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
   - 3.2. 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. Lubrication system
      3.2.17. Device of injection of diesel fuel
      3.2.18. Operation of the car 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 the mode of idling
      3.2.24. Adjustment of the maximum turns
      + 3.2.25. Useful tips to owners of the 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



3.2.2. Replacement of a gear belt

GENERAL INFORMATION

Details of the 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. Lower cover of a gear belt
9. Driving gear wheel of the water pump
10. The directing roller of a gear belt
11. The directing roller of a gear belt
12. Cogwheel of a cranked shaft

Removal of a pulley of a cranked shaft stripper

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

Removal

PERFORMANCE ORDER
1. Take off 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 turn off four nuts of the coupling and remove the coupling with established on it by a pulley and the fan.
3. Turn off a bolt of a pulley of a cranked shaft. For keeping of a cranked shaft from a provorachivaniye include transfer and tighten the emergency brake. Turn off a bolt a key head. For removal of a pulley the stripper established on a pulley by the way represented on rice is usually used. Removal of a pulley of a cranked shaft stripper. Otherwise it is possible to enclose under a pulley from the opposite sides two mounts and with their help snimyat a pulley. Works are carried out under the car.
4. Turn off the top cover of a gear belt from the forward party of the engine. For this purpose it is necessary to remove three clips and five bolts. Remove laying. The lower cover of a gear belt is removed later.
5. Raise the engine on cables or chains of the lifting 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 an engine crankshaft provorachivaniye 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 tag 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 the movement with a felt-tip pen (the belt can be established 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 tags on three cogwheels and a gear belt.
9. Disconnect tweezers a returnable spring of the tension device of a gear belt. Weaken fastening of 2 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 with oil, greasing or similar substances.

If it is not required to perform any works any more, the gear belt can be established. Otherwise follow the following instructions on removal or control of other details of the 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. Turn off 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 also possible to hold a cogwheel, as shown in drawing.
3. Remove a cogwheel from a camshaft. The wheel sits on a shaft on a pin and therefore it is not required to mark its situation on a shaft. After removal of a cogwheel, do not turn a camshaft.
4. In a similar way hold a driving gear wheel of the fuel pump of a high pressure and turn off a nut. Removal of a driving gear wheel requires the stripper shown on rice. Removal of a pulley of a cranked shaft stripper. Screw bolts of a stripper in two carving openings on a gear wheel. In the same way the driving gear wheel of the oil pump is removed.
5. Remove the 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 should be replaced. Measure length of a returnable spring. Repeatedly established spring has to 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 the drive of the mechanism of gas distribution is made upside-down, and the description is provided recognizing that all details of the drive of the mechanism of gas distribution were removed.

PERFORMANCE ORDER
1. Put on a cogwheel of a cranked shaft the end of a shaft, correct a spline 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 spline 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 its moment 47 N. of m. Thus it is necessary to hold a driving gear wheel from a provorachivaniye.
3. Establish the directing roller of a gear belt. Tighten a bolt 37 N.' moment of m. Check that after an inhaling the roller easily rotated.
4. Put on a gear wheel of the fuel pump of a high pressure a shaft, combining a spline with cut, kill a gear wheel and screw a nut. Hold a gear wheel from a provorachivaniye and tighten a nut 65 N.' moment of m.
5. Put on a cogwheel a camshaft. In a cogwheel there is an opening which the camshaft pin has to enter. Screw a bolt with a big washer, to hold a shaft, as shown in drawing, and tighten a bolt 100 N.' moment of m. At a bolt inhaling do not turn a shaft as valves can hit 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 7,5 N.' moment 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 tag on a pulley of a cranked shaft has to settle down from above. The tag on a cogwheel of a camshaft has to be exposed, as shown in drawing, and the tag of a driving gear wheel of the fuel pump of a high pressure has to be combined with a tag 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 has to 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 the directing roller and a driving gear wheel of the oil pump, and in such sequence. Check, whether will draw a belt. All tags have to coincide.
12. At installation of an old gear belt, establish a belt in the above described way, however thus also all tags made a felt-tip pen at removal have to coincide. The arrow also has to be directed correctly. In drawing it is shown how tags coincide. If the belt was displaced on one tooth, it should be laid 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. Zatyanute 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 tags were exposed as it is shown in drawing. If it is necessary, remove and anew to establish a belt.
15. Tighten bolts of a tension roller 37 N.' moment of m, without moving an assembly payment.
16. Establish the bearing bracket of the right engine mount. Smaller bolts tighten 37 N.' moment of m, big 65 N. m.
17. If the hydraulic booster of a steering is installed, still finally do not tighten big bolts.
18. Screw four glow plugs and tighten their moment 13 N. of m. Connect current connectors to candles, put the current tire with the isolating washers, washers and nuts and put on four rubber tips.
19. Put on the directing washer of a gear belt the end of a cranked shaft. Thus expose maple directing on a spline. The unbent edge of the directing washer has to be turned outside, as shown in drawing. Put on the lower 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 spline and cut). For a nasazhivaniye the piece of a pipe is used. Screw and tighten the moment 100 N. of m a bolt. Thus transfer has to be 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. Tighten bolts 40 N.' moment of m. Now establish a pump pulley temporarily.

23. Establish a driving belt of the pump of the hydraulic booster of a steering and the generator of 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 until 45 N.' inhaling of m.