Overhauling My Corolla (My Mate Since'82)

[spitfire]

@Mr1derful...
Thank you dear...Cant open workshop.....as it is only my hobby and belong to an agricultural back ground for bread and butter....
I will be happy to help all the pakwheel brothers according to my very little knowledge about wheels...any time.

[spitfire]

@Thunderbolt..
Thanks dear for your appreciation...Its nice to know that you own an old corolla and still sticking with it (like me)as most people dont like to keep old models and always looking forward towards newer ones.But I tell you that this 82 corolla is still my favourite car and I still love/enjoy to drive it and it gives such smooth and reliable ride that very few new cars offer.Our new corolla have inbuilt brake fault and other stability broblems....front cv joints go if dust boot is damaged and replacement is expensive..But these old cars (rear wheel drive)have no such problems and are real work horses.Having electronic ignition is very good in 4k engine and I am also thinking to go for it.Oil and filters play a great role in engine life..But I am not able to find genuine oil/air filter for 4k any more...next best is VIC oil and GUARD air filter which are being used as there is no other option...
I maintained the whole record for about 20 years for all the oil/filter changes,plugs,points,condenser,fuel filters,tyres and what ever I did in this 82 corolla as per maintainence..your 4k is going to last another 100000 kms INSHALLAH,as you are taking good care of it..

[spitfire]

@2c...
lolz.....yes,I own this car for 26 years...two years before you were born..

[spitfire]

Salamz Pakwheel Brothers,
next step was to push pistons in place (in their respective bores).This is again a very important step and needs a lot of care n patience...
The first thing to observe is the position of rings gaps which is very important in compression afterwards.....
There are specific positions for all rings gaps according to the workshop/owners manual,like first(top) comp ring gap at specific
angle with respect to gudeon pin of the piston,second one at 180 degree then upper oil ring rail again at an angle and lower one at 180 degree away and oil ring gap in between......piston being inserted..

[spitfire]

I divided and measured the exact positions of all piston rings and made drawing/markings of piston rings gap positions on the piston head (top of the piston),which you can see in the following pic on piston number 1.
There is a device which is used to compress rings into their grooves so the piston may move into the bore smoothly and without damaging /breaking the rings which are at tension outwards...This device is called "RING COMPRESSOR" you can see in the following pic.
when you tighten it around the piston,it pushes rings into their grooves and make it easy to push piston into the bore using some wooden dammer....
GREAT CARE is required when using this device no to disturb ring gaps positions which was done before applying ring compressor on the piston...
see the following pic....notice the lines I made on the head of piston for rings gaps...

[spitfire]

Another view of block..piston being pushed into bore using ring compressor....notice the lines/markings of positions of ring gaps.....

[spitfire]

Now the down side story......
as the piston is being pushed down......GREAT CARE is required because bolts of big end of connecting rods have to go on both sides of crankshaft journals,And it is IMPORTANT that they should not touch/scratch the crankshaft journal otherwise that scratch will rub against the delicate white metal of the big end bearing and bearing will fail/less life...
So two people are required for this step,one pushing the piston downwards and other holding connecting rod in alignment and preventing the bolts to touch journals of crank...
Other method is to put rubber/soft plastic pipe on the bolts which are removed after connecting rod is in place.....see..

[spitfire]

Another view ...you can see two caps on the sides at place and one connecting rod being pushed....after all at place caps are replaced and tighten to specific torque....
IMPORTANT...all caps should go to their respective connecting rods (marked before removal)..

[spitfire]

@all pakwheel brothers...
I am trying to explain each and every step in detail so you brothers may get full benefit out of this overhaul....
The only perpose is to tell/educate you according to my little knowledge about the subject.
I know that all brothers are not able to do it them selves but can get it done in a better way if have complete knowledge about it and no mechanic will be able to bluff/trick you....and your engine will last longer giving good performance...

[ansarghani]

good good.... very interesting...

[lotus]

excellent stuff spitfire

[SER_GTR]

@spitfire
Sir Thanks For All Your Kindless..I Really Like Clean Work And I Also Tries To Do....!!
About Heat Shrink...SO I Find It Here In Karachi In Saddar(Co-operative Market).........!!!
Shop Named Patel Electronics I Get From.......!!
No Idea About Lahore But Thats Item Where All Wiring And Electrical Items are Founded

[spitfire]

@ansarghani.....
Thanks dear.

@lotus.....
thanks dear for appreciation.

[spitfire]

@SER_GTR...
Thanks dear,I will go to montgomery road (main market for car stuff) and will try to find sleeves...

[SER_GTR]

If In Case U Won't Find....!
Then Tell Me The Size...I Will Try To Get It For You.....!!
Put Its Item Which Can Be Founded I Think....!

[spitfire]

@SER_GTR..
So nice of you dear.I am really thankful for your offer,But I think I should find them here too,Actually I have not explored in detail yet and I think will find from city....
once again Thanks a lot..
Regards.

[spitfire]

The next item to go back to its place was Camshaft thrust plate which controls the lateral movement of the Camshaft.....see.

[spitfire]

Another closer look....

[SER_GTR]

Ur Welcome

[bluntknife]

@Spitfire
Sir yours threads have been one of the best things that happened to pakwheels off late and highly eductaional for someone who is an illterate at automotive mechanics(thats me).