Toyota Corolla
+ 1. Maintenance instruction
+ 2. Maintenance
- 3. Engines
- 3.1. Petrol engines
+ 3.1.1. Repair work without engine dismantle from the car
- 3.1.2. Dismantle and major maintenance
3.1.2.1. Specifications
3.1.2.2. Engine diagnostics by means of a vakuumer
3.1.2.3. Compression check in engine cylinders
+ 3.1.2.4. Dismantle of the power unit - methods and safety measures
3.1.2.5. Alternatives of major maintenance of the engine
3.1.2.6. Order of dismantling of the engine
3.1.2.7. Head of the block of cylinders
3.1.2.8. Repair of valves
3.1.2.9. Shatunno-porshnevaya group
3.1.2.10. Crankshaft dismantle
3.1.2.11. Block of cylinders
3.1.2.12. Honningovaniye of cylinders
3.1.2.13. Cranked shaft
3.1.2.14. Radical and shatunny bearings
3.1.2.15. Engine assembly order
3.1.2.16. Piston rings
3.1.2.17. Installation of a cranked shaft and check of gaps of radical bearings
3.1.2.18. Back epiploon
3.1.2.19. Installation of shatunno-piston group
3.1.2.20. Engine start-up after repair and a running in
+ 3.2. Diesel engine
+ 3.3. Engine electric equipment
+ 4. Systems of cooling, heating
+ 5. Fuel, exhaust systems
+ 6. System of decrease in toxicity
+ 7. Transmissions
+ 8. Coupling and semi-axes
+ 9. Brake system
+ 10. Suspension bracket and steering
+ 11. Body
+ 12. Electric equipment
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Prevention
In points of repair the manufacturer in the spare part delivers new and repair heads of the block of cylinders. Because procedures of dismantling and check need the specialized tool, and spare parts to find sometimes hardly, acquisition of a new head of the block, than dismantling, check and repair of a head being in operation is represented to more expedient.
Dismantling
| PERFORMANCE ORDER |
| 1. For dismantling of a head of the block of cylinders it is necessary to remove inlet and final valves and accompanying details. At the description it is supposed that cam-shafts and pushers are already removed (see subsection 3.1.1.9). |
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2. Before removal of valves take care of their marking, or prepare a place to lay together all details of the valve and subsequently to establish on a former place. |
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3. Compress a spring of the first valve by means of the suitable adaptation and remove crackers by means of a small magnetic screw-driver or special flat-nose pliers. Carefully release a valve spring, remove a plate of a spring, a spring and a basic washer (if is available). |
Prevention
At compression of springs do not scratch or do not damage internal openings under pushers.
If the adaptation nozzle for compression of springs has no lateral window for removal of crackers, on sale there is an adapter used with the standard adaptation.
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| 4. Get the valve from the directing plug, then remove a maslosjemny cap. If valve extraction from the directing plug is complicated (the valve badly forces the way), push it back into directing plug and slightly process a file or whetstone a core site about a pro-point under crackers. |
| 5. Repeat the same actions for other valves. Remember that it is necessary to lay together all details of the valve subsequently to establish on a former place, without breaking an order. |
| 6. After removal of valves and their sorting out together with details, it is necessary to clear carefully a head of the block of cylinders and to check its condition. If complete major maintenance of the engine is carried out before beginning cleaning and check of a head of the block finish all operations on engine dismantling. |
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Careful cleaning of a head (or heads) the block of cylinders and details of the klapanny mechanism with the subsequent check will allow to estimate amount of works on repair of valves and the mechanism of a drive of valves at major maintenance of the engine.
Prevention
If the engine often overheated, the head of cylinders can be сдеформирована (see below)
Cleaning
| PERFORMANCE ORDER |
| 1. Remove from demountable surfaces of a head of the block with the block of cylinders which is soaking up and final by collectors all remains of a material of laying, being careful not to damage a surface. Use for this purpose the special solvents available on sale dissolving a material of consolidations and facilitating work. |
| 2. From channels of system of cooling remove a scum. |
| 3. Remove from oil channels all deposits by means of rigid wire ершика. If channels of system of cooling are strongly struck with a rust, it is necessary to hand over a head on cleaning in a specialized workshop. |
| 4. Banish a carving in each carving opening by means of a tap to remove corrosion and hermetic traces. If there is a compressed air, blow all channels and openings to remove the material remains after pro-race of carvings. |
| 5. Clear carvings of hairpins of fastening of soaking-up and final collectors by means of a rigid wire brush. |
| 6. Wash out a head of the block of cylinders solvent and carefully dry. Application of the compressed air will accelerate drying and will allow to clear all channels, the hidden cavities and openings. |
Prevention
When cleaning a head of the block and details of the klapanny mechanism application of solvents of a deposit gives very good results. These are very caustic liquids and to use them it is necessary with observance of precautionary measures. Study the instruction on application on a label.
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| 7. Carefully clear pushers, having washed out them solvent and having dried. Application of the compressed air will accelerate drying and will allow to clear oil channels. Do not mix pushers in the course of cleaning, store them in cash desk with the numbered cells. |
| 8. Wash out solvent all springs of valves, crackers, plates and basic washers, carefully dry these details. Wash out details of only one valve not to mix them. |
| 9. To Soskrebita all deposits from valves. Then the wire brush got on an electrodrill, clean off a deposit from heads and cores of valves. Do not forget to take measures not to mix a detail. |
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Check
Prevention
Before drawing a conclusion on need of repolishing of details for a workshop surely execute everything described below procedure. Make the list of that demands especially close attention. Procedure of check of pushers and cam-shafts is described in (see subsection 3.1.1.9).
| PERFORMANCE ORDER |
| Head of cylinders |
| 1. Attentively examine a head, check existence of cracks, traces of penetration of cooling liquid and other damages. At detection of cracks check a head of cylinders in a workshop about repair possibility. If repair is impossible, a head replace. |
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2. Check a deviation of a demountable surface of a head of the block of cylinders from the plane with the help щупа and calibration whetstone. At measurements use щуп with the thickness corresponding to a standard deviation from the plane. If the curvature exceeds the limit specified in subsection 3.1.2.1, a head follows перешлифовать in in a car-care center workshop. |
| 3. Check a condition of saddles of valves in each chamber of combustion. In the presence of a petting (poles), cracks, traces прогара head repair in a car-care center workshop is required, in house conditions repair is impossible and in this management is not described. |
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4. Check a gap between cores of valves and directing plugs. Measurement is carried out by means of calibre of small diameter and a micrometer, or a display nutromer for small openings. In the directing plug it is possible to determine a gap also by size lateral люфта a core of the valve inserted into directing plug so that the valve acted from a saddle approximately on 1,5 mm. |
| 5. Measurement люфта is carried out by a display head. For definition люфта a full speed of the valve at its rocking in the directing plug and registered by the indicator halve. If the size of a gap exceeds norm, the plug replace. If after measurement there will be a suspicion on the increased wear of the directing plug and result will seem doubtful, address in car-care center service where for a moderate payment will execute more exact measurement. |
Prevention
The majority of motorists have no an exact nutromer for small openings, this tool is available in any local workshop.
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| Valves |
| 6. Attentively examine valves, check existence on facets of valves of cracks, traces of non-uniform development, ablation of metal and прогара. Check existence of cracks on necks and cores. Check existence on cores of signs of a navolakivaniye of metal and chips, and also a bend of cores, turning the valve in the directing plug. Check wear of end faces of cores. Presence of any of the specified defects indicates need of repair of valves for a car-care center workshop. |
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7. Measure width of an of a regional corbel of each valve (a) and compare to standard value. If this distance is less than norm, the valve is subject to replacement. |
| Details of the klapanny mechanism |
| 8. Check existence of wear tracks and poles at end faces of each spring of the valve. |
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9. Measure length of a spring in a free condition of c by the help of the calliper combined with glubinometry or with a display head, and compare it to standard value. Springs with a usadka which length in a free condition less set, are subject to replacement. |
| 10. Before installation of springs on the repaired engine it is necessary to check them under loading at the special stand (check should be executed in a car-care center workshop). |
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11. Establish a spring on a flat equal surface and check vertical position. At detection of a deviation of a spring from a vertical and a deflection on length it is necessary to replace a spring. |
| 12. Check existence of visible wear tracks and cracks on plates of springs and crackers. The detail should replace defiant any doubts, as breakage in operating time of the engine will lead them to serious destructions. |
| 13. If at check it will become clear that details of the valve have damages or wear is higher admissible, these details replace. |
| 14. If at check it will become clear that wear of details exceeds admissible and their general condition unsatisfactory that as a rule and is observed in the engines subjected to major maintenance, collect valves on a head of cylinders and be guided by subsection 3.1.2.8 recommendations. |
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Assembly
Before the beginning of assembly it is necessary to be convinced of purity of a head of the block irrespective of repair of this detail in a workshop of car-care center was carried out or not. Keep in mind that in a head of cylinders the design provided some demountable caps intended for removal of tension in a material of a head at thermal expansion (or compression). These caps are subject to replacement both at major maintenance of the engine, and at restoration of a head of cylinders (procedure of replacement is described in subsection 3.1.2.11. If the head of the block was given in a workshop for repair of valves, valves will be already established into place assembled with all details. In this case assembly begin with item 7.
| PERFORMANCE ORDER |
| 1. Napressuyte on directing plugs of valves new maslosjemny caps. |
Prevention
Maslosjemnye caps for inlet and final valves differ with color, do not mix these details at assembly!
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2. Establish a maslosjemny cap (it is specified by an arrow) on directing plug in easy blows of a hammer on an opravka. |
Prevention
Do not strike blows after a full press fitting of a cap on the plug, otherwise a cap it is possible to damage. Avoid a cap provorachivaniye at a napressovka, watch uniformity of its clothing on the plug, otherwise reliable consolidation of cores of valves it is not provided.
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| 3. Oil a valve core for the engine or greasing on the basis of a disulfide of molybdenum and establish the first valve, since any edge on a head of cylinders. |
| 4. Dress a basic washer of a spring (or washers), establish a spring of the valve and a plate. |
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5. Compress a valve spring by means of the adaptation and establish crackers in a flute on a valve core. Carefully release a spring, be convinced that crackers came into the top flute of a core of the valve. If necessary, before release of a spring of the valve grease crackers with konsistentny greasing temporarily to fix on a valve core. |
| 6. Repeat all actions for other valves. Watch that all set of details of the valve was established on a former place, do not mix a detail! |
| 7. After installation of valves check spring height in the loaded condition by means of a calliper with a depth gage or a display head. |
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