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Thread: Corolla 2.0D Saloon Engine and Transmission problem.

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    Default Corolla 2.0D Saloon Engine and Transmission problem.

    AOA members,

    i have a corolla 2.0D saloon, 2003 which has started to create problems when i took it to Pakistan tour in January 2015, before that engine had no issue whatsoever and used to start normally in single glow time and single self.

    few things to notice before i mention the problems are, CSD is operational and pump and nozzles are calibrated from Cummins PK and it is timed with dial gauge, fans are auto, valve clearances as per manual i.e. 0.28-0.30mm.

    Engine problems:

    1 - Cold Starting problem with missing, knocking and white smoke - [SOLVED post#25] - does not start when engine is cold and if push started it produces a lot of white smoke and knocking, before the tour i changed its glow plugs as old plugs were taking about 8,9 seconds to fully glow up while new ones were glowing in 6 seconds, cold start issue was initially because of a weak wire from battery to glow plugs, after changing the wire problem was slightly resolved and engine used to start after 3 glow timers but later on it totally refused to start irrespective of the glow timers.

    my electrician took out the glow plugs for checking purpose and found oil on the 1st and 3rd glow plug from the pulley, i also feel that knocking sound i also from the 3rd cylinder or somewhere near it.

    yesterday i checked the resistance of glow plugs and it was found to be 0.4-0.5 ohm of all four plugs so i again installed old glow plugs whose resistance was varying from 0.9-1.8 ohm and today morning i gave 3 glow timers and it started with 4,5 self and knocking was there but much reduced on old glow plugs.

    2 - Starter motor - [SOLVED post#11] - Mechanics say that the starter motor is taking load and not rotating the engine at the speed it should to start it that's why the engine does not start in cold, i do agree with them to the extent that starter motor is somehow slow but it was starting the engine without any knocking n missing and still it starts the hot engine perfectly, now even if i push start it, engine misses and knocks on cold.


    Gear problem:

    - while i was on the tour, car's 5th gear suddenly came to the position between reverse and 5th just as i left accelerator, when engaged it again into 5th and left clutch there was some sound from the gear it again came between 5th and reverse so without taking any risk i drove it in 4th gear all the way to Karachi. now showed it to a gear mechanic n he said 'faag kat gai hai isski' and if i forcefully keep it in 5th while leaving clutch it'll work fine and the same happened, now i have to hold the gear while leaving clutch in 5th gear.


    -speedometer sensor is installed in gear and its not working properly because original 'garari' of #32-27 is not available. when i cold start it the speedometer doesn't work, after a drive of around 5-7kms speedometer slowly starts working but does not show accurate speed like if i am driving on 60 speedometer will show 50 and if i keep the accelerator pressed speed needle stays constant on wrong speed while if i leave the accelerator the needle starts dancing between 10-20 when actual speed is 30, between 50-60 when actual speed is 70, etc

    -gear gets hard if the ambient temperature is high or if driven with ac or the car is continuously driven on high rpm like when 5th gear wasn't being engaged so while driving on 4th gear rpm was above 3000 rpm n gear got hard, and it is not only hard it gets extremely hard to shift it, however its perfect when cold or driven without ac or on low rpm.

    last year i thought that my car had starting issue when its hot because the starter acted as if battery is down when starting on engine's optimum temperature but i was wrong and found that if i start the car with clutch pressed the starter would act normal so it means the hard gear also makes the starter motor work slow.

    -considering the above problems shall i replace the gear or get it repaired ? and idea of its cost ?


    @Xulfiqar bhai and other senior members kindly help.


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    Check alignment of valve timing.
    Never loose hope in life,every step gives u something.

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    Quote Originally Posted by argtr65 View Post
    Check alignment of valve timing.

    i didn't get u sir, what is valve timing ?

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    Remove timing belt cover and check reference marks on camshaft & crankshaft pulleys for proper alignment.
    Never loose hope in life,every step gives u something.

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    Quote Originally Posted by argtr65 View Post
    Remove timing belt cover and check reference marks on camshaft & crankshaft pulleys for proper alignment.

    last time when timing the engine with dial gauge a seasoned diesel mechanic was helping us in aligning the marks so i am substantially sure that its properly aligned.

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    some queries regarding cooling system.

    i have installed thermostat valve in February 2015 and now i am noticing that car reduces almost 0.5 liter after approx 1500kms of drive, is the water evaporating due to heat or what ? fans are auto from last year but it never reduced water before installation of thermostat.

    water in radiator since 8 years and citric acid cleaning done twice, last done in mid January 2015

    -can i use caltex, castrol, zic, fuchs coolant in place of toyota pink coolant ?

    2C manual say 'use a good brand of ethylene-glycol base coolant'


    two more queries;

    -how to ensure that water pump is working fine and not corroded ?

    -how to drain water completely to pour in coolant ?

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    can i use this liqui moly coolant ? costs 1000/L

    it says that coolant if mixed in 1:1 ratio it will be anti freeze upto -30C, in 1:2 ratio upto -18C, in 1:3 ratio upto -12C. boiling point is 160C.

    plz guide.

    Corolla 20D Saloon Engine and Transmission problem -1572261

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    if u are willing to spend a fortune try Toyota coolant from any Toyota 3S shop - how to flush the coolant read this for reference
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    the above two bottles are BASF G11 and G12, do not mix both. both are used in VW diesel but need the cooling system to be hospital clean to work.

    Why not try some toyota red coolant. or if you are really keen for some diesel rated stuff look for some BASF glysantin G05 - its lightly silicated and works great in old dissimilar metal engines - really great for diesels - infact MB has been specifying it for the past 2 decades in their cars.

    the caltex kinoo coolant is great too.
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    Quote Originally Posted by Xulfiqar View Post
    the above two bottles are BASF G11 and G12, do not mix both. both are used in VW diesel but need the cooling system to be hospital clean to work.

    Why not try some toyota red coolant. or if you are really keen for some diesel rated stuff look for some BASF glysantin G05 - its lightly silicated and works great in old dissimilar metal engines - really great for diesels - infact MB has been specifying it for the past 2 decades in their cars.

    the caltex kinoo coolant is great too.
    Do you have any experience with Cummins DCA4?

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    Quote Originally Posted by capsat View Post
    if u are willing to spend a fortune try Toyota coolant from any Toyota 3S shop - how to flush the coolant read this for reference
    no sir not willing to spend fortune, willing to go for caltex coolant as its easily available and probably in reasonable price.

    Quote Originally Posted by Xulfiqar View Post
    the above two bottles are BASF G11 and G12, do not mix both. both are used in VW diesel but need the cooling system to be hospital clean to work.

    Why not try some toyota red coolant. or if you are really keen for some diesel rated stuff look for some BASF glysantin G05 - its lightly silicated and works great in old dissimilar metal engines - really great for diesels - infact MB has been specifying it for the past 2 decades in their cars.

    the caltex kinoo coolant is great too.
    what if the hospital is clean as civil hospital ?

    no sir i am not mixing both of them, was willing to go for anyone of them. toyota coolant is expensive and i am not really keen to get some very specific diesel coolant like the MB one. willing to go for caltex, 3 concentrated bottle will be enough i think.

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    Corolla 20D Saloon Engine and Transmission problem -1577368
    @Xulfiqar bhai i wanted to do the liqui moly diesel purge process but did not get the diesel purge. can i use this diesel additive as a substitute ?

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    Quote Originally Posted by munim246 View Post
    Do you have any experience with Cummins DCA4?
    yes, its the coolant charge pack - but after the advent of carbooxylate type coolants which are also extreme long life like shell ELC, peak final charge and CAT ELC, there is no need to add the add packs, just drain, clean and refill the cooling system with the new stuff and forget.
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    AOA @Xulfiqar bhai I have bought a gear box today, will be getting it replaced tomorrow or day after tomorrow.

    I am also thinking to replace the clutch and pressure plates too.

    What other things should be taken care off/inspected, precautionary measures and guidelines?

    My car takes 75w85 gear oil, which brand would be fine ? Kixx or zic ?

    Sent from my VS985 4G using Tapatalk

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    Corolla 2.0D Saloon Engine and Transmission problem. - 889160b16684d8a1b3690aff87e403e8

    Corolla 2.0D Saloon Engine and Transmission problem. - de104ea689b9aa3603388f5cec3d73df

    Corolla 2.0D Saloon Engine and Transmission problem. - 6f0be9c3d6d126ffa2bbc9d81d9630b6

    Corolla 2.0D Saloon Engine and Transmission problem. - 0e69c99738e148ce6a51a9effa58bef9

    Corolla 2.0D Saloon Engine and Transmission problem. - 7f7c5bcb17a8d43f82e6f56b9552c34d

    Corolla 2.0D Saloon Engine and Transmission problem. - 29f456b0d5c7374d085fb1c989cc1563

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    Fortunately or unfortunately I did not get this gear installed and returned it instead. I took it to mechanic for installation and he pointed out few things:
    - gear has red colored seal/packing while originally it's grey and done neatly not like the one in this gear (coming out of places, improper fit). Means the gear is repaired.
    -speedo meter sensor missing.
    -black pan sort of thing at one end while the one in my car is in silver color.

    I took a second opinion too and other mechanics also said 'itni mazaydar cheez nai lag rai'

    Talked to the seller and he referred to some mechanic who praised this gear so much as if it's made up of gold. But he was linked to the seller so his opinion wasn't regarded.

    Considering the stated facts gear was returned and now again searching for another piece.

    @Xulfiqar bhai can u kindly confirm about this red seal/packing etc thing ?

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    It seems repaired


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    And regard of that black pan, it's genuinely comes black maybe the one in ur car was painted to silver or idk.


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    Quote Originally Posted by raja20103 View Post
    It seems repaired


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    How did you identified that it's repaired? Doubt mjhe b tha lekin check krna nai ata.

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    Quote Originally Posted by raja20103 View Post
    And regard of that black pan, it's genuinely comes black maybe the one in ur car was painted to silver or idk.


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    No idea. Will check once it comes out.

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    Quote Originally Posted by Xulfiqar View Post
    the above two bottles are BASF G11 and G12, do not mix both. both are used in VW diesel but need the cooling system to be hospital clean to work.

    Why not try some toyota red coolant. or if you are really keen for some diesel rated stuff look for some BASF glysantin G05 - its lightly silicated and works great in old dissimilar metal engines - really great for diesels - infact MB has been specifying it for the past 2 decades in their cars.

    the caltex kinoo coolant is great too.
    Corolla 2.0D Saloon Engine and Transmission problem. - e0d5153c916617ad3f645201cfe3a3ea
    @Xulfiqar bhai i tried to get BASF glysantin G05 but this is the response which I got from them.

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