Repair and Toyota Corolla car operation - 3.2.2. Replacement of a gear belt//Toyota Corolla of 1992-1998 /

Toyota Corolla

1992-1998 of release

Repair and car operation



Toyota Corolla
+ 1. Maintenance instruction
+ 2. Maintenance
- 3. Engines
   + 3.1. Petrol engines
   - 3.2. Diesel engine
      3.2.1. Specifications
      3.2.2. Replacement of a gear belt
      3.2.3. Removal of a head of cylinders
      3.2.4. Dismantling of a head of cylinders
      3.2.5. Partition of a head of cylinders
      3.2.6. Assembly of a head of the block of cylinders
      3.2.7. Installation of a head of cylinders
      3.2.8. Check and adjustment of gaps of valves
      3.2.9. Check of a compression of cylinders
      3.2.10. Pistons and rods
      3.2.11. Measurement of cylinders
      3.2.12. Assembly of pistons and rods
      3.2.13. Installation of pistons and rods
      3.2.14. Cranked shaft and flywheel
      + 3.2.15. Cooling system
      + 3.2.16. Greasing system
      3.2.17. Device of injection of diesel fuel
      3.2.18. Car operation on diesel fuel
      3.2.19. Fuel filter
      3.2.20. Fuel pump of a high pressure
      3.2.21. Nozzles
      3.2.22. Glow plugs
      3.2.23. Adjustment of a mode of idling
      3.2.24. Adjustment of the maximum turns
      + 3.2.25. Good advice to owners of the 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



3.2.2. Replacement of a gear belt

GENERAL INFORMATION

Details of a drive of the gas-distributing mechanism on the diesel engine

1. Top cover of a gear belt
2. Cogwheel of the fuel pump of a high pressure
3. Natyazhitel of a gear belt
4. Camshaft cogwheel
5. Ottyazhny spring of a natyazhitel of a gear belt
6. Gear belt
7. Pulley of a cranked shaft
8. Bottom cover of a gear belt
9. Driving gear wheel of the water pump
10. A directing roller of a gear belt
11. A directing roller of a gear belt
12. Cogwheel of a cranked shaft

Removal of a pulley of a cranked shaft by a stripper

On fig. Details of a drive of the gas-distributing mechanism on the diesel engine are represented details of a drive of the gas-distributing mechanism, drawing can be used at replacement or removal of details. The gear belt should be replaced through each 100.000 km. By this moment it reaches the normal service life. Though the engine works normally, never it is not known precisely when there will come the moment of break of a gear belt. The following description covers removal and installation of all details of a drive of the gas-distributing mechanism. When only the gear belt is replaced, be guided by the following instructions.

Removal

PERFORMANCE ORDER
1. Remove gear belts from separate units from the forward party of the engine. In the presence of the hydraulic booster of a steering, it is necessary to remove a pulley of the pump of the hydraulic booster also.
2. Remove the liquid coupling and a pulley of the water pump together with the radiator fan. For this purpose unscrew four nuts of the coupling and remove the coupling with the pulley established on it and the fan.
3. Unscrew a bolt of a pulley of a cranked shaft. For keeping of a cranked shaft from a provorachivaniye include transfer and tighten the hand brake. A bolt turn on a key head. For removal of a pulley the stripper established on a pulley in the way, represented on fig. is usually used. Removal of a pulley of a cranked shaft by a stripper. Otherwise it is possible to enclose under a pulley from the opposite sides two mounts and with their help снимять a pulley. Works are carried out under the car.
4. Unscrew from the forward party of the engine the top cover of a gear belt. For this purpose it is necessary to remove three clips and five bolts. Remove laying. The bottom cover of a gear belt acts in film later.
5. Raise the engine on cables or chains of the elevating device and remove the right beam of an engine mount.
6. Remove connections between four glow plugs and disconnect a food wire. After that turn out glow plugs.
7. Turn the engine crankshaft before installation of the piston of the first cylinder in the provision VMT of a step of compression. For a provorachivaniye of the crankshaft of the engine temporarily again put a pulley of a cranked shaft. If transfer is still included, it should be switched off. The cranked shaft is turned before installation of a label of a cogwheel of a camshaft to one line with a surface of a head of cylinders (shooter).
8. If the gear belt is repeatedly established, to put on it an arrow of the direction of movement with a felt-tip pen (a belt it is possible to establish by mistake and the protivopolzhny party). It is best of all to put the arrow directed in the direction of rotation of the engine. For installation of a gear belt in initial situation it is necessary to put labels on three cogwheels and a gear belt.
9. Disconnect tweezers a returnable spring of the tension device of a gear belt. Weaken fastening of the 2nd bolts of the tension device of a gear belt. Thus press a belt to the outer side so that it was rather free for its removal. Do not take a belt fat hands and do not allow its contact to oil, greasing or similar substances.

If more it is not required to make any works, the gear belt can be established. Otherwise follow below-mentioned instructions on removal or control of other details of a drive of the gas-distributing mechanism (when for example, the engine has big run).

PERFORMANCE ORDER
1. Turn out two bolts of fastening of a natyazhitel of a gear belt and remove the tension device.
2. Unscrew a bolt of fastening of a cogwheel of a camshaft. Thus it is necessary to hold a cogwheel. For this purpose use a powerful metal core which is inserted into an opening of a cogwheel and rests against a head of cylinders. It is possible to hold also a cogwheel, as is shown in drawing.
3. Remove a cogwheel from a camshaft. The wheel sits on a shaft on a pin and consequently to mark its situation on a shaft it is not required. After cogwheel removal, a camshaft do not turn.
4. In a similar way hold a driving gear wheel of the fuel pump of a high pressure and unscrew a nut. Removal of a driving gear wheel needs a stripper shown on fig. Removal of a pulley of a cranked shaft by a stripper. Bolts of a stripper screw in two carving openings on a gear wheel. The driving gear wheel of the oil pump in the same way acts in film.
5. Remove directing roller of a gear belt (one bolt).
6. Check lack of wear and integrity of all removed details. If the tension device in some places jams, it is necessary to replace it. Measure length of a returnable spring. Repeatedly established spring should have length of 51,93 mm at measurement between inside of both hooks of a spring as it is shown in drawing.

Installation

Installation of a drive of the mechanism of a gazoraspredeleniye is made upside-down, and the description is provided recognizing that all details of a drive of the mechanism of a gazoraspredeleniye acted in film.

PERFORMANCE ORDER
1. Put on a cogwheel of a cranked shaft for the shaft end, correct a shponka and a flute in a cogwheel and bend a cogwheel on a shaft a piece of a pipe of the corresponding diameter. Thus watch a shponka that it did not move.
2. In this way establish a driving gear wheel of the oil pump, but here enter a uvula on a driving gear wheel into cut on a power shaft. Screw a nut and tighten it the moment of 47 N of m. Thus it is necessary to hold a driving gear wheel from a provorachivaniye.
3. Establish directing roller of a gear belt. Tighten a bolt the moment of 37 N of m. Check, that after an inhaling the roller easily rotated.
4. Put on a shaft a gear wheel of the fuel pump of a high pressure, combining a shponka with cut, пристукните a gear wheel and screw a nut. Hold a gear wheel from a provorachivaniye and tighten a nut the moment of 65 N of m.
5. Put on a camshaft a cogwheel. In a cogwheel there is an opening into which the camshaft pin should enter. Screw a bolt with a big washer, to hold a shaft, as is shown in drawing, and tighten a bolt the moment of 100 N of m. At a bolt inhaling a shaft do not turn, as valves can hit about the bottoms of pistons.
6. Tighten two bolts of fastening of the tension device, without tightening them it is final. Tighten an average bolt with a roller the moment of 7,5 N of m. Check, that after an inhaling the roller easily rotated in both parties.
7. Check, whether installation of the piston of the first cylinder in situation VMT got off. Thus the label on a pulley of a cranked shaft should settle down from above. The label on a cogwheel of a camshaft should be exposed, as is shown in drawing, and the label of a driving gear wheel of the fuel pump of a high pressure should be combined with a label on the water pump.
8. At installation of a new gear belt impose it so that after its installation letters and figures on the back party of the engine were visible.
9. At first impose a belt on a camshaft cogwheel. Hold a cap key a driving gear wheel of the fuel pump of a high pressure and impose a belt on a gear wheel. Check correctness of gearing of teeths of a gear belt, on a site between cogwheels of a camshaft and the oil pump the belt should be tense.
10. Continue to hold a gear wheel of the fuel pump of a high pressure, put on a belt a gear wheel of the water pump and a cogwheel of a cranked shaft. Again check correctness of gearing of teeths of a gear belt.
11. Impose a belt on directing roller and a driving gear wheel of the oil pump, and in such sequence. Check, whether will draw a belt. All labels should coincide.
12. At installation of an old gear belt, establish a belt in the above described way, however thus should coincide and all labels made a felt-tip pen at removal. The arrow also should be directed correctly. In drawing it is shown, how labels coincide. If the belt was displaced on one tooth, it is necessary to lay it anew.
13. Connect to the tension device a returnable spring in the way specified in drawing. After connection of a spring weaken fastening of two bolts of the tension device. Thus the tension roller is delayed inside and pulls a gear belt.
14. To Zatyanuta a bolt on the forward end of a cranked shaft prior to the beginning of a provorachivaniye of a cranked shaft. Turn a cranked shaft precisely on two turns and check, that all labels were exposed how is shown in drawing. If it is necessary, remove and anew to establish a belt.
15. Tighten bolts of a tension roller the moment of 37 N of m, without moving an assembly payment.
16. Establish bearing bracket of the right engine mount. Smaller bolts tighten the moment of 37 N of m, big 65 N of m.
17. If the hydraulic booster of a steering is established, big bolts while finally do not tighten.
18. Screw four glow plugs and tighten them the moment of 13 N of m. Connect to candles those connectors, put that tire with isolating washers, washers and nuts and put on four rubber tips.
19. Put on for the end of a cranked shaft directing washer of a gear belt. Thus expose maple directing on a shponka. The unbent edge of a directing washer should be turned outside, as is shown in drawing. Put on the bottom cover of a gear belt with laying and evenly wrap five bolts.
20. Establish a pulley of a cranked shaft (to pay attention to a shponka and cut). For a nasazhivaniye the piece of a pipe is used. Screw and tighten the moment of 100 N of m a bolt. Transfer should be thus included to hold a shaft from a provorachivaniye.
21. Put the top cover of a gear belt with new laying and fix five bolts and three clips.
22. Fix three bolts the pump of the hydraulic booster of a steering. Bolts tighten the moment of 40 N of m. A pump pulley now establish temporarily.

23. Establish a driving belt of the pump of the hydraulic booster of a steering and the generator of an alternating current and adjust a belt tension as it is described in the corresponding chapter and for the pump of the hydraulic booster of a steering. Now it is possible to tighten temporarily established pulley of the pump of the hydraulic booster of a steering. For this purpose press a thumb a belt and in turn a head and a dinamometrichesky key wrap nuts till an inhaling of 45 N of m.