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
Before removal of pistons assembled with rods remove a head of cylinders, the oil pallet and a tube of the index of level of oil (see subsection 3.1.1.11 and subsection 3.1.1.12).
Dismantle
| PERFORMANCE ORDER |
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1. Check a nail existence of the fillet formed as a result of wear of the cylinder from a piston ring (approximately in 6,0 mm from the upper edge of the cylinder). Formed the fillet moves away from a deposit or wear development. Familiarize with the instruction of the manufacturer attached to the tool. If not to execute this operation, at piston extraction with a rod from the cylinder piston breakage is possible. |
| 2. After removal of a fillet overturn the engine so that the crankshaft appeared above. |
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3. Before removal of rods check them axial люфт by means of a set щупов. Lay щуп between a rod and the crankshaft, selecting thickness щупов achieve disappearance люфта. Axial люфт it will be equal to total thickness щупов at which люфт disappears. If axial люфт a rod exceeds standard value, it is necessary to replace a rod. |
| 4. By just the same way measure axial люфт at other rods. If new rods (or the crankshaft) are established, axial люфт can be lower than norm (in this case it is necessary прошлифовать rods, if necessary consult in a car-care center workshop). Repeat procedure for other rods. |
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5. Check existence of labels on rods and covers of rods. If labels are absent, накерните them so that the number of kerneniye corresponded to cylinder number in which this rod is established. The labels specified by an arrow, belong to dimensional group of the shatunny bearing, but not to serial number of a rod!. |
| 6. Weaken an inhaling of nuts, turning on them on 1/2 turns at one time, until then while nuts will not begin to turn away by hand. Uncover a rod of the first cylinder together with the shatunny loose leaf. The Shatunny loose leaf from a cover do not take. |
Prevention
In l engines 1,3 and 1,6 bolts of rods впрессованы in a rod body, and covers fasten nuts, in engines of 1,8 l of a cover fasten bolts which are rolled in a rod body.
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7. Put on bolts of fastening of a cover of a rod pieces of rubber or plastic hoses not to injure at rod extraction a neck of a cranked shaft and a wall of cylinders. |
| 8. To Vytolknita the piston assembled with a rod and the top loose leaf of the shatunny bearing through the top part of the cylinder. For this purpose use a wooden pro-rate, having rested it against the top shatunny loose leaf. If resistance to a piston exit is felt, once again check completeness of removal of a fillet in the top part of the cylinder. |
| 9. Repeat procedure for all other cylinders. |
Prevention
At piston extraction with a rod from the cylinder turn the crankshaft so that to keep parallelism of a rod and cylinder walls. Do not try to take the piston when the corresponding neck of the crankshaft is under a big corner in relation to a cylinder axis.
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| 10. After pistons with rods are removed from cylinders, again collect covers of rods with shatunny loose leaves, tighten nuts of covers by hand. Before assembly store loose leaves on a place of their former installation that will exclude casual damages of internal surfaces of rods and shatunny covers. |
| 11. Do not remove pistons from rods (more detailed information is provided below. |
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Check
Before check rods and pistons it is necessary to clear and remove old rings from the piston.
Prevention
Old piston rings when dismantling engine always are subject to replacement.
| PERFORMANCE ORDER |
| 1. Carefully remove rings from the piston, using the special adaptation. At removal of rings do not damage a surface of pistons. |
| 2. To Soskrebita a deposit from the bottoms of pistons. After removal of the top rough layer of a deposit clean the piston bottom a brush or an emery paper on a basis made of cloth. At all do not clean off the deposit remains the wire brush got on an electrodrill as it can lead to an erosion of a soft alloy from which pistons are cast. |
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| 3. By means of the special adaptation remove a deposit from flutes of piston rings (a photo at the left). If such adaptation is absent, it is possible to use the old broken piston ring (a photo on the right). Delete only a deposit, observing thus care not to remove a piston material. Try not to damage surfaces of flutes of rings. |
| 4. After deposit removal carefully wash out surfaces of flutes of rings solvent, carefully dry the compressed air (if is available). Be convinced of purity of drainage oil grooves in an installation site of a maslosjemny ring, and also an oil opening in a rod. |
| 5. If traces of considerable wear are absent and if boring of cylinders is not required, pistons should not be changed. Normal wear is shown in the form of traces of uniform vertical development on a rubbing surface of the piston and in the form of small weakening of landing of the top kompressionny ring. Nevertheless, replacement of piston rings at major maintenance of the engine is obligatory. |
| 6. Carefully check existence of cracks on a piston skirt, on lugs of a piston finger and on airfields of piston rings. |
| 7. Check existence of chips and задиров on a rubbing site of a surface of a skirt of the piston, traces прогара in the central part of the bottom of the piston, and also a piston obgoraniye along the edges. If chips and teases are observed, it indicates a frequent overheat of the engine, abnormal combustion of a fuel mix can be one of which reasons. In this case careful check of systems of greasing and cooling is required. The burn-out in the bottom of the piston testifies to operation of the engine with the wrong installation of the moment of ignition. The reason of an obgoraniye of the bottom of the piston along the edges as a rule is abnormal combustion (detonation). If the specified defects are found, it is necessary to find their reason and to eliminate, repetition of abnormal wear otherwise is possible. The wrong installation of the moment of ignition, refusal of system of a retsirkulyatsiya of exhaust gases can be the reasons of abnormal operation of the engine подсос air on a soaking-up collector. |
| 8. Piston corrosion in the form of not big poles (petting) testifies to penetration into the combustion chamber (and also in a crankshaft case) cooling liquid. Here again it is required to find their reason and to eliminate, otherwise corrosion will be shown on the repaired engine. |
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9. Measure a gap between a platform of a flute of a ring and a piston ring for what insert into a flute a new ring and lay щуп between a flute and a ring. |
| 10. Check a gap in three-four places on length of all flute. Be convinced that this ring corresponds to that flute in which it will be established as rings have different thickness. If the gap exceeds the established limit, it is necessary to replace the piston. |
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11. Check a gap between the piston and the cylinder, having measured diameter of the cylinder (see subsection 3.1.2.11) and diameter of the piston. Be convinced that measurements are carried out on pair of interfaced details. Measure diameter of the piston on a skirt, in the direction perpendicular axes of a piston finger. |
| 12. The size of a gap is defined as a difference of diameters of the cylinder and a piston skirt. If the gap exceeds the established limit, the block of cylinders is subject to boring, and it is necessary to replace pistons and rings repair. |
| 13. Check a gap between a piston finger and a rod head for what it is necessary to shake the piston and a rod in opposite directions. Notable люфт will point to the raised gap and need of repair of this connection. |
| 14. If it is necessary to remove pistons from rods for replacement of pistons, or for elimination люфта a piston finger, it is necessary to hand over them in a car-care center workshop. At the same time it will be necessary to check a bend and twisting of rods, after it will be necessary to replace pistons. |
| 15. Check existence on rods of cracks and other damages. Remove at this stage of a cover of shatunny bearings, get bearings, wipe landing surfaces of bearings on a cover of a rod and on a rod, and check existence of cracks, scratches and задиров. After check collect a rod, having established the bearings which into place were in operation, and tighten nuts by hand. |
Prevention
If the reason of repair of the engine were strong knocks in rods, rods surely replace.
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