Almera Tino V10 (2003 year). Manual — part 197
EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION
EM
A
EM
ENGINE MECHANICAL
QG
PRECAUTIONS . . . . . . . . . . . . . . .. 5
REMOVAL OF LIQUID GASKET SEALING . . .. 6
LIQUID GASKET APPLICATION PROCEDURE. . 6
PREPARATION . . . . . . . . . . . . . . ... 7
Special Service Tools . . . . . . . . . . . ... 7
Commercial Service Tools . . . . . . . . . . 9
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . ...11
DRIVE BELTS . . . . . . . . . . . . . . ... 13
Checking Drive Belts . . . . . . . . . . . .. 13
Tension Adjustment . . . . . . . . . . . . 14
Removal and Installation . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . ... 15
INSTALLATION . . . . . . . . . . . . ... 15
AIR CLEANER AND AIR DUCT . . . . . . . ... 16
Removal and Installation . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . ... 16
INSTALLATION . . . . . . . . . . . . ... 16
Changing Air Cleaner Element . . . . . . . ... 17
INTAKE MANIFOLD . . . . . . . . . . . . . 18
Removal and Installation . . . . . . . . . . 18
EXHAUST MANIFOLD AND CATALYTIC CON-
VERTER . . . . . . . . . . . . . . . . . 21
Removal and Installation . . . . . . . . . . 21
Disassembly and Assembly . . . . . . . . . 24
OIL PAN AND OIL STRAINER . . . . . . . . . 25
Removal and Installation . . . . . . . . . . 25
IGNITION COIL . . . . . . . . . . . . . . . 27
Removal and Installation . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . ... 27
INSTALLATION . . . . . . . . . . . . ... 27
SPARK PLUG (CONVENTIONAL) . . . . . . ... 28
Removal and Installation . . . . . . . . . . 28
FUEL INJECTOR AND FUEL TUBE . . . . . . 29
Removal and Installation . . . . . . . . . . 29
ROCKER COVER . . . . . . . . . . . . . . 32
Removal and Installation . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . ... 32
INSTALLATION . . . . . . . . . . . . ... 33
CAMSHAFT . . . . . . . . . . . . . . . .. 35
Removal and Installation . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . ... 35
INSTALLATION . . . . . . . . . . . . ... 38
EM-2
INSPECTION AFTER REMOVAL . . . . . . 42
Valve Clearance . . . . . . . . . . . . . .. 45
TIMING CHAIN . . . . . . . . . . . . . . .. 50
Removal and Installation . . . . . . . . . . 50
OIL SEAL . . . . . . . . . . . . . . . . .. 57
Removal and Installation of Valve Oil Seal . . . . 57
REMOVAL . . . . . . . . . . . . . . ... 57
INSTALLATION . . . . . . . . . . . . . 57
Removal and Installation of Front Oil Seal . . . . 58
REMOVAL . . . . . . . . . . . . . . ... 58
INSTALLATION . . . . . . . . . . . . . 58
Removal and Installation of Rear Oil Seal . . . .. 58
REMOVAL . . . . . . . . . . . . . . ... 58
INSTALLATION . . . . . . . . . . . . . 58
CYLINDER HEAD . . . . . . . . . . . . . . 60
On-Vehicle Service . . . . . . . . . . . . . 60
CHECKING COMPRESSION PRESSURE . . . 60
Removal and Installation . . . . . . . . . . 61
REMOVAL . . . . . . . . . . . . . . ... 61
INSTALLATION . . . . . . . . . . . . . 62
Disassembly and Assembly . . . . . . . . . 63
DISASSEMBLY . . . . . . . . . . . . ... 63
ASSEMBLY . . . . . . . . . . . . . . . 64
Inspection After Disassembly . . . . . . . . . 65
ENGINE ASSEMBLY . . . . . . . . . . . . 70
Removal and Installation . . . . . . . . . . 70
CYLINDER BLOCK . . . . . . . . . . . . ... 74
Disassembly and Assembly . . . . . . . . . 74
DISASSEMBLY . . . . . . . . . . . . ... 75
ASSEMBLY . . . . . . . . . . . . . . . 79
How to Select Piston and Bearing . . . . . . .. 84
HOW TO SELECT MAIN BEARING . . . . . 86
Inspection After Disassembly . . . . . . . . ..87
SERVICE DATA AND SPECIFICATIONS (SDS) . ..96
Standard and Limit . . . . . . . . . . . . ..96
Tightening Torque . . . . . . . . . . . . .107
YD
PRECAUTIONS . . . . . . . . . . . . . ...109
REMOVAL OF LIQUID GASKET SEALING . .. 110
LIQUID GASKET APPLICATION PROCEDURE. 110
EM-3
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PREPARATION . . . . . . . . . . . . . . 111
Special Service Tools . . . . . . . . . . . 111
Commercial Service Tools . . . . . . . . . .114
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . .115
DRIVE BELTS . . . . . . . . . . . . . . ..117
Checking Drive Belts . . . . . . . . . . . .117
Tension Adjustment . . . . . . . . . . . ...117
AIR CONDITIONER COMPRESSOR BELT . ..118
ALTERNATOR AND WATER PUMP BELT . . 118
Removal and Installation . . . . . . . . . ...118
REMOVAL . . . . . . . . . . . . . . ..118
INSTALLATION . . . . . . . . . . . . ..118
AIR CLEANER AND AIR DUCT . . . . . . . ..119
Removal and Installation . . . . . . . . . ...119
CHARGE AIR COOLER . . . . . . . . . . . 121
Removal and Installation . . . . . . . . . .. 121
INTAKE MANIFOLD . . . . . . . . . . . ... 123
Removal and Installation . . . . . . . . . .. 123
CATALYST . . . . . . . . . . . . . . . .. 126
Removal and Installation . . . . . . . . . .. 126
REMOVAL . . . . . . . . . . . . . . . 127
INSTALLATION . . . . . . . . . . . . . 127
EXHAUST MANIFOLD AND TURBOCHARGER .. 128
Removal and Installation . . . . . . . . . .. 128
Disassembly and Assembly . . . . . . . . . 131
REMOVAL . . . . . . . . . . . . . . . 132
INSPECTION AFTER REMOVAL . . . . . . 132
Turbocharger . . . . . . . . . . . . . . 133
OIL PAN AND OIL STRAINER . . . . . . . ... 137
Removal and Installation . . . . . . . . . .. 137
GLOW PLUG . . . . . . . . . . . . . . .. 142
Removal and Installation . . . . . . . . . .. 142
REMOVAL . . . . . . . . . . . . . . . 142
INSTALLATION . . . . . . . . . . . . . 142
VACUUM PUMP . . . . . . . . . . . . . .. 143
Removal and Installation . . . . . . . . . .. 143
Disassembly and Assembly . . . . . . . . .. 145
DISASSEMBLY . . . . . . . . . . . . . 145
ASSEMBLY . . . . . . . . . . . . . ... 145
INJECTION TUBE AND FUEL INJECTOR . . . 147
Removal and Installation . . . . . . . . . .. 147
FUEL PUMP . . . . . . . . . . . . . . . 150
Removal and Installation . . . . . . . . . .. 150
ROCKER COVER . . . . . . . . . . . . ... 160
Removal and Installation . . . . . . . . . .. 160
CAMSHAFT . . . . . . . . . . . . . . . 162
Removal and Installation . . . . . . . . . .. 162
Valve Clearance . . . . . . . . . . . . ... 167
INSPECTION . . . . . . . . . . . . . 167
ADJUSTMENTS . . . . . . . . . . . . 168
SECONDARY TIMING CHAIN . . . . . . . . 171
Removal and Installation . . . . . . . . . .. 171
PRIMARY TIMING CHAIN . . . . . . . . . .. 176
Removal and Installation . . . . . . . . . .. 176
CYLINDER HEAD . . . . . . . . . . . . ... 186
On-Vehicle Service . . . . . . . . . . . ... 186
CHECKING COMPRESSION PRESSURE . ... 186
Removal and Installation . . . . . . . . . .. 187
EM-4
ENGINE ASSEMBLY . . . . . . . . . . . .. 197
Removal and Installation . . . . . . . . . .. 197
CYLINDER BLOCK . . . . . . . . . . . . . 201
Disassembly and Assembly . . . . . . . . .. 201
DISASSEMBLY . . . . . . . . . . . . . 202
ASSEMBLY . . . . . . . . . . . . . ... 206
How to Select Piston and Bearing . . . . . . 210
Inspection After Disassembly . . . . . . . ... 213
SERVICE DATA AND SPECIFICATIONS (SDS) . 223
PRECAUTIONS
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PRECAUTIONS
PFP:00001
Precautions for Drain Coolant
EBS00QDT
●
Drain coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping
EBS00QDU
●
Before starting work, make sure no fire or spark producing items are in the work area.
●
Release fuel pressure before disassembly.
●
After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly
EBS00QDV
●
When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
●
Exercise maximum care to avoid damage to mating or sliding surfaces.
●
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
●
Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
●
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and Replacement
EBS00QDW
●
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and Installation
EBS00QDX
●
Use torque wrench to tighten bolts or nuts.
●
When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
●
Replace with new gasket, packing, oil seal or O-ring.
●
Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
●
Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
●
Release air within route after draining coolant.
●
After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
Parts Requiring Angular Tightening
EBS00QDY
●
Use an angle wrench for the final tightening of the following engine parts.
–
Cylinder head bolts
–
Lower cylinder block bolts
–
Connecting rod cap bolts
–
Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
●
Do not use a torque value for final tightening.
●
The torque value for these parts are for a preliminary step.
●
Ensure thread and seat surfaces are clean and coated with engine oil.
EM-6
[QG]
PRECAUTIONS
Precautions for Liquid Gasket
EBS00QDZ
REMOVAL OF LIQUID GASKET SEALING
●
After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
●
In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1.
Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
●
Remove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
2.
Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3.
Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4.
Apply the gasket without breaks to the specified location with the
specified dimensions.
●
If there is a groove for the liquid gasket application, apply the
gasket to the groove.
●
As for the bolt holes, normally apply the gasket inside the holes.
If specified, it should be applied outside the holes. Make sure to
read the text of service manual.
●
Within five minutes of gasket application, install the mating com-
ponent.
●
If the liquid gasket protrudes, wipe it off immediately.
●
Do not retighten after the installation.
●
After 30 minutes or more have passed from the installation, fill the engine oil and coolant.
CAUTION:
If there are specific instructions in the service manual, observe them.
PBIC0275E
PBIC0003E
EMA0622D
PREPARATION
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PREPARATION
PFP:00002
Special Service Tools
EBS00QE0
Tool number
Tool name
Description
ST0501S000
Engine stand assembly
1. ST05011000
Engine stand
2. ST05012000
Base
Disassembling and assembling
Engine attachment assembly
1. KV10106500
Engine attachment
2. KV10113300
Sub-attachment
Overhauling engine
KV10114400
Heated oxygen sensor wrench
Loosening or tightening heated oxygen
sensor
a: 22 mm (0.87 in)
ST10120000
Cylinder head bolt wrench
Loosening and tightening cylinder head bolt
a: 13 mm (0.51 in) dia.
b: 12 mm (0.47 in)
c: 10 mm (0.39 in)
KV10116200
Valve spring compressor
1. KV10115900
Attachment
Disassembling valve mechanism
KV10115600
Valve oil seal drift
Installing valve oil seal
KV10107902
Valve oil seal puller
Removing valve oil seal
NT042
NT029
NT636
NT583
NT022
NT024
NT011
EM-8
[QG]
PREPARATION
KV101151S0
Lifter stopper set
1. KV10115110
Camshaft pliers
2. KV10115120
Lifter stopper
Changing shims
EM03470000
Piston ring compressor
Installing piston assembly into cylinder bore
1. ST15243000
Valve seat drift
2. KV11103710
Adapter
3. KV11103720
Adapter
Installing valve seat drift
KV10111100
Seal cutter
Removing oil pan
WS39930000
Tube presser
Pressing the tube of liquid gasket
KV10112100
Angle wrench
Tightening bolts for bearing cap, cylinder
head, etc. in angle
Tool number
Tool name
Description
NT041
NT044
PBIC1120E
NT046
NT052
NT014
PREPARATION
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Commercial Service Tools
EBS00QE1
ST16610001
Pilot bushing puller
Removing pilot bushing
KV101056S0*
Rear gear stopper
1. KV10105620
Adapter
2. KV10105610
Plate assembly
Preventing crankshaft from rotating
Tool number
Tool name
Description
NT045
NT773
Tool name
Description
Spark plug wrench
Removing and installing spark plug
Crankshaft pulley puller
Removing crankshaft pulley
Manual lift table caddy
Removing and installing engine
Valve seat cutter set
Finishing valve seat dimensions
Piston ring expander
Removing and installing piston ring
NT047
PBIC0887E
ZZA1210D
NT048
NT030
EM-10
[QG]
PREPARATION
Valve guide drift
Removing and installing valve guide
Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
Valve guide reamer
Reaming valve guide 1 or hole for oversize
valve guide 2
Intake & Exhaust:
d
1
: 5.5 mm (0.217 in) dia.
d
2
: 9.685 mm (0.3813 in) dia.
Front oil seal drift
Installing front oil seal
a: 50 mm (1.97 in) dia.
b: 44 mm (1.73 in) dia.
Rear oil seal drift
Installing rear oil seal
a: 102 mm (4.02 in) dia.
b: 90 mm (3.54 in) dia.
Tool name
Description
NT015
NT016
NT049
NT049
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting —Engine Noise
EBS00QE2
SEM937F
EM-12
[QG]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Use the Chart Below to Help You Find the Cause of the Symptom.
EBS00QE3
1.
Locate the area where noise occurs.
2.
Confirm the type of noise.
3.
Specify the operating condition of engine.
4.
Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related
B: Related
C: Sometimes related
—: Not related
Location
of noise
Type of
noise
Operating condition of engine
Source of
noise
Check item
Refer-
ence page
Before
warm-
up
After
warm-
up
When
start-
ing
When
idling
When
racing
While
driving
Top of
engine
Rocker
cover
Cylinder
head
Ticking or
clicking
C
A
—
A
B
—
Tappet
noise
Valve clearance
Rattle
C
A
—
A
B
C
Camshaft
bearing
noise
Camshaft journal clear-
ance
Camshaft runout
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil pan
Slap or
knock
—
A
—
B
B
—
Piston pin
noise
Piston and piston pin
clearance
Connecting rod bush-
ing clearance
Slap or
rap
A
—
—
B
B
A
Piston
slap noise
Piston-to-bore clear-
ance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsion
Knock
A
B
C
B
B
B
Connect-
ing rod
bearing
noise
Connecting rod bush-
ing clearance (Small
end)
Connecting rod bear-
ing clearance (Big end)
Knock
A
B
—
A
B
C
Main
bearing
noise
Main bearing oil clear-
ance
Crankshaft runout
Front of
engine
Timing
chain
cover
Tapping or
ticking
A
A
—
B
B
B
Timing
chain and
chain
tensioner
noise
Timing chain cracks
and wear
Timing chain tensioner
operation
Front of
engine
Squeak-
ing or fizz-
ing
A
B
—
B
—
C
Drive belts
(Sticking
or slip-
ping)
Drive belts deflection
Creaking
A
B
A
B
A
B
Drive belts
(Slipping)
Idler pulley bearing
operation
Squall
Creak
A
B
—
B
A
B
Water
pump
noise
Water pump operation
DRIVE BELTS
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DRIVE BELTS
PFP:02117
Checking Drive Belts
EBS00QE4
●
Before inspecting the engine, make sure the engine has cooled down; wait approximately 30 minutes
after the engine has been stopped.
●
Visually inspect all belts for wear, damage, or cracks on contacting surfaces and edge areas.
●
When measuring deflection, apply 98 N (10 kg, 22 lb) at the
▼
marked point.
CAUTION:
When measuring belt tension immediately after belt is installed, first set the tension to the standard.
Then, rotate crankshaft for more than two turns in order to eliminate variance in belt deflection
between the pulleys. Re-measure and adjust the tension to the standard.
MBIA0034E
Deflection adjustment Unit: mm (in)
Used belt
New belt
Limit
After adjustment
Alternator
Without air conditioner compressor
10.2 (0.402)
6.5 - 7.0
(0.256 - 0.276)
5.5 - 6.1
(0.217 - 0.240)
With air conditioner compressor
8.1 (0.319)
5.3 - 5.7
(0.209 - 0.224)
4.5 - 5.0
(0.177 - 0.197)
Power steering oil pump
7.1 (0.280)
4.4 - 4.9
(0.173 - 0.193)
3.9 - 4.4
(0.154 - 0.173)
Applied pushing force
98 N (10 kg, 22 lb)
EM-14
[QG]
DRIVE BELTS
Tension Adjustment
EBS00QE5
CAUTION:
●
When belt is replaced with a new one, tighten it a little
stronger than current one to accommodate for insufficient
adaptability with pulley grooves.
●
When tension of belt being used exceeds “Retightening
limit”, adjust it to value for “Used belt”.
●
When installing belt, make sure that it is correctly engaged with pulley groove.
●
Keep oil and water away from belt.
●
Do not twist or bend belt excessively.
●
When adjusting belt, remove snap retainer from adjusting bolt thread (to prevent the retainer from becom-
ing pinched or missing).
●
After adjustment, be sure to install snap retainer to adjusting bolt thread.
NOTE:
Snap retainer can prevent adjusting bolt from dropping due to vibration during driving.
POWER STEERING PUMP AND WATER PUMP BELT
1.
Loosen lock nut (A) and power steering pump mounting nut (B).
2.
Turn adjusting bolt (C) to adjust. Refer to
.
3.
Tighten lock nut (A) and power steering pump mounting nut (B)
in this order.
ALTERNATOR AND AIR CONDITIONER COMPRESSOR BELT
1.
Remove RH splash cover (with undercover attached).
2.
Loosen lock nut (G).
3.
Turn adjusting bolt (H) to adjust.
Refer to
.
4.
Tighten lock nut (G).
Portion
Belt tightening method for adjustment
Power steering pump and water pump
belt
Adjusting bolt on power steering pump
Alternator and air conditioner compres-
sor belt
Adjusting bolt on idler pulley
PBIC0531E
Nut A :
: 16.6 - 23.5 N·m (1.7 - 2.4 kg-m, 13 - 17 ft-lb)
Nut B :
: 31.4 - 42.2 N·m (3.2 - 4.3 kg-m, 24 - 31 ft-lb)
PBIC0532E
Nut G :
: 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)
DRIVE BELTS
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Removal and Installation
EBS00QE6
REMOVAL
●
Loosen each belt while referring to “Tension Adjustment”, and remove them one by one starting from the
one in front.
INSTALLATION
1.
Install belts to pulley in reverse order of removal.
2.
Adjust belt tension.
CAUTION:
●
When checking belt tension immediately after installation, first, adjust to specified value. Then,
after turning crankshaft more than two turns, re-adjust to specified value to avoid variation in
deflection between pulleys.
●
Tighten idler pulley lock nut by hand and measure tension without looseness.
3.
Tighten each adjusting bolt and nut to the specified torque.
4.
Make sure that tension of each belt is within the standard.
EM-16
[QG]
AIR CLEANER AND AIR DUCT
AIR CLEANER AND AIR DUCT
PFP:16500
Removal and Installation
EBS00QE7
REMOVAL
1.
Remove air cleaner case assembly, air duct and resonator.
●
Add marks as necessary for easier installation.
2.
Remove harness connector from mass air flow sensor.
3.
Remove mass air flow sensor.
CAUTION:
Handle mass air flow sensor with following cares.
●
Do not shock it.
●
Do not disassembly it.
●
Do not touch its sensor.
●
Do not deform mass air flow sensor's wire mesh.
4.
Remove left fender protector and resonator.
INSTALLATION
1.
Attach each joint aligning marks put at removal. Screw clamps firmly.
2.
Install in the reverse order of removal.
PBIC0533E
1.
Air cleaner case (upper)
2.
Resonator
3.
Air duct
4.
Mass air flow sensor
5.
O-ring
6.
Air cleaner case (lower)
7.
Grommet
8.
Air cleaner element
9.
Bracket
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