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



3.1.2.7. Head of the block of cylinders

GENERAL INFORMATION

Prevention

In points of repair by the manufacturer in the spare part new and repair heads of the block of cylinders are delivered. Because procedures of dismantling and check require the specialized tool, and sometimes hardly to find spare parts, acquisition of a new head of the block, than dismantling, check and repair of the head which was 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 the accompanying details. At the description it is supposed that cam-shafts and pushers are already removed (see subsection 3.1.1.9).
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.
3. Squeeze 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 springs, 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.


4. Get the valve from the directing plug, then remove an oil scraper cap. If extraction of the valve from the directing plug is complicated (the valve badly forces the way), push it back into the directing plug and slightly process a file or whetstone a core site about a pro-point for 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 together with details, it is necessary to clear carefully a head of the block of cylinders and to check its state. If complete capital repairs of the engine are carried out before beginning cleaning and check of a head of the block finish all operations on dismantling of the engine.

Careful cleaning of a head (or heads) the block of cylinders and details of the valvate mechanism with the subsequent check will allow to estimate amount of works on repair of valves and the mechanism of the drive of valves at capital repairs of the engine.


Prevention

If the engine often overheated, the head of cylinders can be a sdeformirovana (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 collectors all remains of material of laying, being careful not to damage a surface. Use the special solvents which are available on sale dissolving material of consolidations and facilitating work for this purpose.
2. From channels of the cooling system remove a scum.
3. Remove from oil channels all deposits by means of the rigid wire brush. If channels of the cooling system are strongly struck with a rust, the head should be handed over on cleaning in a specialized workshop.
4. Banish a carving in each carving opening by means of a tap to remove traces of corrosion and sealant. 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 the 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. Use of 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 valvate mechanism very good results are yielded by use of solvents of a deposit. These are very caustic liquids and it is necessary to use them with observance of precautionary measures. Study the instruction on application on a label.


7. Carefully clear pushers, having washed out their solvent and having dried. Use of 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 only of one valve not to mix them.
9. Scrape off all deposits from valves. Then the wire brush got on the electric drill, clean off a deposit from heads and cores of valves. Do not forget to take a measure not to mix a detail.

Check
Prevention

Before drawing a conclusion on need of repolishing of details for a workshop surely execute everything the procedures described below. 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 regarding possibility of repair. If repair is impossible, replace a head.
2. Check a deviation of a demountable surface of a head of the block of cylinders from the plane by means of the probe and calibration whetstone. At measurements use the probe with thickness corresponding to a standard deviation from the plane. If the curvature exceeds the limit specified in subsection 3.1.2.1, the head should be pereshlifovat in in a workshop of car service.
3. Check a condition of saddles of valves in each combustion chamber. In the presence of pitting (poles), cracks, traces of a progar repair of a head in a workshop of car service will be required, in house conditions repair is impossible and in this manual is not described.
4. Check a gap between cores of valves and the directing plugs. Measurement is taken by means of caliber of small diameter and a micrometer, or an indicator nutromer for small openings. The gap in the directing plug can also be determined by the size of a lateral side play of a core of the valve inserted into the directing plug so that the valve acted from a saddle approximately on 1,5 mm.
5. Measurement of a side play is carried out by an indicator head. For definition of a side play and registered by the indicator halve a full speed of the valve at its rocking in the directing plug. If the size of a gap exceeds norm, replace the plug. If after measurement there is a suspicion on the increased wear of the directing plug and the result will seem doubtful, address to service of car service where for a moderate payment will execute more exact measurement.

Prevention

Most of motorists have no an exact nutromer for small openings, this tool is available in any local workshop.


Valves
6. Attentively examine valves, check existence on facets of valves of cracks, traces of uneven development, ablation of metal and a progar. 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 the need of repair of valves in a workshop of car service.
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 valvate mechanism
8. Check existence of wear tracks and poles at end faces of each spring of the valve.
9. Measure spring length in a free state with the help of the caliper combined with glubinometry or with an indicator head, and compare it to standard value. Springs with shrinkage which length in a free state is less set, are subject to replacement.
10. Before installation of springs it is necessary to check them for the repaired engine under loading at the special stand (check should be executed in a workshop of car service).
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 the spring should be replaced.
12. Check existence of visible wear tracks and cracks on plates of springs and crackers. Details should be replaced the raising any doubts as breakage in operating time of the engine will lead them to serious destructions.
13. If when checking it becomes clear that details of the valve have damages or wear is higher admissible, replace these details.
14. If when checking it becomes clear that wear of details exceeds admissible and their general state unsatisfactory that as a rule and is observed in the engines subjected to capital repairs, collect valves on a head of cylinders and be guided by recommendations of subsection 3.1.2.8.

Assembly

Before 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 service was carried out or not. Keep in mind that in a head of cylinders by a design it is provided some removable caps intended for removal of tension in head material at thermal expansion (or compression). These caps are subject to replacement both at capital repairs 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 installed into place assembled with all details. In this case begin assembly with item 7.

PERFORMANCE ORDER
1. Napressuyte on the new oil scraper caps directing plugs of valves.

Prevention

Oil scraper caps for inlet and final valves differ with color, do not mix these details at assembly!


2. Establish an oil scraper cap (it is specified by an arrow) on the directing plug by easy blows of a hammer to a mandrel.

Prevention

Do not strike blows after a full press fitting of a cap on the plug, otherwise the cap can be damaged. Avoid a cap provorachivaniye at a napressovka, watch uniformity of its clothing on the plug, otherwise reliable consolidation of cores of valves is not provided.


3. Oil a valve core for the engine or greasing on the basis of a disulfide of molybdenum and install 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.
5. Squeeze 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 jellied 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 state by means of a caliper with a depth gage or an indicator head.








dead block