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
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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). The fillet formed from a deposit or wear is removed development. Study the instruction of the manufacturer attached to the tool. If not to execute this operation, at extraction of the piston with a rod from the cylinder breakage of the piston is possible. |
| 2. After removal of a fillet turn the engine so that the crankshaft appeared above. |
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3. Before removal of rods check their axial side play by means of a set of probes. Lay the probe between a rod and the crankshaft, selecting thickness of probes achieve disappearance of a side play. The axial side play will be equal to the total thickness of probes at which the side play disappears. If the axial side play of a rod exceeds standard value, the rod should be replaced. |
| 4. Measure by just the same way an axial side play at other rods. If new rods are established (or the crankshaft), the axial side play can be lower than norm (in this case it is necessary to proshlifovat rods, if necessary consult in a workshop of car service). Repeat procedure for other rods. |
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5. Check existence of tags on rods and covers of rods. If tags are absent, nakernit them so that the number of kerneniye corresponded to number of the cylinder in which this rod is established. The tags 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 off them on 1/2 turns at one time until nuts do not begin to turn away by hand. Uncover a rod of the first cylinder together with a shatunny insert. Do not take the Shatunny insert from a cover. |
Prevention
In l engines 1,3 and 1,6 bolts of rods of a vpressovana 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 pieces of rubber or plastic hoses bolts of fastening of a cover of a rod not to injure a neck of a cranked shaft and wall of cylinders at extraction of a rod. |
| 8. Push out the piston assembled with a rod and the top insert 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 insert. If resistance to a piston exit is felt, double-check completeness of removal of a fillet in the top part of the cylinder. |
| 9. Repeat procedure for all other cylinders. |
Prevention
At extraction of the piston with a rod from the cylinder turn the crankshaft so that to keep parallelism of a rod and walls of the cylinder. 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 inserts, tighten nuts of covers by hand. Before assembly store inserts 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 given 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 the engine are always 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. Scrape off 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. Do not clean off the deposit remains at all the wire brush got on the electric drill as it can lead to an erosion of a soft alloy from which cast pistons. |
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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, being careful thus not to remove piston material. Try not to damage surfaces of flutes of rings. |
| 4. After removal of a deposit carefully wash out surfaces of flutes of rings solvent, carefully dry compressed air (if is available). Be convinced of purity of drainage oil grooves in an installation site of an oil scraper 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 the rubbing surface of the piston and in the form of small weakening of landing of the top compression ring. Nevertheless, replacement of piston rings at capital repairs 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 zadir on the rubbing site of a surface of a skirt of the piston, traces of a progar in the central part of the bottom of the piston, and also a piston obgoraniye at the edges. If chips and teases are observed, it indicates a frequent overheat of the engine, abnormal combustion of fuel mix can be one of which reasons. In this case careful check of lubrication systems 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. At the edges as a rule abnormal combustion (detonation) is the reason of an obgoraniye of the bottom of the piston. If the specified defects are found, it is necessary to find their reason and to eliminate, otherwise repetition of abnormal wear is possible. The wrong installation of the moment of ignition, refusal of system of recirculation of exhaust gases can be the reasons of abnormal operation of the engine an air suction on the soaking-up collector. |
| 8. Corrosion of the piston in the form of not big poles (pitting) 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 a new ring into a flute and lay the probe 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 will be established as rings have different thickness. If the gap exceeds the set limit, the piston should be replaced. |
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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 couple 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 skirt of the piston. If the gap exceeds the set limit, the block of cylinders is subject to boring, and pistons and rings should be replaced repair. |
| 13. Check a gap between a piston finger and a head of a rod for what it is necessary to shake the piston and a rod in opposite directions. The notable side play will indicate 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 of a side play of a piston finger, it is necessary to hand over them in a workshop of car service. Will be at one it is 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. Uncover at this stage 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 zadir. After check collect a rod, having installed into place the bearings which were in operation, and tighten nuts by hand. |
Prevention
If strong knocks in rods were the reason of repair of the engine, surely replace rods.
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