1989 Toyota Corolla

[mark165]

I thought I'd put this up here as it sits nicely with a few other shonky Toyota threads.

 

There's something about an F reg that just draws me in... I'd just started a large building project last year and definitely didn't have time or cash to spare on it, but it popped up in ebay one evening and I saved it in the watch list. You know, just in case. It looked surprisingly clean from the pictures and on googling the plate this came up.

 

Expecting it to go for Covid project money I chucked in a low bid to amuse myself and let me move on, only to win it at £412. Wife not impressed, meaning I then had to balance with some garden furniture. And then pay to get it moved to Kent. So, not that cheap then.

 

Anyway, the guy I bought it off told me the usual story of 'track car', how he'd changed the engine for a starlet one then never got any further so swapped the old engine back in and sold up. I paid the money and then a car transport guy offered recovery cheap on a return leg. Then began a very long weeks wait.

 

To my relief it turned up and was clean, no rust and plenty of beige, with a whole load of parts in the boot. Annoyingly though the old engine was just bolted up to the box and doesn't look there's a release bearing there.

 

With the kids getting a bit older and a garage to now work in, I've just started this week. Plan is to remove the engine, do the belts, water pump, clearances, clutch etc and then just drive it.

 

 

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[Stanky]

Commendably beige 10/10

[Schaefft]

This should be a nice little project. Toyotas of that time are excellent cars and I cannot imagine that there's much on this gen Corolla you'd find hard to get online. Looks to be in pretty nice shape as well!

[mark165]

Few spare hours this afternoon, engine out time. Aldi ratchet straps playing hero once again.

My dad has offered me an engine stand to use, so I'll pick that up over the weekend and then start making a shopping list.

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[grogee]

On 9/29/2023 at 8:04 PM, mark165 said:

Few spare hours this afternoon, engine out time. Aldi ratchet straps playing hero once again.

My dad has offered me an engine stand to use, so I'll pick that up over the weekend and then start making a shopping list.

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Was there a release bearing? 

[mark165]

Release bearing yes... old clutch assembly AWOL.



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[mark165]

Well, after not being able to find any bolts long enough to attach the engine to the bloody stand, I ended up ordering some metric fine threaded bar, which is 2x the price and not at toolstation. But that arrived in the post Thursday enabling me to finally to get it off the hoist.

Then the old kitchen table was extracted from storage.

Now I've not done any internal engine stuff like this before, but YouTubers from Indonesia wearing flipflops seem to have the complete monopoly on Toyota 2E overhaul videos, so I've been watching them a lot. With a bit of pausing and many a 'skip ad', head is now off. The only sad thing is that someone has used water as the coolant so a bit of rust in there. But could be worse.

Overnight parts from Japan ordered (well, Autodoc and definitely not overnight but it's for a japanese car so close enough). Full gasket kit, timing belt kit and a few others. And I found a NOS clutch kit off ebay so ordered that too.



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[mark165]

This week has been spent cleaning up the surfaces on the head and the block surfaces. Pretty much every day, plus two trips to euro car parts for carb cleaner and gasket remover. And a trip to toolstation for a scraper.

The head cleaned up fine just with some discolouration. The block however.. can anyone advise here? Most of it seems to be fine, but there's some carbon? buildup around the top of the piston sleeves that won't budge. Am I over thinking this?

I also took apart the thermostat housing and water pump and then wish I hadn't as it was full of brown grot and the thermostat required 'precision' extraction.

Still, parts arrived and other than a water pump with no pulley, all good!

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[MorrisItalSLX]

I’d give the block mating service a DIY skim with a whet stone. Rub the stone up and down the mating surface in even long strokes until it is clean and smooth.

[mark165]

I’d give the block mating service a DIY skim with a whet stone. Rub the stone up and down the mating surface in even long strokes until it is clean and smooth.

I did this, plus some more scotchbrite rubbing, plus a dab of oven cleaner. Then I went to town and blew the whole thing out with compressed air. Several times. I also cut a groove in a head bolt to clean out the threads. Then finished up with lint free cloths on a stick. Before realising that I was probably into the law of diminishing returns and I had an aura of carb cleaner about me.

In other news after trying to compress the valve springs with a set of mulgrips like they do on YouTube, I quickly realised that was going to end badly so ordered a cheap compressor from amazon and had that done on a lunch break.

Head now on, new bolts in and I'll bust out the aldi torque wrench middle aisle special later to finish up. I'll then move onto the repainting the rocker cover and cleaning up the grime off the engine block.

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[mark165]

Well, most of the past couple of weeks has been spent with a toothbrush and degreaser wiping off 35 years of grime. Pretty grotty.

Plus, brushing up the rocker cover and giving it a bit of a spruce up. Got my '12V' sticker ready and waiting to go on.

And my clutch arrived in correct period packaging.

Next step is to wait on a couple of replacement hoses and then reassemble water pump, thermostat etc.

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[mark165]

Right! All assembled with new belt, tensioner,, pump, thermostat etc. Need to fit the pulley then unbolt from the engine stand and fit the clutch then it's ready to go back in.

Also cleaned up the engine bay.

[Missy Charm]

Commendable effort!  Should be unfalteringly average to drive too, when it's running.  I remember test-driving a five door fastback variant of similar vintage many years ago and finding it acceptable on all fronts.  Unfortunately, purchase was out of the question on the basis of a life by the sea having left the thing rustier than a trawler's propellor.  Yours looks much cleaner.  

I had a purple 1.6 shrieking cam special a few years later; wasn't the same as the eighties Corolla.  

[mark165]

Christmas Corolla update.

Optimistically, I'd thought I could mate the engine to the gearbox instead of doing things traditionally. This was brought on due to the fact I'd shoved another old shonky Toyota to the side of this one and didn't have much room. As you can expect, successful fitment didn't happen. Even with help.

So, after I'd gotten over myself I disconnected everything, ruined a track rod end, dropped the box and spent an inordinate amount of time releasing stuck driveshafts. I then spent more time cleaning up gearbox oil from the floor than I did fitting it as I mistakenly assumed it was empty but nevermind.

Bringing me to now... Twas the night before Christmas.. and the wife had taken the kids to the panto. I strapped it all up and it's now back in, awaiting fitment of the smorgasbord of parts and random bolts. Next step to start the meccano show and fit new gearbox seals and the driveshafts.







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[grogee]

1 hour ago, mark165 said:

I then spent more time cleaning up gearbox oil from the floor than I did fitting it as I mistakenly assumed it was empty but nevermind.

I've done this. Filled up the box before I'd refitted the driveshafts. 

You only do it once. 

[EyesWeldedShut]

11 minutes ago, grogee said:

I've done this. Filled up the box before I'd refitted the driveshafts. 

You only do it once. 

Oh no you don't - ask me how I know

[it's these fancy,  high-falutin, FWD things - confuse an old fecker]

[mark165]

Oh no you don't - ask me how I know

[it's these fancy,  high-falutin, FWD things - confuse an old fecker]

Sadly not the first time for me either. Even though I'd vowed back then never to repeat it. Any ideas on how to get the smell of gearbox oil out the bench/concrete floor/wooden dolly/bin/clothes/pallet truck/tools/vice/air welcomed!

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[Datsuncog]

Great to see progress on this one - a rare sight now, and should be very usable once running again.

Agree the smell of gearbox oil is pervasive and utterly vom-inducing, and sadly I have no easy remedies... I once managed to put a bottle of Castrol Syntrax in the back of a Subaru estate without checking the lid tightness, and of course it leaked all over the rear bed and under the back seats... Despite my very best efforts I never did get it fully cleaned off, and the occasional whiffs of what appeared to be rotting fish mixed with Satan's own guffs made it almost a relief when terminal rot was pronounced and off it went to be cubed.

I sometimes wonder if some luckless punter now wonders why their new Zanussi smells faintly of fish...

[mark165]

Where were we? Ah yes, it was all going swimmingly. Too well in fact.

After poking around the pile of parts I noticed one that looked very 'engine mounty'. Ah, that'll be the one under the engine I've just put in then. That should be easy but the flywheel cover had been bent back and had a lot of springiness. I got it on there with various clamps and by relifting the engine on one side after a few evenings of trying.

On that theme i then discovered a missing engine mount at the front. Mounts are available, trying to find the bracket to attach it to a bit harder. I thought i could graft one from my stash of celica parts but no deal. I then took a punt and after scatter gunning breakers got both parts from a 97 model. Bracket OK, mount different fitment. More Autodoc (but fitted in 10 min)

Starter motor? Not present. Got one from a starlet turbo.

Clutch slave cylinder. Bled nothing. Took the boot off to find fluid and rust. New one fitted, still no joy. New master now on the way. Courtesy of Ebay and JANPAY20.

Then the driveshafts. I'd ruined one of the threads trying to get it out the hub, so I just ordered a NOS cv joint for £notalot. Only to find that they weren't intended to be replaceable. After hitting it with various hammers i went via an angle grinder and made a horrible mess, plus with the added drama of a brake cleaner/wire wool bench fire. Then just to rub it in I had to pay six quid each for some retaining clips from Toyota. Pic of the aftermath attached.

Still, in a fit of optimism, I've just ordered oils and coolant and some gasket material. Plus I bought some wheels.

However, the carburettor is still sitting on my bench staring at me. I don't understand it, and it probably doesn't understand me either.


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[junkyarddog]

Starlet manual choke Carbs were a popular "upgrade" on these.

[mark165]

Starlet manual choke Carbs were a popular "upgrade" on these.

That's interesting, I didn't know that was a thing, presumably the auto choke wasn't the finest?

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[tooSavvy]

I was never brave enough [lies >>CBA] to F#ck about with ToMM auto carb 🙀 'teh fearz'.

 

[artdjones]

20 hours ago, mark165 said:

Where were we? Ah yes, it was all going swimmingly. Too well in fact.

After poking around the pile of parts I noticed one that looked very 'engine mounty'. Ah, that'll be the one under the engine I've just put in then. That should be easy but the flywheel cover had been bent back and had a lot of springiness. I got it on there with various clamps and by relifting the engine on one side after a few evenings of trying.

On that theme i then discovered a missing engine mount at the front. Mounts are available, trying to find the bracket to attach it to a bit harder. I thought i could graft one from my stash of celica parts but no deal. I then took a punt and after scatter gunning breakers got both parts from a 97 model. Bracket OK, mount different fitment. More Autodoc (but fitted in 10 min)

Starter motor? Not present. Got one from a starlet turbo.

Clutch slave cylinder. Bled nothing. Took the boot off to find fluid and rust. New one fitted, still no joy. New master now on the way. Courtesy of Ebay and JANPAY20.

Then the driveshafts. I'd ruined one of the threads trying to get it out the hub, so I just ordered a NOS cv joint for £notalot. Only to find that they weren't intended to be replaceable. After hitting it with various hammers i went via an angle grinder and made a horrible mess, plus with the added drama of a brake cleaner/wire wool bench fire. Then just to rub it in I had to pay six quid each for some retaining clips from Toyota. Pic of the aftermath attached.

Still, in a fit of optimism, I've just ordered oils and coolant and some gasket material. Plus I bought some wheels.

However, the carburettor is still sitting on my bench staring at me. I don't understand it, and it probably doesn't understand me either.


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Toyota CV joints are theoretically replaceable, but the spring clips in the driveshaft ends stick out so far that they can't be knocked off by normal means. They can only be removed by using a chisel to break up the cage that holds the balls in place. 

[junkyarddog]

2 hours ago, mark165 said:

That's interesting, I didn't know that was a thing, presumably the auto choke wasn't the finest?

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Not sure,I know there was on type of carb fitted that was rubbish,so Starlet conversions were popular.

[grogee]

22 hours ago, mark165 said:

Where were we? Ah yes, it was all going swimmingly. Too well in fact.

After poking around the pile of parts I noticed one that looked very 'engine mounty'. Ah, that'll be the one under the engine I've just put in then. That should be easy but the flywheel cover had been bent back and had a lot of springiness. I got it on there with various clamps and by relifting the engine on one side after a few evenings of trying.

On that theme i then discovered a missing engine mount at the front. Mounts are available, trying to find the bracket to attach it to a bit harder. I thought i could graft one from my stash of celica parts but no deal. I then took a punt and after scatter gunning breakers got both parts from a 97 model. Bracket OK, mount different fitment. More Autodoc (but fitted in 10 min)

Starter motor? Not present. Got one from a starlet turbo.

Clutch slave cylinder. Bled nothing. Took the boot off to find fluid and rust. New one fitted, still no joy. New master now on the way. Courtesy of Ebay and JANPAY20.

Then the driveshafts. I'd ruined one of the threads trying to get it out the hub, so I just ordered a NOS cv joint for £notalot. Only to find that they weren't intended to be replaceable. After hitting it with various hammers i went via an angle grinder and made a horrible mess, plus with the added drama of a brake cleaner/wire wool bench fire. Then just to rub it in I had to pay six quid each for some retaining clips from Toyota. Pic of the aftermath attached.

Still, in a fit of optimism, I've just ordered oils and coolant and some gasket material. Plus I bought some wheels.

However, the carburettor is still sitting on my bench staring at me. I don't understand it, and it probably doesn't understand me either.


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ISTRC a stuck driveshaft on my Puma, seized into the splines. I bought some sort of tool that mounted on the wheel studs then pushed on the driveshaft end which got it shifted. 

Probably not relevant to yours though because Toyota. 

[delux]

Great work so far Mark!

When you cant knock a CV joint off the shaft its usually because the edges of the splines have burred outwards due to the circlip being smashed into them. When this happens it effectively locks the joint on.

Ive seen people snap the section after the circlip off trying to smash it off!

If you have a new CV joint, the easiest way may be to cut up the old CV joint. If you angle grind down into the outer cup you should be able to open it up enough to release it leaving the inner bit on the shaft. You can then knock it back up, pop the circlip off and clean up the splines or cut into it. When you are nearly thru get a thick chisel in and split it. CV joint is gonna be easier to source than a new driveshaft!

[mark165]

Thanks to all your replies! Suffice to say it seems after the big hammery waste of time approach, I took the long, messy washing machine unfriendly route, with extra fire.

Next time, I will buy that tool....

[mark165]

Some more progress, little 15 min jobs but they all add up. Looking like a real car again.

Connected the loom back up, fitted some interior panels, put the radiator back, sealed the rocker cover and filled up engine and gearbox, fitted HT leads and torqued a few bits up with my shiny high spec amazon torque wrench.

My clutch master cylinder arrived after two weeks only to find even after supplying all the details and cross referencing that it was a LHD one. I took a punt on one for the later model for £30 as the correct one is 80 quid. Luckily, it fits, just needed to change the rod over so well happy with that. The old one was well past it and full of sludge. Working clutch!

Started cleaning the intake manifold. I need to fix the vacuum valve with some tubing as the plastic has snapped and make up some new gaskets. Also I'm not sure what to do with the carb. Thinking of *carefully* applying carb cleaner everywhere and putting compressed air through. Someone has also helpfully mangled one of the adjustment screws. Amazingly, you can buy rebuild kits from the phillipines for £30 delivered so that's currently my Plan B.

[mark165]

A little bit of faffing this weekend.

Intake Manifold now on, gaskets made and carb subjected to liberal amounts of cleaner.

I thought I'd get lucky and have the model corolla with a drain plug in the fuel tank, but after five minutes on the cold floor i was sadly disappointed. After a memorable siphoning tasting event with vegetable oil and diesel during my student days i decided it was time for a Plan B ...12 litres of six year old lucozade removed using a screwfix bulb pump, through the sender unit mounting. Brilliant little bit of kit.

I inherited some batteries with the car but they both seem dead even after being left to charge overnight so i borrowed one off another car and checked the electrics. All OK other than an indicator dash bulb. Even the cassette player works and gives out comfortingly bad quality sound from the 35 year old speakers.

[mark165]

All back together! Five litres of tesco petrol.

Optimistic turn of the key and.....

Crank, crank, crank.

I got the tiniest of splutters then nowt. Doesn't fire on easy start, then I noticed multiple petrol leaks from the carb. Time to order that rebuild kit then!