This is a clutch disk of Toyota L engine. It is not noticeable that this has already a defect upon driving but since the engine was overhauled and is obviously thin it should be replaced to minimize time and work.
1. Components of the Clutch Disk
the cover plate
the friction surface
2.Functions of the Clutch Disk
The clutch disk transmits power from the engine to the transmission through the hub wherein the gearbox shaft is inserted.
The producer company may have made a mistake in packaging the materials for Toyota L series which may have identical gaskets but not exactly the same, or its really the one but they made a mistake in the measurement and so produced a not fitted one.
I am referring to the head cover gasket referred to as valve gasket for Toyota L upon knowing that the mechanic had a difficulty in placing the gasket during the assembly of the engine. Because it is in the package so he believes it must be the right one that fits.
Until after a week of test drive that I noticed when we opened it for timing adjustment and to check the valve gaps. It was really stretched and it shows that it is not a normal fitting.
Because the alignment of the gasket is somewhat tilted I have to find for something that is better. Because there was no available head cover gasket for Toyota L I bought the one for Toyota 2L head cover gasket and it fits. The video below will prove the anomaly about the case.
The video above shows the fact that not all in the package of Toyota L overhauling gasket are fitted. Even if you reverse the placement it’s really too far to fit.
This video shows the exact gasket that is bought from Toyota 2L head cover gasket.
I wonder why the company causes confusion to Toyota L series users and customers by having different series with the same parts. The engine is Toyota L and you have to look for Toyota L parts and accessories. It is not bad if you can find parts exactly the same in Toyota 2L but when you are given a package with any of the parts unfit that makes it considerably defective and the producer company has to replace it for free.
Reminder and Warning
Be sure to inspect all overhauling gasket package before you use it one by one. The only way to assure that you have all the gaskets fit is to take with you to the auto supply center all the samples to be replaced.
This is to avoid extra ordinary expenses in buying another part you needed just because some of what is in the package is unfit.
It is also saving time and effort in doing repairs to your car or vehicle.
It’s enlightening to know how to do it if you have enough guide to follow. It will not waste your time and you can avoid mistakes and control or lessen expenses.
In the engine valves installation, there are hints that let you realize that every valve is not to be inserted in any valve guide.
On the Toyota L engine, valves are arranged from 0 to 3 marks. It is found on the flat surface of the valves. If you cannot find it there examine the whole valve to be sure that nothing will be interchanged rather they are in the proper places.
The arrangement should start from cylinder one which is the nearest to the front of the engine. If that is the case cylinder one receives exhaust and intake valves with no marks and the other cylinders receive the valves with their own marks from 1 to 3 respectively.
The standard for most of the cars is to change oil every 5,000 kilometers or three months, whichever comes first or as often as possible depending on your driving habits and the road conditions.
Have it drained only just after a hard drive, at least 15 kilometers. When the oil is hot and thin, sludge will not settle and harden at the bottom of the oil pan. Or if you leave the car at a service station for a change later in the day, the cold sludge won’t flow out.
The piston, piston rings, oil rings, and connecting rods are parts that should be installed and connected to each other before it will be inserted into the block.
In installing or assembling these parts be sure to wet it with oil. The purpose is that on the first crank of the engine the engine oil is not yet distributed to the engine parts. At least before the oil reaches all the moving parts there is lubrication provided so it will not immediately get hot.
Here are the parts:
The piston rings and oil ring
The piston pins
The connecting rod
Tools to use in assembling the parts
There is only two that you needed. It is the snap ring pliers that you use in placing the rings and the piston ring installer pliers.
Watch the video on how all the parts are placed.
It is such important to be careful enough in placing all the parts. Remember the piston has marks and that is according to arrangements when inserted in the cylinders. Observe the dots on the images below.
Piston 1 with no mark
Piston 2 with one dot
Piston 3 with two dots
Piston 4 with 3 dots
Not only the piston has marks, but the connecting rod also has. If you are keen on observing the marks such as dots you will never be mistaken to pair the right piston with the right connecting rod. And of course, you will not also be mistaken in the insertion of right pistons on the right cylinders of the block.
Cylinder 1 must be the nearest in the front of the engine. It is the nearest to the camshaft timing gear and cylinder 4 must be the nearest to the transmission.
With that hints to bear in mind, you won’t waste time disassembling the engine when you come to your senses that you have not been conscious enough to observe marks provided by the manufacturers as the guide in assembling after doing an overhaul.
If you have followed the guide you will save time and possibly save resources to be incurred through errors.
You can find additional helpful information on this website page.
Thank you again and I hope I have helped you in some way. If you have any question, comments, and observations please feel free to leave it in the comment box and I’ll be willing to get back and answer you as soon as I read your message.
This fuel shutoff valve is a part of the injection pump that functions as the shutoff of fuel and engine. It is operated by a current from the battery through the ignition switch.
When the ignition switch is on and current goes to this shutter it opens and fuel will flow to the injection pump that supplies the nozzles spraying fuel to the combustion chambers. When the ignition switch is off this valve will close and no fuel will flow to the injection pump.
How do you know this?
I would like to share with you our experience in the Toyota L engine. We have just overhauled it, the radiator was overhauled too, and the injection pump calibrated. Everything should have been fine as expected. The engine was cranked and it started smoothly, the engine noise is just right, the thick white smoke is gone and is about to be on a road test.
But as the engine is warmed up it suddenly stalled, no matter how you crank it in order to start it didn’t. Because it’s newly overhauled maybe the fuel has not yet fully saturated the injection pump and air maybe inside. The remedy is to loosen the nozzles so that air may be blown out.
This process if the air had been totally out from the injection pump fuel should follow to come out of the nozzles. If there are no bubbles coming out it’s time to tighten it. Loosening the nozzles to test if there is fuel in it should be done one after the other.
However, this time there was no air coming out and there was no fuel too. So how would the engine start if there is no fuel supplied by the nozzles? It will not. It’s good the fuel hose is transparent and obviously, the fuel is still sufficiently available from the tank.
The next step is to check if there is a current going to the fuel shutoff valve. So we checked it and there was no current. Upon examination, it was the wiring connected to the shutoff valve that has been cut off inside, however, it was not obvious until we stretched it out and it was only connected temporarily through the insulation of the wiring.
When the connection was restored the engine was cranked and it started until it was tested on the road and until this time of writing the engine did not stall.
Too weak, and overheating after it has been overhauled. It ‘s unbelievable. When your engine is pretty working when it was not yet overhauled you will wonder why and you may blame the mechanic for such condition. It should work efficiently because it was newly overhauled.
This newly overhauled Toyota L Engine displayed a weak power when it was road tested. Whatever you do with the timing either you advance it or retard it, it does not make any change in the power. The engine nearly cannot pull its body on an elevated road.
The technician believes everything is in its proper place and the issue has nothing to do with the overhauling. He rather recommended that the injection pump is calibrated.
What is Calibration?
Calibration includes replacement of O-rings, oil seals, cleaning and testing with a machine if the injection pump functions accurately or not.
This is an additional expense for it is not easy when you don’t have the budget. The cost is two thousand seven hundred pesos (P2,700.00).
The injection pump was brought to the Calibration Center, disassembled and cleaned.
And then assembled and put to the test machine. Now, we don’t know what would have been the defect of the injection pump since it was disassembled without the test first. If it would have been tested before it was disassembled maybe we have known if it is clogged or any of the adjusting screws have been meddled in by a mechanic in the previous years.
The purpose of the calibration now is all specks of dirt which have been sucked from the fuel are to be removed and to return the function of all parts in the normal way.
All tests have been done and the injection pump was hopefully in good condition. Back to the engine and the pump was attached. After everything had been placed, the engine was started.
Noticeably, the engine is now quieter, less smoke and the engine’s power was restored. It was a grueling task but it’s worthy to have been done. No issue on the overhauling but it’s outside the engine, it’s the fuel injection pump.
It was a shocking experience about overheating engine when it was not really overheating before it was overhauled. It was a sudden additional situation which we addressed after trying to solve the issue of weak power. The story is this:
We overhauled the engine because it came to a stage that it emits thick white smoke and it does not have the power. Other than that is because oil and water are mixing in the radiator. But in addressing that issue another problem came up when we test drive, it was overheating reaching 180 degrees Fahrenheit (°F). That is already near to the boiling point of water which is 212. That 180 degrees Fahrenheit (°F) should be the temperature when fully loaded and you climb uphills and the temperature of the day is really hot.
When the temperature reaches that point all moving parts inside the engine starting from the piston will stop to move because they are stuck due to the heat. Meaning, the oil and the water or coolant are no longer capable of providing the proper lubrication for the engine to work smoothly.
The Radiator Overhaul
In our, analysis there would be no other source of the overheating problem other than the cooling system. The oil is working properly as seen in the oil gauge so it must be the radiator.
I had to bring this to the shop for overhauling.
The usual overhauling of a radiator is detaching the top cover to clean the core tubes by rubbing the core tubes with a thin deep stick. However, if there is clogging that cannot be pricked they will just leave that clogged.
So what we did is to remove both the top and bottom covers. Here is the picture below.
So we found out that there were several core tubes clogged. Aside from that, there was a perforation where the water leaks. We did the cleaning and fixing. But as you see after it has been assembled there are perforations on some of the core tubes so it has to be soldered.
The overhauling has been over the usual fixing that is only the top cover. This time both the top and the bottom covers were removed and the clogged core tubes were cleaned thoroughly which is much better than the prior condition.
We have fixed it by maybe four times testing it with water if there no leaks. After proving that it’s already free from any defects I took it to the vehicle and attached it to its proper place.
We test drive it and the issue of overheating has already been solved. Thanks for a job well done by the repairman for both the engine and the radiator.
See you again on the next posts. If you have any questions, suggestions or opinions that you think it can be incorporated here just use the comment box and we will consider all of them. We will get back to you as soon as we read your messages.
We have overhauled a Toyota L engine just this week and came to a puzzling issue on why it lost its power and is overheating.
Prior to overhauling the engine had overheated due to the radiator hose bursting. It was immediately addressed during that day and everything was fixed and we used the car onto the occasion we went through.
However, after going back home the owner noticed that the coolant was being mixed with oil. The oil cooler gasket was replaced and to make sure everything was fine the cylinder head gasket was also replaced. Those steps did not solve the issue, the more the car emits thick white smoke.
This time the owner decided to let the engine overhauled.
The car was brought to the mechanic and the engine disassembled. Noticeably, the four cylinders were having the same uneven and marked sides.
The mechanic recommended that the cylinders be replaced with a standard size or oversize it with a 0.50mm.
The owner happened to decide on the 0.50 sleeves be oversized. He brought the block to the Machine Shop for oversizing and went ahead and bought all the 0.50 piston, piston rings.
After one day he went back to the Machine Shop because he was called to decide on what will they do. On the image below they have shown the owner that the sleeve has a crack around near the top and they don’t recommend it for oversizing rather it should be replaced with a standard.
Since he bought all the oversize piston and piston rings through an order, it cannot be returned and the only remedy is to buy a standard sleeve then oversize it. It was an unexpected additional expense, however, the parts have to be utilized and no other choice.
The four standard sleeves were rebored and honed
After these sleeves were rebored and honed the engine is ready to be assembled. With new overhauling gasket, it includes the cylinder head gasket, the oil cooler gasket, new crankshaft oil seal, new camshaft oil seal, new cylinder head cover gasket, new crankcase cover gasket and others. New sets of 0.50 sleeves, 0.50 piston, and piston rings.
The engine assembled with a new look, freshly cleaned inside and outside.
The engine attached to the body and the new engine life is first started successfully. The sound is fine enough and you are contented with what you have done. The noise is just fine and it needs breaking-in for hours before it is normally used again for services anywhere.
After one day we tested it on the road and upon climbing up the hill there was no power even to the first gear. It could just move on a plane lane and when you forced it to an elevated road it overheats and stalls.
The coolants are obviously circulating both oil and water that clearly puts impression that the coolant pump is working fine.
This is the first time I experienced a newly overhauled engine with no power. It’s a puzzle I and the mechanic have to discover.
I wish my readers could help in the solution of the issue at hand. Please kindly post your comments down below the comment box.
What do you think is the reason behind why this engine has no power instead of a renewed strength and life? What steps and solutions should be done to restore this engine to its power?
The image below is called a cylinder liner or a cylinder sleeve. This auto part is inserted into the engine block. In other engines, there are no cylinder liner or cylinder sleeve, they only have cylinders directly part of the block.
The cylinder liner is where the piston goes up and down for intake and exhaust system. This is directly lubricated by the engine oil. In order for the oil not to be mixed with the fuel, a piston ring is needed to seal the space between the piston and cylinder liner or cylinder sleeve for better compression and avoid overheating in the engine.
When the piston ring or the cylinder liner is perforated oil will be pushed up into the fuel chamber and it will be mixed making a bluish smoke emitted by the engine.
In many cases, if signs are obvious there is a need for the piston rings to be replaced for proper engine oil sealing.
However, if the cylinder liner has already scratches which the piston rings cannot seal, the cylinder liner has to be replaced, it can be oversized from the standard measurement to 0.25mm or to 0.50mm.
If cylinder or cylinder liner is necessary for oversizing piston and piston rings should also be replaced with 0.25mm to 0.50mm.
However, others opt not to replace the piston but only the piston rings for practicality reason. If your car is not for racing they don’t advice you to replace the piston but only the piston rings.
Oversizing the cylinder liner, piston and piston rings has started with the myth of having a larger size other than the normal one is stronger and faster you can take advantage of.
So make a choice if you are the owner of the car. If you are in a race and you believe on the myth of oversized cylinder liner then you do. Because this will surely be the advice of the persons who work in the Machine Shops.
However, if you use your car for family services and necessities you may just have the piston rings to be replaced with an oversized one.
The Issue on this Cylinder Sleeve
As you can see from the above image of the cylinder which is about to be oversized, there is a lining around near to the top. You don’t see a crack but a color pencil like. The serviceman decided not to continue oversizing it until the owner decides for it.
The oversizing is to 0.50mm because of deep scratches made by an unknown cause. For sure even you replace the piston ring it cannot seal the engine oil to go up and be mixed with the fuel.
The mark is far above where the piston ring can reach. It’s a part of the combustion chamber.