Toyota 21R, 21R-C 2.0 Litre 4 Cylinder Petrol Factory Engine Rebuild Manual | PDF Download

INTRODUCTION

The Toyota 21R and 21R-C engines are a series of 2.0-liter, four-cylinder petrol engines produced by Toyota Motor Corporation. These engines were widely used in various Toyota models from the late 1970s to the mid-1980s, gaining a reputation for reliability and durability. This manual provides comprehensive information on engine tune-up, rebuild procedures, and system diagnostics for mechanics and enthusiasts working on these engines.

ENGINE TUNE-UP

Regular engine tune-ups are essential for maintaining optimal performance and fuel efficiency. The following items should be checked and adjusted as needed:

• Drive Belt: Inspect for wear and proper tension. Replace if necessary.

• Battery: Check the battery's condition and terminal connections.

• Engine Oil: Change the oil and filter according to the vehicle's maintenance schedule.

• Cooling System: Inspect coolant levels, hoses, and radiator for leaks.

• Air Cleaner: Replace the air filter to ensure proper airflow.

• Spark Plugs: Inspect, clean, and replace spark plugs as needed. Ensure proper gap setting.

• High Tension Cord: Inspect the high-tension cords for wear and damage.

• Distributor: Check the distributor cap, rotor, and points for wear.

• Ignition Timing: Adjust the ignition timing to the manufacturer's specifications.

• Valve Clearance: Set the valve clearance to the specified values.

• Carburetor: Inspect and clean the carburetor. Adjust idle speed and mixture.

ENGINE REBUILD

An engine rebuild becomes necessary when the engine exhibits signs of significant wear, such as excessive oil consumption, low compression, or unusual noises.

• Cylinder Head Rebuild: The cylinder head should be disassembled, cleaned, and inspected for cracks or damage. Valves, valve guides, and valve seats should be inspected and replaced or reconditioned as necessary.

• Timing Chain Replacement: Replace the timing chain and sprockets to ensure proper camshaft timing.

• Cylinder Block Rebuild: The cylinder block should be thoroughly cleaned and inspected for cracks or damage. The cylinder bores may need to be honed or bored to accommodate oversized pistons.

LUBRICATION SYSTEM

The lubrication system is crucial for reducing friction and wear within the engine.

• Lubrication System Circuit: Understanding the oil flow path is essential for diagnosing lubrication problems.

• Oil Pump: Inspect the oil pump for wear and proper operation.

COOLING SYSTEM

The cooling system maintains the engine's operating temperature within the optimal range.

• Cooling System Circuit: Familiarize yourself with the coolant flow path.

• Water Pump: Inspect the water pump for leaks and bearing wear.

• Radiator: Clean the radiator fins and inspect for leaks.

• Thermostat: Test the thermostat to ensure it opens and closes at the correct temperature.

FUEL SYSTEM

The fuel system delivers fuel to the engine for combustion.

• Fuel Pump: Inspect the fuel pump for proper operation.

• Carburetor: Adjust the carburetor for optimal fuel-air mixture.

STARTING SYSTEM

The starting system cranks the engine to initiate combustion.

• Conventional Starting System Circuit: Understand the components and operation of the starting system.

• Conventional Starter: Inspect the starter motor for proper operation.

IGNITION SYSTEM

The ignition system provides the spark needed to ignite the air-fuel mixture.

• Ignition System Circuit: Familiarize yourself with the components and operation of the ignition system.

• Distributor: Inspect the distributor for wear and proper function.

CHARGING SYSTEM

The charging system replenishes the battery and provides electrical power to the vehicle.

• Charging System Circuit: Understand the components and operation of the charging system.

• Alternator: Inspect the alternator for proper output.

SST & SERVICE SPECIFICATIONS

Special service tools (SST) may be required for certain procedures. Always refer to the service specifications for torque values, clearances, and other critical data.

History and Uses

The Toyota 21R and 21R-C engines were used in a variety of Toyota vehicles, including:

• Toyota Hilux

• Toyota Corona

• Toyota Celica

• Toyota Cressida

These engines were known for their reliability and were a popular choice for both passenger cars and light trucks. While they are no longer in production, many of these engines are still in service today, a testament to their durability and the quality of Toyota engineering.

This manual serves as a valuable resource for anyone working on these engines, providing the necessary information to perform tune-ups, repairs, and rebuilds with confidence.

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