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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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    Quote Originally Posted by Salman922 View Post
    I am trying to get my hands on G05, otherwise Caltex it is.

    Btw I did citric acid flush and my radiator leaked badly, I replaced the radiator with a new one and after the replacement pick up of the engine feels increased, idling sound reduced and runs better, how did this happen ?

    3 weeks after the radiator replacement it's water body leaked as well due to which system isn't holding the pressure but maintaining the engine temperature at 45% gauge as long as I keep on topping up the water in the reserve tank, I have already put in a new radiator cap (0.9), what more should I inspect/replace before filing in the coolant ? Someone was telling me about water jacket (or water packet maybe).

    And btw while replacing radiator cap I found rusty water in new radiator installed and used for approx two weeks, where did it came from after the citric acid flush ?

    Sent from my VS985 4G using Tapatalk

    your pump is leaking due to corrossion caused by running it on tap water, it will need to be changed. Diesels will cause lots of corossion and pock marks in the cylinder head if a proper coolant is not used.
    ZRS - Zulfiqar Racing Systems ..... - professionals at work - at crackwheels.com

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    Further update:

    -yesterday morning i tried to start engine on self but it did not start and battery almost drained, meanwhile i found ONE shareef admi who agreed to push my car so that I can start it, he started pushing slightly in very slow speed and max 10 feet area was covered and i left clutch and dead cold engine started normally without any smoke. which means it needed slight push to start but it wont start on self even if provided with double battery, jumper cables etc. i still dont get its reason ? 1 person cant apply much force still engine needs slight jerk, why ?

    -yesterday evening i got its starter motor's some star kind of front part replaced which is now as per the other gear installed, after that weird kind of sound while cranking has gone and starter motor's engine rotation speed has increased. while getting it done sulf wala told me that starter motor has been damaged/mishandled while installation of gear and thus that tick tok sound sometimes, that was point issue and it was also sorted out, piston was also replaced. now hot start has shown major improvement and hot engine starts just on the touch of the key, while before this hot engine was taking 5,6 selfs which i considered normal.

    -today morning i was eager to test cold start and after one glow timer i started cranking, it took many selfs, starter motor was rotating engine on much improved speed and after good 12-15 selfs car started without any puff or black smoke or something, it was just normal on dead cold start. while it was taking selfs engine acted like 'bas start hotay hotay reh gaya' after every 5,6 selfs and then suddenly started. after that worked great on hot start and number of selfs increased as the number of hours parked increased.

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    Quote Originally Posted by argtr65 View Post
    Did you tested the glow plugs individually by removing busbar ?
    not yet, i am extremely busy in some family commitments, will do this in next 7-10 days IA. btw electrician did check by putting his tester on the busbar and it showed that current is being transferred in all 4 glow plugs for 12 seconds in single glow timer.

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    Quote Originally Posted by Xulfiqar View Post
    you have an air leak into the fuel system. your pump is losing prime and hence not starting up. the fuel lines are on the gearbox side of the engine., if they are loose or oozing replace them.

    this seems fairly logical. but mechanic also tested that diesel is being supplied or not by taking out the pipe from pump on 'out' bolt and cranking engine, it started throwing out diesel as it was cranked.

    btw sir what do u mean by prime ? and kindly also tell me the procedure to check the fuel lines ?

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    Back with new set of problems linked with old issues as well !

    -glow plugs were replaced in 2015 January because original ones were talking little longer then usual to fully heat up, now from the day i got new gear installed cold start problem persists.

    After removing all the glow plugs and checking them individually it was found that all of the 4 were burnt and not working so I got the old OEM ones installed which were bit weak still worked. They started to take nearly 4 glow timers to start a dead cold engine that too on many rotations however when they were taken out they used to start the engine in 1 glow timer and 4,5 rotations that too in winters.

    -last week I got another set of glow plugs installed hoping that cold start issue will be resolved but the glow plugs were again burnt just as I turned the key to switch 'on' where i wait for glow timer. And as i cranked the engine battery acted as it was almost dead and than again came to life after the new glow plugs burnt.

    -point I am trying to link is that my car is not accepting any other glow plugs except for OEM part and it burns it right away.

    -on OEM plugs too it takes 4 glow timers, why ?

    -anyways I bought brand new 4 OEM glow plugs just the same as original ones in shape but the ones came out were 11v and the ones I got now have written 12V on it. Now these have not burnt and still working but are unable to start the cold engine but a slight push will start it always.

    -one more thing is that my engine is reducing oil, like 1L in 700kms approx, I want to get its valve seals changed but no one is ready to do according to Zulfiqar bhai's way so still searching for the one who agrees on it.

    -w.r.t. oil reduction: engine produces light tik tik tik kind of sound when low on oil which increases/decreases along with the rpm and when it's topped up with oil the tik tik sound vanishes.

    P.S. my car's CSD is working, rad has coolant, fans auto, valve clearances checked, battery is AGS gr85 installed 18-20months back, pump done by Cummins pk. Engine runs great and fuel avg is also nice, hot start is perfect.

    Now what am I missing which is making this cold start issue ?

    Mechanics r saying "hum apko pichay 6,7 saal se keh rahay hain k engine kamzor hai lekin ap mantay hi nahi, ab pura beth gaya hai apka engine aur overhaul hoga"

    I don't agree with them and wont be going for overhaul unless I get it compression tested and the person who has agreed to test it's compression for me is out of Karachi and will return after a week or so.
    @Xulfiqar bhai and other experts kindly help.

    Sent from my VS985 4G using Tapatalk

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    Quote Originally Posted by Salman922 View Post
    Back with new set of problems linked with old issues as well !

    -glow plugs were replaced in 2015 January because original ones were talking little longer then usual to fully heat up, now from the day i got new gear installed cold start problem persists.

    After removing all the glow plugs and checking them individually it was found that all of the 4 were burnt and not working so I got the old OEM ones installed which were bit weak still worked. They started to take nearly 4 glow timers to start a dead cold engine that too on many rotations however when they were taken out they used to start the engine in 1 glow timer and 4,5 rotations that too in winters.

    -last week I got another set of glow plugs installed hoping that cold start issue will be resolved but the glow plugs were again burnt just as I turned the key to switch 'on' where i wait for glow timer. And as i cranked the engine battery acted as it was almost dead and than again came to life after the new glow plugs burnt.

    -point I am trying to link is that my car is not accepting any other glow plugs except for OEM part and it burns it right away.

    -on OEM plugs too it takes 4 glow timers, why ?

    -anyways I bought brand new 4 OEM glow plugs just the same as original ones in shape but the ones came out were 11v and the ones I got now have written 12V on it. Now these have not burnt and still working but are unable to start the cold engine but a slight push will start it always.

    -one more thing is that my engine is reducing oil, like 1L in 700kms approx, I want to get its valve seals changed but no one is ready to do according to Zulfiqar bhai's way so still searching for the one who agrees on it.

    -w.r.t. oil reduction: engine produces light tik tik tik kind of sound when low on oil which increases/decreases along with the rpm and when it's topped up with oil the tik tik sound vanishes.

    P.S. my car's CSD is working, rad has coolant, fans auto, valve clearances checked, battery is AGS gr85 installed 18-20months back, pump done by Cummins pk. Engine runs great and fuel avg is also nice, hot start is perfect.

    Now what am I missing which is making this cold start issue ?

    Mechanics r saying "hum apko pichay 6,7 saal se keh rahay hain k engine kamzor hai lekin ap mantay hi nahi, ab pura beth gaya hai apka engine aur overhaul hoga"

    I don't agree with them and wont be going for overhaul unless I get it compression tested and the person who has agreed to test it's compression for me is out of Karachi and will return after a week or so.
    @Xulfiqar bhai and other experts kindly help.

    Sent from my VS985 4G using Tapatalk
    I got mine overhauled back there and oil leaking problem still there got it fixed 3 times from different mechanics still of no use so driving it as it is+ am using valvoline oil, it used to decrease oil whenever i use delo gold but on valvoline i can see little drops but doesnt decrease like it use to on delo

    Sent from my GT-S5301 using PW Forums mobile app
    A real driver knows exactly what's in his car.

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    Quote Originally Posted by akash190 View Post
    I got mine overhauled back there and oil leaking problem still there got it fixed 3 times from different mechanics still of no use so driving it as it is+ am using valvoline oil, it used to decrease oil whenever i use delo gold but on valvoline i can see little drops but doesnt decrease like it use to on delo

    Sent from my GT-S5301 using PW Forums mobile app
    Leaking ? I am talking about oil consumption sir.

    Btw how's the performance on valvoline in terms of fuel efficiency and engine performance? And what's drain interval of valvoline?

    Sent from my VS985 4G using Tapatalk

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    Quote Originally Posted by Salman922 View Post
    Back with new set of problems linked with old issues as well !

    -glow plugs were replaced in 2015 January because original ones were talking little longer then usual to fully heat up, now from the day i got new gear installed cold start problem persists.

    After removing all the glow plugs and checking them individually it was found that all of the 4 were burnt and not working so I got the old OEM ones installed which were bit weak still worked. They started to take nearly 4 glow timers to start a dead cold engine that too on many rotations however when they were taken out they used to start the engine in 1 glow timer and 4,5 rotations that too in winters.

    -last week I got another set of glow plugs installed hoping that cold start issue will be resolved but the glow plugs were again burnt just as I turned the key to switch 'on' where i wait for glow timer. And as i cranked the engine battery acted as it was almost dead and than again came to life after the new glow plugs burnt.

    -point I am trying to link is that my car is not accepting any other glow plugs except for OEM part and it burns it right away.

    -on OEM plugs too it takes 4 glow timers, why ?

    -anyways I bought brand new 4 OEM glow plugs just the same as original ones in shape but the ones came out were 11v and the ones I got now have written 12V on it. Now these have not burnt and still working but are unable to start the cold engine but a slight push will start it always.

    -one more thing is that my engine is reducing oil, like 1L in 700kms approx, I want to get its valve seals changed but no one is ready to do according to Zulfiqar bhai's way so still searching for the one who agrees on it.

    -w.r.t. oil reduction: engine produces light tik tik tik kind of sound when low on oil which increases/decreases along with the rpm and when it's topped up with oil the tik tik sound vanishes.

    P.S. my car's CSD is working, rad has coolant, fans auto, valve clearances checked, battery is AGS gr85 installed 18-20months back, pump done by Cummins pk. Engine runs great and fuel avg is also nice, hot start is perfect.

    Now what am I missing which is making this cold start issue ?

    Mechanics r saying "hum apko pichay 6,7 saal se keh rahay hain k engine kamzor hai lekin ap mantay hi nahi, ab pura beth gaya hai apka engine aur overhaul hoga"

    I don't agree with them and wont be going for overhaul unless I get it compression tested and the person who has agreed to test it's compression for me is out of Karachi and will return after a week or so.
    @Xulfiqar bhai and other experts kindly help.

    Sent from my VS985 4G using Tapatalk
    May be you burnt your glow plugs due to long heating intervals...do you have a manual glow plug timer installed or the one which comes with car and automatically adjusts time delay according to temp..
    I'll advice you to use double element glow plugs(if I'm not wrong about name)..these works great even with manual timers..
    I'm using these with my mazda and Nissan engines

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    Quote Originally Posted by Salman922 View Post
    Leaking ? I am talking about oil consumption sir.

    Btw how's the performance on valvoline in terms of fuel efficiency and engine performance? And what's drain interval of valvoline?

    Sent from my VS985 4G using Tapatalk
    Sorry my bad and about valvoline i get 16+ in local with ac, sounds better last time i changed at 4500 but this time ill take it to 5k and am using everything genuine

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    Quote Originally Posted by YamahaYB100 View Post
    May be you burnt your glow plugs due to long heating intervals...do you have a manual glow plug timer installed or the one which comes with car and automatically adjusts time delay according to temp..
    I'll advice you to use double element glow plugs(if I'm not wrong about name)..these works great even with manual timers..
    I'm using these with my mazda and Nissan engines
    Glow timer is original.
    And only different spec Glow plugs burnt, original ones r working fine.

    Sent from my VS985 4G using Tapatalk

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    Quote Originally Posted by akash190 View Post
    Sorry my bad and about valvoline i get 16+ in local with ac, sounds better last time i changed at 4500 but this time ill take it to 5k and am using everything genuine

    Sent from my GT-S5301 using PW Forums mobile app
    That's nice. I may try valvoline on my next oil change.

    Sent from my VS985 4G using Tapatalk

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    Update: from last couple of days I am noticing that car is taking long self to start on hot engine as well but it does start.

    In hot engine first n second rotations r very slow like the battery is down and suddenly it speeds up n starts the engine in 7,8 rotations.

    Does it seem to be battery issue? I am thinking to install AGS GR100 this time to support the starting, currently having GR85.

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    Quote Originally Posted by Salman922 View Post
    Update: from last couple of days I am noticing that car is taking long self to start on hot engine as well but it does start.

    In hot engine first n second rotations r very slow like the battery is down and suddenly it speeds up n starts the engine in 7,8 rotations.

    Does it seem to be battery issue? I am thinking to install AGS GR100 this time to support the starting, currently having GR85.

    Sent from my VS985 4G using Tapatalk
    How much is old ur.current battery?

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    Quote Originally Posted by Salman922 View Post
    That's nice. I may try valvoline on my next oil change.

    Sent from my VS985 4G using Tapatalk
    Its very good oil far better than local, whats ur sources to get as itsnt easy available?

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    Quote Originally Posted by akash190 View Post
    How much is old ur.current battery?

    Sent from my GT-S5301 using PW Forums mobile app
    About 20 months old. AGS batteries have worked good for me upto 4 years in the same car.

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    Quote Originally Posted by akash190 View Post
    Its very good oil far better than local, whats ur sources to get as itsnt easy available?

    Sent from my GT-S5301 using PW Forums mobile app
    I'll check with Al Hamd autos mukka chowk, it's probably available with them.

    Sent from my VS985 4G using Tapatalk

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    Quote Originally Posted by Salman922 View Post
    I'll check with Al Hamd autos mukka chowk, it's probably available with them.

    Sent from my VS985 4G using Tapatalk
    I order online at jambos.pk and they deliver at my door step it costs me about 2100 with free delivery

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    Quote Originally Posted by Salman922 View Post
    About 20 months old. AGS batteries have worked good for me upto 4 years in the same car.

    Sent from my VS985 4G using Tapatalk
    Mine was doing same that slow speed sulf changed battery problem solved

    Sent from my GT-S5301 using PW Forums mobile app
    A real driver knows exactly what's in his car.

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    Quote Originally Posted by akash190 View Post
    I order online at jambos.pk and they deliver at my door step it costs me about 2100 with free delivery

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    That's great, can u please mention the exact details of valvoline oil like grade, viscosity, etc ?

    And how much time do they take to deliver ?

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    Quote Originally Posted by akash190 View Post
    Mine was doing same that slow speed sulf changed battery problem solved

    Sent from my GT-S5301 using PW Forums mobile app
    I will try jump starting it with another car in hot n cold both, just to know if battery is the real culprit.

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