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Location:
Laverton, Vic
Registered:
July 2003
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3k Tosco (TRD) Manual
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Sun, 09 October 2005 11:13
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Hey People
i found a TOSCO manual on the net on how to turn a 3k into a race engine. Tosco is what TRD used to be called in the late 60's early 70's.
just wondering if anyone had seen this before, and if you have then do you know anyone that has done all the stage 3 mods?
If you have no idea what I'm on about the I can give an over view of it.
Basicly it is a manual on how to turn a standard 3k into a race version of a 3k while maintaining the same general apperance of the engine.
here is my overview of things that need to be done. basicly I read the manual and these are the things that need to be change. now there are a bit bare compared to actually reading it cos I just made notes for me. anyway here it is
Cylinder Head
Intake and exhaust port enlarged.
Machined valve spring seats
inserted Valve seat rings and valve guides
Combustion Chamber machining
Cylinder Head surface Grinding
Cylinder Block
Increase Cylinder Bore from 75mm to 79mm (1293cc)
Surface Grinding
Chamfering the Cylinder skirt (2-3 degrees)
Change bolts securing the oil filter and the alrenator braket (Threaded to M10 P -1.25)
Piston & Piston Rings
Piston shape revised to a flat head
Compression ring 1mm thick
Oil ring is a three piece 2.5mm piece
Piston Pin from 18mm to 20mm
Pistons must be same weight (max difference 2 grams)
Chamfering Ring ends to prevent scratching of cylinder bore
Connecting Rod, Crankshaft & Flywheel
Rods of different material
Small end has less bushing
Crank is balanced, and has oil clearance
Flywheel lightend and balanced
Balance Crank and Flywheel together (unbalaned volume max of 2g-cm)
Valve Mechanism
Camshaft, Cam profile and valve timing changed
Valves changed shape and dimension
Valves changed to double valve springs
Spring retainer change for double valve springs
Valve stem pad installed
Replace rocker arm spring with spacer
Push-rod different material
Valve Lifter machined to lighten
Timing gear with 7 dowel pin holes
Lubrication System
Oil pump Modified
Sump Shape Changed
Oil Strainer Shape changed
Oil Cooling system Cmashaft driven
Oil pump has Shim inserted to increase pressure
Intake & Exhaust Systems
Intake manifold ports enlarge to match cylindr head
Intake Manifold suited for twin side draght carbies
Exhaust extractors 4-2-1 type
Metal plate between head and carbies due to seperation of exhaust and intake manifolds
Fuel System
Carburetor changed to twin side draughts
Fuel pump change to electric fuel pump.
Accelerator Linkage
Changed to suit different carbies
Ingition System Components & Cooling System
Distributor Advancing device change to stationary type
Alternator pully made to a larger diameter
Cooling system has a larger radiator
Engine mounts, Transmission Housing & support
Engine mounts changed to have engine sit Upright
Change bellhousing to suit upright position
Anyway let me know what you all think.
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Location:
Kita-Ku, Sapporo, Japan
Registered:
January 2003
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Re: 3k Tosco (TRD) Manual
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Sun, 09 October 2005 11:28
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you mean the one thats been on my site for X number of years? 
or the huge PDF of it from Finland?
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Location:
1st street on the right
Registered:
November 2002
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Re: 3k Tosco (TRD) Manual
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Sun, 09 October 2005 12:35
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Now try finding the parts on ebay.
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Location:
Brisbane / Gold Coast
Registered:
May 2002
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Re: 3k Tosco (TRD) Manual
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Sun, 09 October 2005 13:39
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| wombat wrote on Sun, 09 October 2005 21:13 |
just wondering if anyone had seen this before, and if you have then do you know anyone that has done all the stage 3 mods?
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Yep, me.
They go okay, but aren;t very reliable and need to have a minor rebuild every three hours of running. There's no power below about 6000rpm and they run to nearly 9000rpm.
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Location:
Kita-Ku, Sapporo, Japan
Registered:
January 2003
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Re: 3k Tosco (TRD) Manual
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Sun, 09 October 2005 13:56
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that said tho, you can adapt some of the mods for lower revving motors and make them a bit better... just don't go wild on cam chice  ...
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Location:
Laverton, Vic
Registered:
July 2003
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Re: 3k Tosco (TRD) Manual
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Mon, 10 October 2005 00:48
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yeah sorry old corollas, I forgot where I found it.
so you guys think it's good, but maybe not go all out on what they say to do, so then I'll get some more reliability?
So suggestions on which parts I should and shouldn't do would be good.
I'm only asking cos I've never work on a K motor before so unsure what limitations I should follow as far as that goes. now 2tg's I know back to front.
Or should I just stick with the stage 2 stuff
which is
Piston & Piston Rings
a. Piston
The oversize is 3mm (78mm dia) with the displacement of 1,261 cc.
b. Piston rings
Two compression rings with the thickness of 1mm are utilized.
The oil ring is of three-piece type with the thickness of 2.5mm.
Valve Mechanism
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.
Intake & Exhaust System
a. Intake manifold.
Matched with the carburettor throttle bore, enlarged the ports to reduce the intake resistance.
b. Exhaust manifold
Revised the shape to improve the exhaust efficiency.
Fuel System & Accelerator Linkages
a. Carburetor.
Revised the throttle bore to match the specification for high speed driving.
b. Accelerator linkage.
Due to the revision of the carburettor, the shape of the linkage is revised.
So what do you guys think?
Also where should I chase parts?
Oh and one thing Stage 2 doesn't say is revised thinkness of Cylinder Head Gasket. so should I say that I do all stage 1 and stage 2?
And Bill considering you have done this do you have any pics of the finshed engine you could show me?
[Updated on: Mon, 10 October 2005 00:55]
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Location:
Kita-Ku, Sapporo, Japan
Registered:
January 2003
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Re: 3k Tosco (TRD) Manual
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Mon, 10 October 2005 04:24
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well, are you building a race motor? or a street motor?
basically it comes down to where you want your power band and then you choose EVERYTHING else to suit..
where do you want power to start? 3000? 4000? 5000? 6000?
what do you want redline to be?
then we go from there
i will try to distinguish between the race only and the street oriented mods... (but i don't know everything about them of course...)
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Location:
Laverton, Vic
Registered:
July 2003
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Re: 3k Tosco (TRD) Manual
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Mon, 10 October 2005 07:33
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Ok well race or street isn't an issue cos it will be on club plates, so as far as restrictions go there is no issue.
Um power, I guess above 3,000 and a red line at say 7,000 would be good, but not know how a 3k can go it makes it hard for me to guess.
ok so look as far as I can forsee what I want out of this engine I guess it would be I want a borderline street and race engine, leaning more towards race engine. I will be using it for some sprint races at sandown, winton, calder. so obivously I need something with some performance obviously, but also some reliability. but overall it ain't ever gonna be a daily driver, mainly fast cruises, or the od sprint, so that low end isn't of major interest.
hopefully that can help to guide me in some direction.
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Location:
Kita-Ku, Sapporo, Japan
Registered:
January 2003
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Re: 3k Tosco (TRD) Manual
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Mon, 10 October 2005 07:43
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well, my street motor started coming on cam at around 3500-4000.. around 3500 with the EFI.
power peak is around 7-7500rpm and revs to 8000..... thats what i call a street motor . it idles around 1000rpm with the EFI.
3000-7000 is a mild to warm motor. you'd want around 270 degcams (220-225@50thou), maybe about 400thou lift,
for those rpm, don't bother with the race pistons, or do much intake porting.... no need..
i'll have a look at the list later...
meanwhile, i've detailed my build a number of times, so have a look for those threads...
actually, have a look on the new forum in tech.
Cya, Stewart
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Location:
Laverton, Vic
Registered:
July 2003
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Re: 3k Tosco (TRD) Manual
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Mon, 10 October 2005 08:21
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i like the sound of your engine dude. that may be what I'm after.
Only thing is that I have no intetion of using efi. I'll be using twin side draught solex off a 2tg. cos I already got the carbs and manifold sitting here.
I'll have a search for stuff about your car in the tech section
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Location:
Laverton, Vic
Registered:
July 2003
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Re: 3k Tosco (TRD) Manual
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Tue, 11 October 2005 01:33
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Hey oldcorollas can't seem to find the stuff on your engine with the search. Your engine sounds like what I want. from what you just said. so let me know where the topic is in the forum, or just what you've done.
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Location:
Adelaide
Registered:
October 2002
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Re: 3k Tosco (TRD) Manual
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Tue, 11 October 2005 04:11
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Whats the advantage of siting the engine upright? I've noticed the KE15 in the classic adelaide is set up like this too..
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Location:
Kita-Ku, Sapporo, Japan
Registered:
January 2003
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Re: 3k Tosco (TRD) Manual
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Tue, 11 October 2005 05:38
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Malcolms car has the engine upright (as does the TOSCO spec) to make enough room to fit the intake manifold and side draught carbies, otherwise they will hit the inner guard.
as for exhaust, you have about a 30cm cube to fit it all in.... unless you tile it up.
also, tilting up increases rate of oil return to the sump from the head...
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Location:
Adelaide
Registered:
February 2005
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Re: 3k Tosco (TRD) Manual
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Tue, 11 October 2005 09:08
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I have seen this tosco manual and also thought about the uprighting of the engine, how do you go about gearbox bellhousing modification? Has anyone on this site done this? As for hitting the strut tower, i can only run really thin filters on my dellortos otherwise i can run up to 20mm trumpets and thats it, with about 10mm breathing space.
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Location:
Kita-Ku, Sapporo, Japan
Registered:
January 2003
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Re: 3k Tosco (TRD) Manual
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Tue, 11 October 2005 10:30
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tosco use a twisted BH for a T50. Malcolm just ran the K50 or T50 at an angle (as with the sump) and never had issues.
his intake runners are much longer than the usual twin carb versions, and there would not be enough space for just the carbies without tilting.
so all you really need to do is to mod the engine mounts.. and maybe mod the sump to allow the engine to sit lower at the new angle..
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Location:
Laverton, Vic
Registered:
July 2003
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Re: 3k Tosco (TRD) Manual
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Wed, 12 October 2005 06:21
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Yeah in the manual it says to mod a sump so that it can sit lower.
so you found that post about your car yet oldcorollas. I'm very interested in your engine from what you said.
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Location:
geelong
Registered:
August 2005
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Re: 3k Tosco (TRD) Manual
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Thu, 20 October 2005 02:17
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were can u get these types of manuals i want one. 
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Location:
Kita-Ku, Sapporo, Japan
Registered:
January 2003
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Re: 3k Tosco (TRD) Manual
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Thu, 20 October 2005 02:30
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| wombat wrote on Wed, 12 October 2005 16:21 |
Yeah in the manual it says to mod a sump so that it can sit lower.
so you found that post about your car yet oldcorollas. I'm very interested in your engine from what you said.
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sorry moighty, been a bit busy in japan atm... i have replied to many threads about K motors and given the specs.... if i have time next week, i will look, but in the meantime, try using google t search toymods for "4K bigport camtech" perhaps.
as for getting tosco manual, there is a pdf around to download.. something like 50 megs? or i had a pdf on my site. i'll see if i can locate it... next week...
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