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Thread: Overhauling My Corolla (My Mate Since'82)

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    Default Overhauling My Corolla (My Mate Since'82)

    salamz brothers,

    I own a corolla 1982 which I bought brand new in the same year.Now this car is with me for last 25 years and I have driven it about 2.50.000 km without any problems.(never touched engine except tune ups)..still runs very good.But after this much kms now it started burning oil so I decided to overhaul the engine AT HOME.as I have almost every possible tool at home for my rides.

    I have taken the engine out and dismantled it and now going to reassamble...I can take pics and post STEP BY STEP procedure that how an engine is overhauled.....

    (1)PLZ SUGGEST ME THAT WILL THIS THREAD BE OF SOME INFORMATIVE VALUE????

    (2)SHOULD I START IT OR NOT????

    waiting for your suggestions brothers.....................

  2. #121
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    could have got a new engine and swaped in. overhaul cost too much. rear wheel 20v bhee mil jata hay.

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    @simply11..thanks dear...
    @topracer....you are absolutely right that overhauling an engine is expensive and headache and a replacement can go into the place...But actually this corolla 82 is with me for last 25 years and is all original/genuine.not even a screw replaced with non genuine.The only point to keep this vehicle is its originality nothing else.....thats why I took so much pain in overhauling its engine.I have also got it painted and will receive it tomorrow from the paint shop and will post its pics...after looking at the pics,suggest that should I go for some alterations in this car....

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    The first thing to go into its place is the crankshaft.As I have told you before that it was as good as new and could be used as such with the standard bearing pieces even after 250000 KM and 25 years of constant use but I preferred that It should be ground to the next smallest value and that is 0.25.so it was ground down to 0.25 and 0.25 sized(thicker)bearing pieces were used.After receiving from machine shop,it was full of small metal particle.First of all it was washed with kerosine oil and then with high pressure water followed by high pressure air.After throughly drying,was coated lightly with engine oil and it started looking like this...
    Overhauling My Corolla My Mate Since82 -768352

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    yaar spit fire bhai.... do you have the manual for this machine... i seriously want it... ill be very grateful to you....
    thnx..
    -

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    @chichi_wala_baby...yes dear I have owners/workshop manual for this car..there are many parts like engine,transmission.suspenssion,steering etc etc....In which topic you are interested in??I can always send you photo copy of the required section and it will be my pleasure.....please mail me...

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    another view of the crankshaft ready for assembling.the juornals on the shaft is drilled by crossholes its like every journal(the shining parts it rotates around)is connected with the other through these crossholes for the circulation of oil.you can see these holes in the following pic..see.
    Overhauling My Corolla My Mate Since82 -770868

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    nice work going on,, wish you were putting that much effort in a 4ag engine.
    ,,, unless you know the track, you're not good enough to sit behind the wheel." K T

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    before going any further I would like to mention the "THRUST WASHERS".as you know that crankshafts are rotated at very high speeds aroung their main bearings.The rotational motion is controlled by main bearings and lateral(forward and backward) motion is controlled by thrust washers.These washers are in four pieces like two washers cut into four pieces.In this particular engine which has five main bearings,these washers are fitted towards the outer sides of the middle bearing.The sides of these washers which are facing towards the crankshaft are coated with the same white metal which is present on the main and big end bearing pieces.When we push clutch,we are basically pushing crankshaft forward via clutch thrust bearing and pressure plate fingers.All this push is taken by these thrust washers....I hope I have made it clear.the location and shape of these Thrust Washers are like this ...see

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    Overhauling My Corolla My Mate Since82 -770913

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    @levin..Next time INSHALLAH....lol

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    Another view of the half thrust washer fitted in the block.the other half is fitted in the cap.this arrangement is on the both sides of this middle main bearing...see.
    Overhauling My Corolla My Mate Since82 -770914

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    And now its time to fit the crankshaft in the engine block.As you have seen in the previous pic,all the bearing pieces were well lubricated with engine oil and crankshaft was lowered with great care....something like this...see.

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    Overhauling My Corolla My Mate Since82 -770969

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    Salamz Pakwheel brothers,
    This is an old/dormant and incomplete thread,which I could not continue due to lack of time because of spitfire thread and other commitments in life leaving a limited time to be on line......
    Today I came across the CD in which I stored all the pics (100+) during the overhaul of KE 70 engine of my 82 corolla which I took to share with you brothers,but due to unavoidable circumstances and lack of time could not...
    spitfire is in the paint shop now waiting for the paint to be decided...
    Due to some bad health,(cough,flu,fever)etc,could not visit spitfire for quite some time and dont think that will be going to the paintshop for another 2/3 days.So I thought that I should continue this incomplete thread ,complete it and post the detailed pics which I took for some interesting/serious knowledge at every step of assembling the engine only for my Pakwheel brothers....
    So this thread is on its way to completion.....INSHALLAH

  16. #135
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    Walaikom Assalam n get well soon SPITFIRE
    we will b waiting for its completion
    -

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    @ehsan Zafar...
    Thanks dear...
    so we go ahead after a looooooonnng pause..
    I have told you about cylender boring,which I did +50 oversize because I wanted the original block material to be in contact with piston/rings.The other reason was that I could find +50 original piston and rings.....
    I have also told you about "thrust washers",their placement and function.(please refer to previous posts)..
    Also told you about crossholes in between journals of crankshaft for oil circulation and holes drilled in the block where main bearing pieces are installed...
    So,Block was cleaned in detail with water,compressed air,kerosine oil and then with petrol and then was lightly lubricated to avoid surface rust as it is cast iron..
    Pieces on the main bearings were placed aligning holes for oil circulation(previous pics).Thrust washers were placed (previous pic) and crankshaft was lowered with great care (previous pic)...

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    And the crankshaft was placed on the main bearings..
    Overhauling My Corolla My Mate Since82 -822542

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    The other halves of main bearing pieces were fixed in the caps...
    Overhauling My Corolla My Mate Since82 -822543

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    Another pic of main bearings with pieces in engine block and in caps..
    Overhauling My Corolla My Mate Since82 -822544

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    Main bearing caps in place,except middle one which contains halves of thrust washers....
    Overhauling My Corolla My Mate Since82 -822599

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