder bore in relation to the thrust direction at between 15 ~ 110 mm from the cylinder top surface and the difference (clearance) with the maximum actual value above 7 mm from the end of the piston skirt in thrust direction must accord to the List 8 upon assembly. (Refer to cylinder block paragraph.)

{| class="wikitable" border="1"
|+ List 8
! Item !! Sports parts
|-
| Piston standard diameter mm || {{Tolerance|size=78.96|upper=+0.02|lower=-0}}
|-
| piston clearance mm || 0.07~0.10
|}

;b. Weight difference of pistons.

:The weight difference of each per one unit (including piston pin) must be within 2 grams.

;c. Piston pin.

:Heat the piston to 80&deg;C in oil and further chamfer the end surface of the pin with an oil stone to smoothen then insert carefully without scratching the corresponding part.


{| class="wikitable" border="1"
|+ List 9
! Item !! Sports parts
|-
| Piston pin bore mm ||  {{Tolerance|size=20|upper= +0.012 |lower= -0 }}
|-
| Piston pin outer diameter || {{Tolerance|size=20|upper=+0.017|lower=+0.005}}

|}

;Caution:

:'''It is satisfactory when the pin can be pushed into the piston with the thumb at 80&deg;C.


;d. Piston rings.

{| class="wikitable"
|+List 10
! Item !! Sports parts !! S. T. D
|-
| Piston clearance mm || 0.06~0.08 || 0.03~0.05
|}

{| class="wikitable" border="1"
!rowspan="3"|Item 
!colspan="3"|Sports parts 
!colspan="3"|S. T. D
|-
!colspan="2" rowspan="2"|Compression
ring
!rowspan="2"|Oil ring
!colspan="2"|Compression rings
!rowspan="2"|Oil ring
|-
| No. 1 || No.2
|-
| Clearance between ring & ring groove (mm) 
|colspan="2"| 0.02~0.04 || 0.015~0.06 || 0.03~0.07 || 0.02~0.06 || 0.015~0.06

|-

| Gap clearance (mm)  

|colspan="2"| 0.15~0.35 || 0.20~0.90 || 0.15~0.35 || 0.15~0.35|| 0.20~0.90
|} 

;Caution:
:'''To prevent vertical scratching of the cylinder bore with the compression ring ends, assemble after shamfering smoothly with an (ed: missing word, file?)'''

===4. CONNECTING ROD, CRANKSHAFT & FLYWHEEL===

====(1) Main modifications.

;a. Connecting rod.

:Revise the material to improve durability.

:Also, the small end is of less bushing type.

;b. Crankshaft.

:Oil clearance is provided and dynamic balancing has been performed.

;c. Flywheel.

:Lightened the weight and dynamic balancing has been performed.



====(2) Required parts.====

{|
!No. !! Part No. !! Description !! Qty. !! Remark
|-
|1 || 13201-KE001 || Rod sub-assy, connecting || 4 
|-
|2 || 90105-10030 || Bolt, flywheel set || 6 || "O"
|}

====(3) Installing procedures & assembling standards.====

;a. Connecting rod.
:For fitting the piston pin, apply oil onto the piston pin and it is excellent when it can be easily inserted at normal temperature.

{| class="wikitable"
|+List 11
!Item !! Sports parts !! S. T. D
|-
|Connecting rod bolt tightening torque kg.cm || 500 || 400~520
|-
|Clearance between piston pin & connecting rod mm || 0.09~0.014 || 0.004~0.008
|-
|Bend limit (per 100 mm) mm || 0.04 || 0.05
|-
|Twist limit (per 100 mm) mm || 0.04 || 0.15
|}

;b. Crankshaft.
:Adjust the clearances of the journals and crankpins.

{| class="wikitable"
|+List 12
!Item !! Racing specification !! S. T. D
|-
|Journal oil clearance mm || 0.05~0.07 || 0.016~0.040
|-
|Crankpin oil clearance mm || 0.04~0.06 || 0.024~0.048
|-
|Journal thrust clearance mm || 0.04~0.15 || 0.01~0.222
|-
|Bearing cap bolt tightening torque kg.cm || 600 || 540-660
|-
|Roundness limit mm || 0.008 || 0.01
|-
|Bend limit mm || 0.02 || 0.03
|}

;c. Flywheel.
:Discontinued the standard flywheel securing bolts (90105-01005) and lock plates and will utilize (2) (90105-10030).
:Crankshaft x flywheel
::Tightening torque - 800kg.cm

;Caution:
:'''It is desirable to perform the dynamic balancing with the flywheel and crankshaft as a unit and the unbalancing volume must be within 2g.cm.'''

===5. VALVE MECHANISM===
====(1) Main modifications.====
;a. Camshaft.
:The valve timing and cam profiles are revised.

[[File:TRD_Fig8.png]]


[[Category:K Motor]]


{| class="wikitable" style="text-align:center;"
|+List 13
!rowspan="2"|Part No.
!colspan="4"|Valve timing
!rowspan="2"|Cam lift
mm
!rowspan="2"|Valve clearance
mm
!colspan="2"|Cam top center
|-
|A||B||C||D||E||F
|-
|13511-KE001 || 53 || 91 || 87 || 55 || 7.5 ||IN:0.35
EX:0.38
|106||109
|-
|13511-KE003 || 35 || 70 || 70 || 35 || 7.4 ||IN:0.35
EX:0.35
|110||110
|-
|13511-KE005 || 54 || 86 || 94 || 46 || 7.2 ||IN:0.3
EX:0.4
|106||114
|-
|13511-KE051 || 36 || 64 || 70 || 30 || 6.8 ||IN:0.3
EX:0.3
|104||110
|}


;b. Valves.
:To improve the intake and exhaust efficiency and to lighten the weight, revised the shape and dimension.

{| class="wikitable" style="text-align:center;"
|+List 14
!rowspan="2"|Item
!colspan="2"|Sports parts
!colspan="2"|S. T. D
|-
|IN||EX||IN||EX
|-
|Head diameter mm || 38 || 33 || 36 || 29
|-
|Stem diameter mm || 6.6 || 6.6 || 8 || 8
|-
|Overall length mm || 96.8 || 95.8 || 100.1 || 100.1
|-
|Head thickness limit mm || 0.5 || 0.5 || 0.8 || 0.9
|}

;c. Valve springs.
:For high performance of the engine, revised the valve springs from single to dual type.

{| <!-- Oh boy, another table...--> class="wikitable" style="text-align:center;"
|+List 15
!Item!!Outer!!Inner
|-
|Free length mm||41.8||37.6
|-
|Installed length mm||38||32
|-
|Installed load kg||16||7
|-
|Effective windings||3.3||5.8
|-
|Coil wire diameter mm||4.2||2.6
|-
|Average coil diameter mm||28||18.4
|}

;d. Valve spring retainer.
:Revised the shape for dual spring type.
;e. Valve stem pad.
:To maintain contact surface with the rocker arm the pad will be utilized.
;f. Rocker support.
:Due to the revision of the valve length provided an addition machining on the standard part.
;g. Rocker arm spacer
:The spring between the rocker arm is replaced with the spacer to reduce the resistance.
;h. Push-rod.
:To lighten, the material is revised.
;i. Valve lifter.
:Provided an additional machining on the standard part for desirable lightening.
;j. Timing gear (for camshaft).
:Provided with 7 dowel pin holes for easy selection of the camshaft.



The racing specification sports parts described here have been established by sufficiently maintaining the basic features of the Toyota 3K model engine and right-hand-drive car.

Select the tuning detail in accordance to the racing regulations. When the tuning is performed the driving on public roads must not be performed.

;Reference:
:#The parts indicated in the remark column of this manual with the "O" marks indicate the genuine parts.
:#Always adhere to precautions upon handling and on assembling standards.
:#Please utilize genuine parts when the parts are not specially specified.
:#We reserve the right to modify the sports parts without notice.


====(2) Required parts.====

{| class="wikitable"
!No. !! Part No. !! Description !! Qty. !! Remark
|-
|1||13708-KE003||Rod sub-assy., valve push||8
|-
|2||13711-KE003||Valve, intake||4
|-
|3||13715-KE003||Valve, exhaust||4
|-
|4||90501-KE001||Spring, compression (outer)||8
|-
|5||90502-KE001||Spring, compression (inner)||8
|-
|6||90201-24215||Seat, valve spring (outer)||8||"O"
|-
|7||13734-11010||Seat, valve spring (inner)||8||"O"
|-
|8||13741-KE002||Retainer, valve spring||8
|-
|9||90913-KE001||Lock, valve spring retainer||16
|-
|10||90072-72661
90072-72681
||Pad, retainer||8||"O"
|-
|11||26908-KE005||Spacer, rocker arm No.2||2
|-
|12||26908-KE006||Spacer, rocker arm No.3||1
|-
|13||13951-KE001||Support, valve rocker||4
|-
|rowspan="4"|14
|13511-KE001||Camshaft
|rowspan="4"|either one
|-
|13511-KE003||Camshaft
|-
|13511-KE005||Camshaft
|-
|13511-KE051||Camshaft
|-
|15||13523-KE002||Gear, camshaft timing||1
|}

[[File:TRD_Fig9.png]]

;Caution:
:'''On the camshafts 13511-KE001 and 13511-KE005, as the cam for driving the fuel pump is not provided, electric fuel pump is adapted.'''

;b. Valves

{| class="wikitable"
|+List 16
!colspan="2"|Item!!Sports parts
|-
|colspan="2"|Face contact width mm||{{Tolerance|size=1.2|upper=+0.2|lower=-0}}
|-
|rowspan="2"|Oil clearance between valve guide ||(specified) mm|| 0.05
|-
||(limit) mm||0.08
|-
|colspan="2"|Valve stem end correction limit mm||0.5
|}

;Caution:
:'''Be careful with the face contact surface and contact width and the dressing of the valve and valve seat must be performed sufficiently.'''

;c. Rocker support.
:Cut the bottom surface of the standard part (13951-22010).

[[File:TRD_Fig11.png]]

:Parallelism limit of the rocker shaft center and rocker support bottom surface - 0.03 mm.

;d. Valve lifter.
:To lighten, reduceds(sic) the thickness of the standard part.

[[File:TRD_Fig12.png]]


===6. LUBRICATION SYSTEM===
====(1) Main modifications====
;a. Oil pump
:Partially revised the standard part.
;b. Oil pan.
:Due to up-right positioning of the engine, revised the shape.
;c. Oil strainer.
:Due to the revision of the oil pan, revised the shape.
;d. Oil cooling system.
:Newly established the camshaft driven oil cooler pump.


{| class="wikitable"
!No.!!Part No.!!Description!!Qty.!!Remark
|-
|1||157710-26010||Cooler assembly, oil||1
|-
|2||11321-KE001||Cover sub-assy., timing chain||1
|-
|3|| ||Drive set, oil pump||1
|-
|4||15115-KE001||Cover, oil pump No.1||1
|-
|5||04151-KE001||Rotor set, oil pump||1
|-
|6||15115-KE002||Cover, oil pump No.2||1
|-
|7||90301-44049||Ring, "O"||1||"O"
|-
|8||91611-60650||Bolt (for oil pump cover securing)||4 "O"
|-
|9||90404-KE001||Union||2
|-
|10|| ||Clamp||6
|-
|11||90405-KE002||Union||4
|-
|12||90401-12075||Union||4||"O"
|-
|13||90430-12015||Washer||8||"O"
|-
|14|| ||Hose, oil cooler
|-
|15||15100-24010||Pump assembly, oil||1||"O"
|-
|16||15104-KE002||Strainer sub-assy., oil||1
|-
|17||12101-KE002||Pan sub-assy,. oil||1||For 3K-B
|-
| ||12101-KE003||Pan sub-assy,. oil||1||For 3K-H
|}


[[File:TRD_Fig13.png]]


====(3) Machining procedures &amp; assembling standards.
;a. Oil pump.
:Shim with the thickness of 2 ~ 4 mm is inserted between the relief valve spring and relief valve to maintain the oil pressure at 6kg/cm&sup2; (standard 4kg/cm&sup2;).
:Also, with the engine prior to April 1974, please always utilize the 15100-24100.
;b. Oil filter.
:For 3K model, utilize (15601-33020) or (15600-25100) for T and 2T models. When utilizing 15600-25010 modification is required on the oil filter bracket (15609-254010).
:(Refer to Fig. 14)

[[File:TRD_Fig14.png]]


;Caution:
:'''If there is a by-pass inside the filter, it is desirable to utilize the 15600-25100.'''
:'''As the front timing cover rear oil seal retainer shape differs from the 3K-H model engine (after April 1974) and 3K-B model, sufficient care should be taken upon installation and modification.'''

===7. INTAKE &amp; EXHAUST SYSTEMS===
====(1) Main modifications.====
;a. Intake manifold.
:It is of separate type from the exhaust manifold and it is of alloy metal.
:The ports are also enlarged to match the carburetor throttle bore to reduce the intake resistance.
;b. Exhaust manifold.
:To improve the exhaust efficiency, it is of 4-2-1 type and for 4-speed (for K-40) and for 5-speed (for T-50), these are made available.
;c. Manifold stay.
:Due to the separation of the intake and exhaust manifolds, the alloy metal stays are prepared for installation of the manifolds.

====(2) Required parts.====
{| class="wikitable"
!No.!!Part No.!!Description!!Qty.!!Remark
|-
|1||17118-KE001||Stay, manifold||1
|-
|2||17111-KE001||Manifold intake||2
|-
|3||17104-KP702||Manifold sub-assy., exhaust
|rowspan="2"|Either one||For 4-speed
|-
| ||17104-KP703||Manifold sub-assy,. exhaust||For 5-speed
|-
|4||17173-KE001||Gasket, exhaust manifold No.1||2
|-
|5||17173-KE002||Gasket, exhaust manifold No.2||1
|-
|6||17177-KE001||Gasket, intake manifold||2
|-
|7||17172-KE001||Gasket, manifold to cylinder head||2
|-
|8||92132-40820||Bolt, stud||6||"O"
|-
|9||92122-KE001||Bolt, stud||4
|-
|10||92122-41020||Bolt, stud||5||"O"
|-
|11||92132-41035||Bolt, stud||2||"O"
|}

[[File:TRD_Fig15.png]]


====(3) Machining procedures &amp; assembling standards.====
;a. Intake manifold.
:Grind the ports to match the size of the gaskets
;b. Exhaust manifold.
:Grind the ports similar to the intake manifold.
;c. Manifold stay.
:Grind the contact surfaces of the cylinder head and manifolds so that these can be connected with gradual curved surfaces without any irregularity.

===8. FUEL SYSTEM===
====(1) Main modifications.====
;a. Carburetor.
:Revise the throttle bore to meet the specification for high speed driving.

{| class="wikitable"
|+List 17
!Item!!Specification
|-
|Throttle valve diameter||45&empty;
|-
|Large venturi diameter||38&empty;~40&empty;
|-
|Small venturi||8011-1
|-
|Main jet size||160#~200#
|-
|Air jet size||180#~220#
|-
|Emulsion tube||ET7772-2
|-
|Idle jet side||50#
|-
|Pump jet size||33#~
|-
|Needle valve size||170#
|-
|Fuel level height||8.0mm
|-
|Air horn length||50mm
|}

;b. Fuel pump & filter.
:Due to the revision of the camshaft and carburetor, will utilize the electric pump.

{| class="wikitable"
|+List 18
!Item!!Sports parts!!S. T. D
|-
|Type||Electro-magnet||Diaphragm
|-
|Discharge volume||1500cc/min||900cc/min
|-
|Discharge pressure||0.36kg/cm&sup2;||0.2~0.3kg/cm&sup2;
|-
|Rated voltage||12V||
|-
|Rated current||2.3A||
|}

====(2) Required parts.====

{| class="wikitable"
!No.!!Part No.!!<!--I'm sick of tables-->Description!!Qty.!!Remark
|-
|1||21001-SP002||Carburetor set||1||Dellorto
DHLA45 x 2
|-
|2||23100-SP001||Pump assembly, fuel||1
|-
|3||23300-SP001||Filter assembly, fuel||1
|-
|4||23109-50010||Mounting sub-assy., fuel pump||2
|}

[[File:TRD_Fig16.png]]

====(3) Assembling procedures & assembling standards.====
Replace with the above parts.
;Caution:
:'''Upon installation of the fuel pump, the rubber mounting which is supplementary to the assembly, must always be utilized.'''

===9. ACCELERATOR LINKAGE===
====(1) Main modifications.====
Due to the revision of the carburetor, exclusive linkage has been established.

====(2) Required part.====

{| class="wikitable"
!No.!!Part No.!!Description!!Qty.
|-
|1||78022-KE002||Linkage set, accelerator||1
|}

[[File:TRD_Fig17.png]]

===10. IGNITION SYSTEM COMPONENTS & COOLING SYSTEM.===
====(1) Main modifications.====
;a. Distributor.
:The advancing device is revised to stationary type and also improved the durability of the spiral gear.

{| class="wikitable"
|+List 19
!colspan="2"|Item
!Sports parts!!S. T. D
|-
|rowspan="2"|Advancing device||Centrifugal type||None||Yes
|-
|Vacuum type||None||Yes
|-
|colspan="2"|Point contacting pressure g||&rarr;||510-690
|-
|colspan="2"|Point gap mm||&rarr;||0.4~0.5
|-
|colspan="2"|Condenser capacity uF||&rarr;||0.20~0.24
|-
|colspan="2"|Weight kg||0.7||1.1
|}


;b. Alternator pulley.
:To prevent the over-running of the alternator during high speed, revised the pulley diameter.
;c. Cooling system.
:Replaced the radiator with a larger radiation.

====(2) Required parts.====

{| class="wikitable"
!No.!!Part No.!!Description!!Qty.
|-
|1||19100-KE001|Distributor assembly||1
|-
|2||27411-KE001|Pulley, alternator||1
|}

====(3) Assembling procedures &amp; assembling standards.====
:Ignition timing
::B.T.D.C - 38 ~ 40&&deg;/4,000rpm

===11. ENGINE MOUNTS, TRANSMISSION HOUSING & SUPPORT===
====(1) Main modifications.====
Due to the revision of the engine from slanting to up-right type, newly established the engine mounts, transmission housing (for 5-speed) and transmission support (for 4-speed).

====(2) Required parts.====

{| <!-- I for one welcome our new table driven overlords--> class="wikitable"
!No.!!Part No.!!Description!!Qty.!!Remark
|-
|1||12301-KE001||Bracket sub-assy., engine mount Front RH||1
|-
|2||12302-KE001||Bracket sub-assy., engine mount Front LH||1
|-
|3||31111-KP701||Housing assembly||1||For 5-speed
|-
|4||57209-KE001||Member sub-assy., engine rear support||1||For 4-speed
|}

====(3) Assembling procedures.====
Replace with the above parts.


==Service Standards==

===Cylinder Head===
{{TRD SS Table|colspan=3}}
|-
|colspan="3"|Bottom surface warpage limit {{Right|mm}}
{{numcell|0.10}}
{{numcell|0.05}}
|-
|rowspan="3"|Valve seat
|colspan="2"|Contact surface angle
{{numcell|45&deg;}}
{{numcell|45&deg;}}
|-
|rowspan="2"|Contact surface width {{Right|mm}}||Intake
{{numcell|1.4}}
{{numcell|{{Tolerance|size=1.2|upper=+0.2|lower=-0}}}}
|-
|Exhaust
{{numcell|1.5}}
{{numcell|{{Tolerance|size=1.2|+0.2|-0}}}}
|}

===Cylinder Block===

{{TRD SS Table}}
|colspan="2"|Top surface warpage limit {{Right|mm}}
{{numcell|0.05}}
{{numcell|0.05}}
|-
|colspan="2"|Valve lifter hole bore{{Right|mm}}
{{numcell|20.000~20.021}}
{{numcell|&larr;}}
|-
|rowspan="4"|Cylinder||Bore {{Right|mm}}
{{numcell|75.00~75.05}}
{{numcell|79.03~79.08}}
|-
|Wear limit{{Right|mm}}
{{numcell|0.2}}
{{numcell|0.06}}
|-
|Taper, roundness limit{{Right|mm}}
{{numcell|0.02}}
{{numcell|&larr;}}
|-
|Cylinder bore difference{{Right|mm}}
{{numcell|0.05}}
{{numcell|&larr;}}
|-
|rowspan="2"|Liner||Fitting allowance{{Right|mm}}
{{numcell|0.055~0.15}}
{{numcell|&larr;}}
|-
|Fitting load{{Right|kg}}
{{numcell|2000~3000}}
{{numcell|&larr;}}
|}

===Piston, Piston Pin, Piston Rings===

{{TRD SS Table}}
|colspan="2"|Piston Diameter{{Right|mm}}
{{numcell|74.97~75.02}}
{{numcell|78.96~78.98}}
|-
|colspan="2"|Clearance between cylinder{{Right|mm}}
{{numcell|0.03~0.05}}
{{numcell|0.07~0.10}}
|-
|colspan="2"|Piston pin fitting temperature{{Right|C&deg;}}
{{numcell|70~80}}
{{numcell|80}}
|-
|rowspan="2"|Piston ring gap||Compression ring No.1 No.2 {{Right|mm}}
{{numcell|0.15~0.35}}
{{numcell|&larr;}}
|-
|Oil ring{{Right|mm}}
{{numcell|0.015~0.06}}
{{numcell|&larr;}}
|-
|rowspan="2"|Clearance between ring & groove||Compression ring {{Right|mm}}
{{numcell|0.015~0.06}}
{{numcell|0.03~0.05}}
|-
|Oil ring {{Right|mm}}
{{numcell|0.015~0.06}}
{{numcell|&larr;}}
|-
|colspan="2"|Piston pin outer diameter{{Right|mm}}
{{numcell|17.999~18.011}}
{{numcell|20.005~20.017}}
|}

===Connecting Rod, Bearing===
{{TRD SS Table}}
|colspan="2"|Bend limit (per 100mm){{Right|mm}}
|{{align|center}}|0.05
|{{align|center}}|0.05
|-
|colspan="2"|Twist limit (per 100mm){{Right|mm}}
|{{align|center}}|0.15
|{{align|center}}|0.05
|-
|rowspan="2"|Large end thrust clearance||Limit {{Right|mm}}
|{{align|center}}|0.3
|{{align|center}}|0.3
|-
|Specified {{Right|mm}}
|{{align|center}}|0.110~0.214
|{{align|center}}|&larr;
|-
|rowspan="2"|Clearance between||Limit {{Right|mm}}
|{{align|center}}|0.05
|{{align|center}}|0.05
|-
|Specified {{Right|mm}}
|{{align|center}}|0.004~0.008
|{{align|center}}|0.009~0.014
|-
|rowspan="2"|Bearing oil clearance pin & bore||Limit {{Right|mm}}
|{{align|center}}|0.10||
|-
|Specified{{Right|mm}}
|{{align|center}}|0.024~0.048
|{{align|center}}|0.04~0.06
|}

===Crankshaft===
{{TRD SS Table}}
|colspan="2"|Bend limit{{right|mm}}
{{numcell|0.03}}
{{numcell|0.02}}
|-
|rowspan="2"|Thrust clearance||Limit{{right|mm}}
{{numcell|0.3}}
{{numcell|0.3}}
|-
|Specified{{right|mm}}
{{numcell|0.04~0.222}}
{{numcell|0.06~0.15}}
|-
|colspan="2"|Taper, roundness limit{{right|mm}}
{{numcell|Less than 0.01}}
{{numcell|&larr;}}
|-
|colspan="2"|Journal diameter{{right|mm}}
{{numcell|49.976~50.00}}
{{numcell|&larr;}}
|-
|colspan="2"|Journal oil clearance{{right|mm}}
{{numcell|0.016~0.040}}
{{numcell|0.05~0.07}}
|-
|colspan="2"|Crankpin diameter{{right|mm}}
{{numcell|41.976~42.000}}
{{numcell|&larr;}}
|-
|colspan="2"|Crankpin oil clearance{{right|mm}}
{{numcell|0.024~0.048}}
{{numcell|0.04~0.06}}
|-
|colspan="2"|Thrust washer width{{right|mm}}
{{numcell|2.43~2.48}}
{{numcell|&larr;}}
|}


===Timing Chain, Sprocket===
{{TRD SS Table}}
|colspan="2"|Deflection limit (load 10kg){{right|mm}}
{{numcell|13.5}}
{{numcell|&larr;}}
|-
|colspan="2"|Vibration damper thickness limit{{right|mm}}
{{numcell|7}}
{{numcell|&larr;}}
|-
|colspan="2"|Tension plunger head thickness limit{{right|mm}}
{{numcell|12}}
{{numcell|&larr;}}
|-
|colspan="2"|Camshaft timing sprocket wear limit{{right|mm}}
{{numcell|113.8 
(Measure diameter w/chain installed)}}
{{numcell|&larr;}}
|-
|colspan="2"|Crankshaft timing sprocket wear limit
{{numcell|59.4 
(Measure diameter w/chain installed)}}
{{numcell|&larr;}}
|-
|colspan="2"|Chain deflection limit{{right|mm}}
{{numcell|272.7 
(load 5kg)}}
{{numcell|&larr;}}
|}


2 pages of tables to go...