Toyota Corolla

1992-1998 of release

Repair and operation of the car



Toyota Corolla
+ 1. Maintenance instruction
+ 2. Maintenance
- 3. Engines
   - 3.1. Petrol engines
      + 3.1.1. Repair work without dismantle of the engine from the car
      - 3.1.2. Dismantle and capital repairs
         3.1.2.1. Specifications
         3.1.2.2. Diagnostics of the engine by means of a vakuumer
         3.1.2.3. Check of a compression in engine cylinders
         + 3.1.2.4. Dismantle of the power unit - methods and safety measures
         3.1.2.5. Alternatives of capital repairs 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. Dismantle of the crankshaft
         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. Start-up of the engine after repair and a running in
   + 3.2. Diesel engine
   + 3.3. Electric equipment of the engine
+ 4. Cooling systems, heating
+ 5. Fuel, exhaust systems
+ 6. System of decrease in toxicity
+ 7. Transmissions
+ 8. Coupling and half shafts
+ 9. Brake system
+ 10. Suspension bracket and steering
+ 11. Body
+ 12. Electric equipment



3.1.2.19. Installation of shatunno-piston group

GENERAL INFORMATION

Arrangement of joints of piston rings for engines of 1,3 l

1. Top compression ring (number 1)
2. Dilator of an oil scraper ring
3. To forward part of the engine
4. Lower disk of an oil scraper ring
5. Lower compression ring
6. Top disk of an oil scraper ring

Arrangement of joints of piston rings for l engines 1,6 and 1,8

1. Compression ring number 1
2. Orientation tag of the piston
3. Lower disk of an oil scraper ring
4. Compression ring number 2
5. Dilator of an oil scraper ring
6. Top disk of an oil scraper ring

Before installation of pistons assembled with rods the wall of the cylinder has to be absolutely pure, edges of cylinders has to be chamfered, and the cranked shaft is installed in the block of cylinders.
PERFORMANCE ORDER
1. Remove a bearing cover from a rod of the first cylinder (being guided on the tags put when dismantling). Remove old inserts of the shatunny bearing and wipe landing surfaces of inserts in a core of a rod and in a cover the pure fabric which is not leaving pile. These surfaces have to be always absolutely pure.
2. Wipe a back surface of the top shatunny insert and lay it in a place in a rod. Be convinced that the ledge on an insert came into selection in a rod and lubricant openings coincided.
3. At installation of an insert is inadmissible to use a hammer, it is necessary to observe extreme care not to damage a working surface of an insert. At this stage greasing of an insert is not required.
4. Wipe a back surface of the lower insert and enclose it in a rod cover. Be again convinced that the ledge on an insert coincides with selection on a rod cover, do not grease an insert. It is very important that the interfaced surfaces of an insert and a rod in the course of assembly were absolutely pure, without oil traces.
5. Place joints of piston rings according to rice. Arrangement of joints of piston rings for engines of 1,3 l, rice. Arrangement of joints of piston rings for l engines 1,6 and 1,8.
6. Put on pieces of rubber hoses that will protect a cylinder surface from damage bolts of covers of rods.
7. Oil pistons and rings pure for the engine, dress on the piston a mandrel for sinking of rings. Length of the site of a skirt of the piston acting from the adaptation has to be about 6,0 mm to provide the correct entrance of the piston to the cylinder. Rings have to be aflush with a piston surface.
8. Turn a cranked shaft to the lower dead point in the first cylinder, oil cylinder walls for the engine.
9. Turn the piston with a rod so that tags (1) on a rod and (2) on the bottom of the piston were turned towards forward part of the engine, carefully enter the piston with a rod into the first cylinder against the stop of the adaptation for sinking of rings in the block of cylinders.
10. Slightly knock on the upper edge of a mandrel to provide uniform contact with the plane of the block of cylinders on all circle.
11. Carefully knock with the wooden handle of a hammer on the piston bottom, directing a rod on the corresponding neck of a cranked shaft. Piston rings can jump out of a mandrel just before entry into the cylinder therefore, the mandrel always has to nestle on the block of cylinders.
12. Carry out this operation carefully, immediately stop pushing-in of the piston at feeling of any resistance at an entrance to the cylinder. Define the reason of jamming of the piston and eliminate it then continue installation of the piston in the cylinder.

Prevention

It is not allowed to make effort at installation of the piston in the cylinder, irrespective of the reason which caused resistance to occurrence of the piston. Otherwise it is possible to break rings or the piston.


13. After installation of the piston in the cylinder it is necessary to measure a gap between shatunny bearings and a neck of a shaft, and only after that to finalize a rod cover.
Check of gaps in shatunny bearings
14. Prepare a piece of a calibration plastic wire which length is a little less than width of the shatunny bearing, and put it on a shatunny neck (it is specified by an arrow) the first cylinder parallel to a crankshaft axis.
15. Clear the rod cover surface adjacent to an insert, remove hoses from bolts of fastening of covers and establish a cover. Be convinced that tags of mutual orientation on a cover and on a rod are on the one hand. Be convinced that the forward tag on a cover is directed towards a gear belt.
16. Slightly grease internal surfaces of nuts, wrap nuts and tighten them with the set moment. Tighten nuts a face head with the picked-up outer diameter that will allow to avoid the wrong indication of the moment of an inhaling in case of a head zadevaniye for a cover of the shatunny bearing.
17. If the head starts touching a cover, raise a head so that to provide its free turn. Rotation of the crankshaft at an inhaling of nuts is not allowed.

Prevention

On l engines 1,6 and 1,8 after an inhaling of nuts tighten them on 90 °.


18. Turn off nuts and carefully uncover, without having damaged plastic caliber.
19. Compare thickness of the crushed calibration wire to the value caused on on packing of caliber and determine the size of a lubricant gap (the scale is graduated in millimeters and in inches). Compare the received value to the standard.
20. If the gap does not correspond established, the wrong selection of shatunny bearings can be the cause (in this case pick up inserts of bearings). Before coming to the decision on need of replacement of inserts be convinced that at measurement of a gap there were no pollution or oil between bearings and surfaces of rods and shatunny covers. Check also diameter of shatunny necks. If width of the crushed calibration wire on the ends strongly differs, the radical neck of the crankshaft has conicity (see subsection 3.1.2.13).
Final installation of rods
21. Carefully remove the remains of calibration material from shatunny necks of the crankshaft and / or with in surfaces of shatunny bearings. Do not allow damage of surfaces of shatunny bearings, scratch out a forefinger or the edge of plastic.
22. Be convinced of full purity of working surfaces of shatunny bearings, apply on bearing inserts a thin uniform layer of jellied greasing with a disulfide of molybdenum or oil for assembly of the engine. For access to a surface of the top shatunny insert it is necessary to push the piston into the cylinder, previously having dressed pieces of hoses on cover bolts.
23. Attract a rod to a neck of a cranked shaft, remove hoses from bolts of covers, establish covers and tighten nuts with the moment specified in subsection 3.1.2.1.
24. Repeat the described procedure for pistons and rods of other cylinders. In the course of assembly watch purity of the interfaced surfaces of a rod and external surfaces of shatunny inserts. Watch that each piston assembled with a rod corresponded to this cylinder. At installation of the piston dredging or an arrow have to be turned into the cylinder towards forward part of the engine. Oil the cylinder the fresh. After measurement of a gap grease working surfaces of shatunny bearings.
25. After final installation of pistons with rods, check freedom of rotation of the crankshaft, having turned it on some turns by hand.
26. At the last stage of assembly it is necessary to check an axial side play of a rod. Procedure of check is described in subsection 3.1.2.9.
27. Compare the size of an axial side play to the value specified to a vpodrazdela 3.1.2.1. If the axial side play met standard before dismantling of the engine, and in the course of repair the former crankshaft and rods are installed, after repair the axial side play also has to be within norm. If new rods and the crankshaft are established, the side play can not meet standard. In this case rods should be removed and handed over in a workshop of car service for polishing.