Overhauling My Corolla (My Mate Since'82)

[c123pk]

Hope the car is on the road again, by the year 2010

@Spitfire brother , dont take this to your heart, am just kidding brother remember one thing always "slow and Steady Wins the Race"

[spitfire]

@APACHE...
more pics on their way....dont worry at the end of this thread ,you will feel that this engine was overhauled in front of you...INSHALLAH

[spitfire]

@tauseef...
I explain....
you are right that some engines have cam shaft in the head and not in the block...the setup with the camshaft in the head is called OHC(over head cam).some sports and GT engines have two Camshafts in the head this setup is called DOHC (double overhead cam).In the above stated two setups,Cam/Cams shaft is driven by crankshaft through a timing belt or timing chain.And cam shaft/shafts operate valves directly as one end of rockers (levers which operate valves)is resting directly on the Cam lobes...and like this two or four valves per cylender are operated directly by 1 or 2 Camshafts....
In this particular(4k)engine,as it is an old engine,a different setup of valve operation is used.Cam shaft is fitted in the engine block receiving drive via timing Chain.The motion of cam lobes is transmitted to the valves via cam followers which are also fitted in the block,and then push rods....These push rods are connected to one end of rockers and in this way operationg valves......In this set up,motion of cam lobes is transmitted to the valves through Cam follower and push rods,But in over head cam set up,Camshaft directly operate valves......
I hope I explained well...
you will see all this set up in coming pics of this overhaul..

[spitfire]

@c123pk....
lolzzz...Actually I have established an image of being slow in restorations as spitfire is still not complete after quite a long time...but as you said that slow and steady wins the race,is true.One thing more that if you go in details of any work ,it takes more time than expected.Its again a matter of habit/choice.The persons like me (perfectionist)create many undue problems for them,but we cant help ourselves due to this nature.
Some times going in avoidable details,causes extra stress and makes you tired/turned off.....but cant go against ones nature,what to do dear???
But this car is on the road for last 2/3 months and is driven 4000+ Kms after this overhaul..Actually I could not find time to complete this thread.So doing it right now....

[spitfire]

Salamz Pakwheel brothers,
next thing which we did was connecting pistons with connecting rods.In other words pushing piston pins(gudeon pins) in the pistons.
Its a very close fit.normally mechanics hammer them in place and then locks are installed but that is the wrong method (sorry in advance from mechanics).As I have two owner's/workshop manuals for this particular car...Haynes and chiltons....
The proper method to push gudeon pins into the pistons is to heat pistons in boiling water.........sounds strange??????but that is the proper method.As pistons are made of alloys of aluminium and some other so they expand by boiling them in water and gudeon pins are pushed into hot pistons by hand pressure......yes just by hand pressure.....so went to kitchen and cooked the pistons.....:)..see

[spitfire]

So heated the pistons in boiling water and after that pushed the gudeon pins in place connecting pistons and connecting rods..
one thing is very important that when we dismanlte the engine,connecting rods are marked as 1,2,3,4...and they should go back to their original place..failing to do this results in disturbing the dynamic balance of the engine...
one thing more..that when cylender bores are polished according to the pistons......pistons are also marked as to which bore was polished for that particular piston...and they should also go in their respective bores.....ENGINE LIFE DEPENDS A LOT ON ALL THIS...

[spitfire]

And final results....pistons complete with connecting rods and rings...ready to go in place...

[SER_GTR]

Damn...Thats So Cool And Drooling Stuff......!!
This All Happens Before That CNG Problem You Have Earlier Or After That????
Damn...This Looks So Clean..Hard Worked And So Many Efforts In This Overhaul I Can See....
Thats How I Also Like To Work (y)
I Must Say TOYOTA K Series Motors...One Hell Thing Made..!
We Also Own KP61 Starlet 82 From 86 Till 2007 And We Know How Good These Engines Are

(y)(y) For You...!!

[lotus]

afterall its a TOYOTA....... i know a lot of people who have kept their toyotas over more than 2 decades....... any such honda around???

[KamranAslam]

@spitfire: salam to the patience of our Bhabhi jee. Cooking pistons lol.

Though the idea makes sense

[c123pk]

Cooking the Pistons part is way better then hammering those pins, you are a Perfectionist dear Sir, I pray everything goes fine with your projects

[Mr1derful]

@spitfire
oh my god u r so genius!

y dnt u open a workshop for the ppl of lahore it wud b gud for us.
i m serious

[Thunderbolt]

Hi! there Really great to go through the whole experience of overhauling through the eyes of an expert hatsoff to u Mr.Spitfire. I also own a corolla and the very first model of corolla with a 82' corolla engine fitted in it. 4K-Twin Squish full TTC. I totally agree with u it's a work horse, after fitting it in my car I have ran it for about 110000 Kms. without any trouble only tuneups and some other little stuff. But in any case I really like this engine and corolla overall. I also agree with the Oil filter and oil change routine which u mentioned. I do the same with every oil change, oil filter is also replaced with a genuine one after every 3500kms and same case with Air filter no mileage restriction with as and when it gets dirty replace it. Since it has electronic ignition so worries of CB points or condensor. So in a way satisfying experience wih it. I have been following ur other project had no idea about this one just got to know about this today. So eagerly waiting for ur other project to complete soon.

[spitfire]

@SER_GTR...
First of thanks for appreciation.I am obliged that you liked what we did.I am a silent observer/admirer of your 86 sprinter project.The ECU wiring which you did is amazing/very clean and requires some serious knowledge.I remeber you said that I dont want to be a nitto tape electrician and used a special heat shrunk sleeves..which I have not seen any where and could not find any where..:).
I overhauled this engine before that CNG EVENT..Now you can imagine that after such work,if some one abuses your engine,how you feel???
You are absolutely right that these K series engines are REAL work horses and do not need any maintainence as I used it for about 26 years and 2,50,000 kms and when opened,believe me only rings replacement was enough and engine was good for another 50000+ kms..But I thought that after 26 years of service,This motor deserved this treat...:)Starlets are nice machines too,I am sure that from 76 to 80,3K motors were used in starlets but not sure that which was the last model having K series motor.
One request....
I have asked few electricians about those heat shrunk sleeves you used in sprinter project but no one knows about them..Can you please tell me from where I can get hold of them as I am planning to wire Spitfire in near future...
Thanks in advance..

[spitfire]

@lotus....
You are right that its a TOYOTA...and specially Made in japan...:)rear wheel drive...This car is with me for 26 years now as I bought it in 82..my all time favourite machine.still runs like new...

[spectra]

K series engine was used till 1998 in liteace. It was a 7k and had new toyota emblem on valve cover. A successful workhorse no doubt. How is the car going now?

[spitfire]

@KamranAslam....
lolzz...actually I am a car buff since my child hood..Never liked muscle cars but always had a liking for older/classic ones..
As I am married for last 16 years now so my wife is very useto with all my bad and good habits....lolz.and there is nothing she can do about it..j/k..
she is very supportive and is always willing to become an active participant according to her capacities....:)in all my projects.
By heating,piatons expand and only finger pressure is enough to fit gudeon pins in place....

[spitfire]

@spectra..
Salamz Saqib Bhai,
Never knew that liteace also used K series engines..you are right that there is no doubt about their durability and long life...Car is running fine and its driven 4000+ kms now..very nice feel.running on petrol as I removed CNG after that bad experience...
How is your 74 running??how much kms done since it was restored???

[2c]

@spitfire
wow
this is your mate since i wasnt born

[spitfire]

@c123pk.....
First of all I am obliged for the wishes and thankful for the appreciation...
Actually these small tips make a big difference on the age of engine afterwards.
as you know that pistons are made from some alloys and are quite delicate but last lifetimes....Same is the case with Main and big end bearings(pieces).The only thing that works is a very thin layer of white metal coating inside those pieces(where crankshaft and connecting rods move).this white metal is so delicate that you can easily scracth them with your finger nail,but it holds the heavy crankshaft rotating inbetween for years and years....Actually its the oil which is there between very hard crankshaft and delicate bearings due to a very very little clearence for oil to be there...if that clearence is not there or less...you are looking forward towards premature wear and very short engine life...
So like this during rebuilding engines,very small things make very big differences...