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
            3.1.2.4.1. Dismantle and installation of the power unit
         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



3.1.2.4.1. Dismantle and installation of the power unit

GENERAL INFORMATION

Prevention

Before performance of work study contents of the present section. The manufacturer recommends dismantle of the engine assembled with transmission by a raising of all power unit up and removals from a motor compartment. Transmission separates from the engine after removal of the power unit and lowering on a workshop floor. If repair of transmission is not planned, it is possible to remove the engine separately, and to leave transmission on the car. The engine is removed by rise up and removals from a motor compartment for what it is necessary to remove a pulley of the crankshaft and to raise the engine from a gear belt not to touch a body

. The considered cars are equipped with safety cushions. At any time at the connected battery the pillow (which has a rigid design) can be developed (to be inflated). To exclude casual operation of a pillow (and possible injuries) when performing any works near details of a safety cushion turn the ignition key in the situation LOCK and disconnect the battery from weight. After shutdown of the battery wait two minutes (necessary for a full discharge of the reserve condenser). More detailed description is provided in subsection 12.24


Dismantle

PERFORMANCE ORDER
1. Execute actions for a decompression of fuel system (see subsection 5.2).
2. Disconnect the battery from weight.
3. Remove the battery and a tray of the battery.
4. Remove a cowl, having spread a sheeting (see subsection 11.8).
5. Remove the air filter (see subsection 5.9).
6. Lift the car and establish on supports. Merge liquid from the cooling system, oil from the engine and take off drive belts (see subsection 2.6.4).
7. Apply accurate tags on hoses of the cooling system and decrease in toxicity of exhaust gases, on vacuum hoses, sockets of conducting, the tire of connection with weight and fuel pipes. Paste the put tags an adhesive tape or put with paint that they were well visible. Make instant pictures or sketch a relative positioning of details and arms.
8. Remove a washer reservoir of a windshield and a tank of cooling liquid.
9. Remove the fan(s) and a radiator (see subsection 4.8 and subsection 4.5).
10. Disconnect heater hoses.
11. Dump the residual pressure of fuel in a tank for what turn off a stopper of a jellied mouth and disconnect fuel tubes from the engine (see subsection 5.2).
12. Disconnect draft of a butterfly valve, draft of the throttle valve of transmission and a cable of gear shifting on the engine (if is available).
13. Remove the battery and a tray of the battery (see subsection 3.3.2).
14. Remove the soaking-up and final collectors, being guided by the description in subsection 3.1.1.4 and subsection 3.1.1.5.
15. On the cars equipped with the hydraulic booster turn off bolts of the pump of the hydraulic booster. If the place is enough, bind the pump, having taken aside, without disconnecting hoses. If necessary disconnect hoses (see subsection 10.19).

Prevention

Tie up the compressor a wire, do not allow that it hung on hoses.


16. Attach slings to the engine, bring tal the elevator and fix slings on a waist. Choose a weak point to a small tension of a waist.
17. Remove half shafts (see subsection 8.3).
18. Turn off a coupling bolt of a back support of the engine (from a wall of a motor compartment), get rubber caps from a longitudinal longeron of a support of the engine and turn off four nuts and five bolts (see subsection 7.1.5).
19. Take off drive belts, a pulley of the pump of cooling liquid and a pulley of the crankshaft.
20. Turn off a bolt of fastening of a support of the engine from a radiator to the chassis.
21. On the cars equipped with automatic transmission get the plastic filter from the lower part of a case of transmission. Turn off bolts of fastening of the hydrotransformer to the leading disk (see subsection 7.2.8) and slightly give the hydrotransformer towards transmission.
22. Turn off bolts of fastening of transmission to the engine and separate the engine from transmission (see subsection 7.1.5). The hydrotransformer has to remain on transmission.

Prevention

If with the engine also transmission is removed, it is necessary to disconnect the left support of the engine, cables, conducting and hoses from transmission. Not to turn off bolts of fastening of transmission to the engine at this stage.


23. Be once again convinced that all details connecting the engine to a body or transmission are removed. Remove all remained details previously having marked.
24. Record a transmission case, having established a support and having laid a board not to damage a case. Turn off bolts of support of the engine, except what treat transmission.

Prevention

After posting of the power unit performance of any works under the engine or transmission is forbidden.


25. Carefully lift the engine (or the power unit assembled) from a motor compartment. If necessary wring out support from engine frame arms.

Prevention

At dismantle of the engine from the car equipped with a manual transmission in that case when the check point remains on the car, it is required to lower a check point by means of a support. It is necessary to incline the engine and to get it from a motor compartment.


26. Take the engine aside from the engine and carefully lower against the stop in a floor, or remove the leading disk (coupling) and install the engine on the stand or a workbench.

Prevention

On the cars equipped with automatic transmission apply tags on internal and external remote washers (if are available) and store washers together with the leading disk.



Installation

PERFORMANCE ORDER
1. Check a condition of support of the engine. At detection of damages or wear tracks of a support replace.
2. On the cars equipped with a manual transmission check a condition of coupling (see subsection 8.2), and on the cars equipped with automatic transmission, examine an epiploon of the hydrotransformer and the plug.
3. On the cars equipped with automatic transmission apply on nasal part of the hydrotransformer of a little jellied greasing.
4. Carefully establish transmission on the engine, being guided by the description in subsection 7.1.5 and subsection 7.2.8.

Prevention

If transmission badly gives in to installation, it is not necessary to force installation by an inhaling of bolts at all. Otherwise breakages of a case or the block of cylinders are possible.


5. Wrap bolts of fastening of transmission to the engine and tighten with the moment specified in subsection 7.1.1.
6. Attach to the engine tal and carefully lower the engine (or the power unit) in a motor compartment.

Prevention

If the engine was removed without transmission, lower the engine until the assistant does not combine adjusting pins on the block of cylinders with transmission. The correct combination of transmission with the engine requires a manipulation by both units.


7. Reliably tighten fastening bolts.
8. Establish other removed details and elements of fastening upside-down.
9. Restore liquid level in the cooling system, oils in the engine, liquid in automatic transmission and a hydraulic actuator of a steering (see subsection 2.8.4, subsection 2.5.1.1 and subsection 2.5.1.2).
10. Start the engine, check operation of the engine and existence of leaks. Stop the engine and check the level of liquids in all systems.