Almera Tino V10 (2003 year). Manual — part 203
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-97
[QG]
C
D
E
F
G
H
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L
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A
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SPARK PLUG
CYLINDER HEAD
Unit: mm (in)
VALVE
Valve Dimensions
Unit: mm (in)
Valve Clearance
Shim Type
Unit: mm (in)
*: At a temperature of approximately 20
°
C (68
°
F)
Shimless Type
Make
NGK
Champion
Type
Standard
LFR5A-11
REC10YC4
Hot
LFR4A-11
—
Cold
LFR6A-11
—
Plug gap
1.0 - 1.1 mm (0.039 - 0.043 in)
Standard
Limit
Head surface distortion
Less than 0.03 (0.0012)
0.1 (0.004)
Height
117.9 (4.642)
—
Valve head diameter “D”
Intake
29.9 - 30.2 (1.177 - 1.189)
Exhaust
24.9 - 25.2 (0.980 - 0.992)
Valve length “L”
Intake
92.00 - 92.50 (3.6220 - 3.6417)
Exhaust
92.37 - 92.87 (3.6366 - 3.6563)
Valve stem diameter “d”
Intake
5.465 - 5.480 (0.2152 - 0.2157)
Exhaust
5.445 - 5.460 (0.2144 - 0.2150)
Valve seat angle “
α
”
44
°
15
′
- 44
°
45
′
Valve margin “T”
0.8 - 0.14 (0.031 - 0.055)
Valve margin “T” limit
More than 0.5 (0.020)
Valve stem end surface grinding limit
0.2 (0.008)
SEM188
For adjusting
For checking
Hot
Cold* (reference data)
Hot
Intake
0.304 - 0.416 (0.012 - 0.016)
0.25 - 0.33 (0.010 - 0.013)
0.21 - 0.47 (0.008 - 0.019)
Exhaust
0.348 - 0.472 (0.014 - 0.019)
0.32 - 0.40 (0.013 - 0.016)
0.30 - 0.56 (0.012 - 0.022)
Hot
Cold* (reference data)
Intake
0.32 - 0.40 (0.013 - 0.016)
0.24 - 0.32 (0.009 - 0.013)
Exhaust
0.33 - 0.41 (0.013 - 0.016)
0.26 - 0.34 (0.010 - 0.013)
EM-98
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
*: At a temperature of approximately 20
°
C (68
°
F)
Available Shims
Thickness
mm (in)
Identification mark
2.00 (0.0787)
200
2.02 (0.0795)
202
2.04 (0.0803)
204
2.06 (0.0811)
206
2.08 (0.0819)
208
2.10 (0.0827)
210
2.12 (0.0835)
212
2.14 (0.0843)
214
2.16 (0.0850)
216
2.18 (0.0858)
218
2.20 (0.0866)
220
2.21 (0.0870)
221
2.22 (0.0874)
222
2.23 (0.0878)
223
2.24 (0.0882)
224
2.25 (0.0886)
225
2.26 (0.0890)
226
2.27 (0.0894)
227
2.28 (0.0898)
228
2.29 (0.0902)
229
2.30 (0.0906)
230
2.31 (0.0909)
231
2.32 (0.0913)
232
2.33 (0.0917)
233
2.34 (0.0921)
234
2.35 (0.0925)
235
2.36 (0.0929)
236
2.37 (0.0933)
237
2.38 (0.0937)
238
2.39 (0.0941)
239
2.40 (0.0945)
240
2.41 (0.0949)
241
2.42 (0.0953)
242
2.43 (0.0957)
243
2.44 (0.0961)
244
2.45 (0.0965)
245
2.46 (0.0969)
246
2.47 (0.0972)
247
2.48 (0.0976)
248
2.49 (0.0980)
249
2.50 (0.0984)
250
2.51 (0.0988)
251
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-99
[QG]
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Valve Spring
2.52 (0.0992)
252
2.53 (0.0996)
253
2.54 (0.1000)
254
2.55 (0.1004)
255
2.56 (0.1008)
256
2.57 (0.1012)
257
2.58 (0.1016)
258
2.59 (0.1020)
259
2.60 (0.1024)
260
2.61 (0.1028)
261
2.62 (0.1031)
262
2.63 (0.1035)
263
2.64 (0.1039)
264
2.65 (0.1043)
265
2.66 (0.1047)
266
2.68 (0.1055)
268
2.70 (0.1063)
270
2.72 (0.1071)
272
2.74 (0.1079)
274
2.76 (0.1087)
276
2.78 (0.1094)
278
2.80 (0.1102)
280
2.82 (0.1110)
282
2.84 (0.1118)
284
2.86 (0.1126)
286
2.88 (0.1134)
288
2.90 (0.1142)
290
2.92 (0.1150)
292
2.94 (0.1157)
294
2.96 (0.1165)
296
2.98 (0.1173)
298
Thickness
mm (in)
Identification mark
AEM236
Free height
mm (in)
40.0 (1.57)
Pressure N (kg, lb) at height
mm (in)
147.5 - 166.3 (15.04 - 16.96, 33.2 - 37.4) at 23.64 (0.9307)
Out-of-square
mm (in)
Less than 1.80 (0.0709)
EM-100
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve Lifter
Unit: mm (in)
Standard
Valve lifter outer diameter
29.960 - 29.975 (1.1795 - 1.1801)
Lifter guide inner diameter
30.000 - 30.021 (1.1811 - 1.1819)
Clearance between lifter and lifter guide
0.025 - 0.061 (0.0010 - 0.0024)
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-101
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Available Valve Lifter (Shimless Type)
Thickness mm (in)
Identification Mark
3.000 (0.1181 in)
00
3.020 (0.1189 in)
02
3.040 (0.1197 in)
04
3.060 (0.1205 in)
06
3.080 (0.1213 in)
08
3.100 (0.1220 in)
10
3.120 (0.1228 in)
12
3.140 (0.1236 in)
14
3.160 (0.1244 in)
16
3.180 (0.1252 in)
18
3.200 (0.1260 in)
20
3.220 (0.1268 in)
22
3.240 (0.1276 in)
24
3.260 (0.1283 in)
26
3.280 (0.1291 in)
28
3.300 (0.1299 in)
30
3.320 (0.1307 in)
32
3.340 (0.1315 in)
34
3.360 (0.1323 in)
36
3.380 (0.1323 in)
38
3.400 (0.1339 in)
40
3.420 (0.1346 in)
42
3.440 (0.1354 in)
44
3.460 (0.1362 in)
46
3.480 (0.1370 in)
48
3.500 (0.1378 in)
50
3.520 (0.1386 in)
52
3.540 (0.1394 in)
54
3.560 (0.1402 in)
56
3.580 (0.1409 in)
58
3.600 (0.1417 in)
60
3.620 (0.1425 in)
62
3.640 (0.1433 in)
64
3.660 (0.1441 in)
66
3.680 (0.1449 in)
68
EM-102
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve Guide
Unit: mm (in)
PBIC1077E
Intake
Exhaust
Standard
Service
Standard
Service
Valve guide
Outer diameter
9.523 - 9.534
(0.3749 - 0.3754)
9.723 - 9.734
(0.3828 - 0.3832)
9.523 - 9.534
(0.3749 - 0.3754)
9.723 - 9.734
(0.3828 - 0.3832)
Inner diameter
(Finished size)
5.500 - 5.515 (0.2165 - 0.2171)
5.500 - 5.515 (0.2165 - 0.2171)
Cylinder head valve guide hole diameter
9.475 - 9.496
(0.3730 - 0.3739)
9.685 - 9.696
(0.3813 - 0.3817)
9.475 - 9.496
(0.3730 - 0.3739)
9.685 - 9.696
(0.3813 - 0.3817)
Interference fit of valve guide
0.027 - 0.059
(0.0011 - 0.0023)
0.027- 0.049
(0.0011 - 0.0019)
0.027 - 0.059
(0.0011 - 0.0023)
0.027- 0.049
(0.0011 - 0.0019)
Stem to guide clearance
0.020 - 0.050 (0.0008 - 0.0020)
0.040 - 0.070 (0.0016 - 0.0028)
Valve deflection limit (Dial gauge read-
ing)
0.2 (0.008)
Projection length “L”
11.5 - 11.7 (0.453 - 0.461)
MEM096A
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-103
[QG]
C
D
E
F
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Valve Seat
Unit: mm (in)
CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)
Dia
A
27.8 - 28.0 (1.094 - 1.102)
B
29.5 - 29.7 (1.161 - 1.169)
C
31.9 - 32.1 (1.256 - 1.264)
D
31.500 - 31.516 (1.2402 - 1.2408)
E
24.5 - 24.7 (0.9646 - 0.9724)
F
26.500 - 26.516 (1.043 - 1.0439)
G
26.2 - 26.4 (1.031 - 1.039)
SEM573DA
SEM574DA
Standard
Camshaft runout [TIR*]
Less than 0.02 (0.0008)
Cam height “A”
Intake
40.217 - 40.407 (1.5833 - 1.5908)
Exhaust
39.205 - 39.395 (1.5435 - 1.5510)
Outer diameter of camshaft journal
No. 1
27.935 - 27.955 (1.0998 - 1.1006)
No. 2, 3, 4, 5
23.935 - 23.955 (0.9423 - 0.9431)
SEM671
EM-104
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
*: Total indicator reading
CYLINDER BLOCK
Unit: mm (in)
PISTON, PISTON RING AND PISTON PIN
Available Piston
Unit: mm (in)
Inner diameter of camshaft bracket
No .1
28.000 - 28.021 (1.1024 - 1.1032)
No.2, 3, 4, 5
24.000 - 24.021 (0.9449 - 0.9457)
Camshaft journal clearance
0.045 - 0.086 (0.0018 - 0.0034)
Camshaft end play
Intake
0.070 - 0.143 (0.0028 - 0.0056)
Exhaust
0.115 - 0.188 (0.0045 - 0.0074)
Standard
Standard
Limit
Surface flatness
Less than 0.03 (0.0012)
0.1 (0.004)
Height “H” (nominal)
213.95 - 214.05 (8.4232 - 8.4271)
—
Cylinder bore
inner diameter
Standard
Grade No. 1
80.000 - 80.010
(3.1496 - 3.1500)
0.2 (0.008)
Grade No. 2
80.010 - 80.020
(3.1500 - 3.1504)
Grade No. 3
80.020 - 80.030
(3.1504 - 3.1508)
Out-of-round (X
−
Y)
Less than 0.015 (0.0006)
—
Taper (A
−
B)
Less than 0.01 (0.0004)
—
Difference in inner diameter between cylinders
0.05 (0.0020)
0.2 (0.008)
SEM171D
Standard
SEM882E
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-105
[QG]
C
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Piston Ring
Unit: mm (in)
Piston Pin
Unit: mm (in)
CONNECTING ROD
Unit: mm (in)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
Piston skirt diame-
ter “A”
Standard
Grade No. 1
79.965 - 79.975
(3.1482 - 3.1486)
Grade No. 2
79.975 - 79.985
(3.1486 - 3.1490)
Grade No. 3
79.985 - 79.995
(3.1490 - 3.1494)
0.5 (0.002) oversize (service)
80.215 - 80.245
(3.1581 - 3.1592)
1.0 (0.039) oversize (service)
80.465 - 80.495
(3.1679 - 3.1691)
“a” dimension
42.3 (1.665)
Piston pin hole inner diameter
18.993 - 18.999
(0.7478 - 0.7480)
Piston to bore clearance
0.025 - 0.045 (0.0010 - 0.0018)
Standard
Limit
Side clear-
ance
Top
0.040 - 0.080
(0.0016 - 0.0031)
0.110 (0.0043)
2nd
0.030 - 0.070 (0.0012 - 0.0028)
0.100 (0.0039)
Oil ring
0.045 - 0.155
(0.0018 - 0.0061)
—
End gap
Top
0.20 - 0.39 (0.0079 - 0.0154)
0.54 (0.0213)
2nd
0.32 - 0.56
(0.0126 - 0.0220)
0.67 (0.0264)
Oil (rail ring)
0.20 - 0.69 (0.0079 - 0.0272)
0.95 (0.0374)
Piston pin outer diameter
18.989 - 19.001 (0.7476 - 0.7481)
Piston pin to piston clearance
0.002 - 0.006 (0.0001 - 0.0002)
Piston pin to connecting rod bush-
ing clearance
Standard
0.005 - 0.017 (0.0002 - 0.0007)
Limit
0.023 (0.0009)
Center distance
140.45 - 140.55 (5.5295 - 5.5335)
Bend [per 100 (3.94)]
Limit
0.15 (0.0059)
Torsion [per 100 (3.94)]
Limit
0.30 (0.0118)
Connecting rod bushing inner diameter* (small end)
19.000 - 19.012 (0.7480 - 0.7485)
Connecting rod big end inner diameter
43.000 - 43.013 (1.6929 - 1.6934)
Side clearance
Standard
0.20 - 0.470 (0.0079 - 0.0185)
Limit
0.50 (0.0197)
Main journal dia. “Dm”
Grade No. 0
49.956 - 49.964 (1.9668 - 1.9671)
Grade No. 1
49.948 - 49.956 (1.9665 - 1.9668)
Grade No. 2
49.940 - 49.948 (1.9661 - 1.9665)
EM-106
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
*: Total indicator reading
MAIN BEARING
Standard size
Unit: mm (in)
Undersize
Unit: mm (in)
Bearing Clearance
Unit: mm (in)
CONNECTING ROD BEARING
Standard Size
Unit: mm (in)
Undersize
Unit: mm (in)
Pin journal dia. “Dp”
Grade No. 0
39.968 - 39.974 (1.5735 - 1.5738)
Grade No. 1
39.962 - 39.968 (1.5733 - 1.5735)
Grade No. 2
39.956 - 39.962 (1.5731 - 1.5733)
Out-of-round (X
−
Y)
Standard
Less than 0.003 (0.0001)
Limit
Less than 0.005 (0.0002)
Taper (A
−
B)
Standard
Less than 0.004 (0.0002)
Limit
Less than 0.005 (0.0002)
Runout [TIR*]
Standard
Less than 0.04 (0.0016)
Limit
Less than 0.05 (0.002)
Free end play
Standard
0.060 - 0.260 (0.0024 - 0.0102)
Limit
0.3 (0.012)
Grade No.
Thickness
Identification color
0
1.826 - 1.830 (0.0719 - 0.0720)
Black
1
1.830 - 1.834 (0.0720 - 0.0722)
Red
2
1.834 - 1.838 (0.0722 - 0.0724)
Green
3
1.838 - 1.842 (0.0724 - 0.0725)
Yellow
4
1.842 - 1.846 (0.0725 - 0.0727)
Blue
Thickness
0.25 (0.0098)
1.960 - 1.964 (0.0772 - 0.0773)
0.50 (0.0197)
2.085 - 2.089 (0.0821 - 0.0822)
Main bearing clearance
Standard
0.020 - 0.044 (0.0008 - 0.0017)
Limit
0.1 (0.004)
Grade No.
Thickness
Identification color or number
0
1.503 - 1.506 (0.0592 - 0.0593)
Black
1
1.506 - 1.509 (0.0593 - 0.0594)
Red
2
1.509 - 1.512 (0.0594 - 0.0595)
Green
Grade No.
Thickness
Identification color or number
0.08 (0.0031)
1.542 - 1.546 (0.0607 - 0.0609)
—
0.12 (0.0047)
1.562 - 1.566 (0.0615 - 0.0617)
—
0.25 (0.0098)
1.627 - 1.631 (0.0641 - 0.0642)
—
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-107
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Bearing Clearance
Unit: mm (in)
MISCELLANEOUS COMPONENTS
Unit: mm (in)
*: Total indicator reading
Tightening Torque
EBS00QEW
*1: Parts to be tightened in particular orders.
1)-: Order of tightening when tightening two or more times separately.
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*
2
Connecting rod bearing clear-
ance
Standard
0.014 - 0.039 (0.0006 - 0.0015)
Limit
0.1 (0.004)
Flywheel runout [TIR*]
Less than 0.1 (0.004)
Camshaft sprocket runout [TIR*]
Intake
Less than 0.2 (0.008)
Exhaust
Less than 0.15 (0.0059)
Mass air flow sensor
8.4 - 10.8 (0.9 - 1.1, 75 - 95)*
2
Resonator
3.8 - 4.5 (0.39 - 0.45, 34 - 39)*
2
Air cleaner case lower
3.8 - 4.5 (0.39 - 0.46, 34 - 39)*
2
Intake manifold
16.7 - 23.5 (1.7 - 2.4, 13 - 17)
Intake manifold collector
7.0 - 9.5 (0.71 - 0.97, 62 - 84)*
2
Intake manifold support
16.7 - 23.5 (1.7 - 2.4, 13 - 17)
Electric throttle control actuator
17.7 - 21.6 (1.8 - 2.2, 13 - 15)
Exhaust manifold
25.5 - 29.4 (2.6 - 2.9, 19 - 21)
Exhaust manifold cover
6.3 - 8.3 (0.64 - 0.85, 56 - 73)*
2
Heated oxygen sensor
58.8 - 78.4 (6.0 - 7.9, 44 - 57)
Ground nut
79.4 (8.1, 59)
Oil pan
6.28 - 8.34 (0.64 - 0.85, 56 - 73)*
2
Oil pan drain plug
29.4 - 39.2 (3.0 - 3.9, 22 - 28)
Oil strainer
6.28 - 8.34 (0.64 - 0.85, 56 - 73)*
2
Ignition coil
3.8 - 5.0 (0.38 - 0.51, 33 - 44)*
2
Spark plug
19.6 - 29.4 (2.0 - 3.0, 15 - 21)
*1
Fuel tube
1)
11.8 - 13.7 (1.2 - 1.4, 9 - 10)
2)
16.7 - 23.5 (1.7 - 2.4, 12 - 17)
Rocker cover
2.0 - 3.9 (0.20 - 0.40, 17.4 - 34.7)*
2
Intake valve timing control solenoid valve
6.3 - 8.3 (0.64 - 0.85, 56 - 73)*
2
Camshaft position sensor (PHASE)
7.2 - 10.8 (0.73 - 1.1, 64 - 95) *
2
Camshaft sprocket (INT)
78.4 - 88.2 (8.0 - 9.0, 58 - 65)
Camshaft sprocket (EXH)
98.1 - 127.5 (10.0 - 13.0, 73 - 94)
*1
Camshaft bracket
1)
2.0 (0.2, 18) *
2
2)
5.9 (0.6, 52) *
2
3)
9.0 - 11.8 (0.92 - 1.20, 80 - 104)*
2
Crankshaft pulley
132.4 - 152.0 (14.0 - 15.0, 98 - 112)
Front cover
6.92 - 9.5 (0.71 - 0.96, 62 - 84)*
2
Timing chain tension guide
15.7 - 20.6 (1.6 - 2.1, 12 - 15)
EM-108
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
*1
Cylinder head
1)
29.4 (3.0, 22)
2)
58.8 (6.0, 43)
3)
0 (0.0, 0)
4)
27.4 - 31.4 (2.8 - 3.2, 21 - 23)
5)
50
°
- 55
°
(Angle tightening)
Cylinder head front cover
7.0 - 9.5 (0.72 - 0.96, 62 - 84)*
2
Flywheel (M/T)
83.4 - 93.2 (8.5 - 9.5, 62 - 68)
Drive plate (A/T)
93.2 - 103 (9.5 - 10.5, 69 - 75)
*1
Connecting rod bearing cap
1)
13.72 - 15.68 (1.4 - 1.5, 10.2 - 11.5)
2)
35
°
- 40
°
(Angle tightening)
Knock sensor
20.6 - 26.5 (2.1 - 2.7, 15 - 20)
Crankshaft position sensor (POS)
7.2 - 10.8 (0.8 - 1.1, 64 - 95)*
2
Rear oil seal retainer
6.3 - 8.3 (0.65 - 0.84, 56 - 73)*
2
Signal plate
7.6 - 9.2 (0.78 - 0.93, 68 - 81)*
2
PRECAUTIONS
EM-109
[YD]
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[YD]
PRECAUTIONS
PFP:00001
Precautions for Drain Coolant
EBS00QEX
●
Drain coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping
EBS00QEY
●
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
EBS00QEZ
●
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
EBS00QF0
●
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and Installation
EBS00QF1
●
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
EBS00QF2
●
Use an angle wrench for the final tightening of the following engine parts:
–
Cylinder head bolts
–
Main bearing cap bolts
–
Connecting rod cap nuts
–
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-110
[YD]
PRECAUTIONS
Precautions for Liquid Gasket
EBS00QF3
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.
Occasionally, it should be applied outside the holes. Make sure
to read this 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 this service manual, observe
them.
PBIC0275E
PBIC0003E
EMA0622D
SEM159F
PREPARATION
EM-111
[YD]
C
D
E
F
G
H
I
J
K
L
M
A
EM
PREPARATION
PFP:00002
Special Service Tools
EBS00QF4
Tool number
Tool name
Description
ST0501S000
Engine stand assembly
1 ST05011000
Engine stand
2 ST05012000
Base
Disassembling and assembling
KV10106500
Engine stand shaft
KV11105900
Engine sub-attachment
Used with KV10106500
KV10115600
Valve oil seal drift
Installing valve oil seal
Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
Unit: mm (in)
KV10107902
Valve oil seal puller
1 KV10116100
Valve oil seal puller adapter
Removing valve oil seal
KV11103000
Injection pump drive gear puller
Removing crankshaft pulley
NT042
NT028
NT799
NT603
NT605
NT676
EM-112
[YD]
PREPARATION
KV101056S0
Ring gear stopper
1 KV10105630
Adapter
2 KV10105610
Plate
Preventing crankshaft from rotating
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)
KV101151S0
Lifter stopper set
1 KV10115110
Camshaft pliers
2 KV10115120
Lifter stopper
Changing valve lifter shims
ST16610001
Pilot bushing puller
Removing crankshaft pilot bushing
KV10111100
Seal cutter
Removing steel oil pan and rear timing chain
case
WS39930000
Tube presser
Pressing the tube of liquid gasket
KV10112100
Angle wrench
Tightening bolts for bearing cap, cylinder
head, etc.
KV10109300
Pulley holder
a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.
Tool number
Tool name
Description
NT617
NT041
NT045
NT046
NT052
NT014
NT628
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