Almera Tino V10 (2003 year). Manual — part 204
PREPARATION
EM-113
[YD]
C
D
E
F
G
H
I
J
K
L
M
A
EM
KV11106010
Hexagon wrench
a: 5 mm (0.20 in) (Face to face)
b: 20 mm (0.79 in)
KV11106020
Hexagon wrench
a: 6 mm (0.24 in) (Face to face)
b: 20 mm (0.79 in)
KV11106030
Positioning stopper pin
a: 6 mm (0.24 in) dia.
b: 80 mm (3.15 in)
KV11106040
TORX wrench
a: T70
b: 26 mm (1.02 in)
KV11106050
Hexagonal wrench
a: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)
Removing and installing mounting bolts of
fuel pump sprocket
KV11106060
Sprocket holder
Holding fuel pump sprocket
Tool number
Tool name
Description
NT801
NT803
NT804
NT805
SBIA0224E
SBIA0225E
EM-114
[YD]
PREPARATION
Commercial Service Tools
EBS00QF5
Tool name
Description
Valve seat cutter set
Finishing valve seat dimensions
Piston ring compressor
Installing piston assembly into cylinder bore
Piston ring expander
Removing and installing piston ring
TORX socket
Standard Universal
NT048
NT044
NT030
NT807
NT808
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
EM-115
[YD]
C
D
E
F
G
H
I
J
K
L
M
A
EM
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting —Engine Noise
EBS00QF6
SBIA0148E
EM-116
[YD]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Use the Chart Below to Help You Find the Cause of the Symptom.
EBS00QF7
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 oil clearance
Camshaft runout
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil pan
Slap or
knock
—
A
—
B
B
—
Piston pin
noise
Piston to piston pin
clearance
Connecting rod bush-
ing oil clearance (Small
end)
Slap or
rap
A
—
—
B
B
A
Piston
slap noise
Piston to cylinder bore
clearance
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 oil clearance (Small
end)
Connecting rod bear-
ing oil 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
EM-117
[YD]
C
D
E
F
G
H
I
J
K
L
M
A
EM
DRIVE BELTS
PFP:02117
Checking Drive Belts
EBS00QF8
●
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 contact-
ing surfaces and edge areas.
●
When measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point ( ).
CAUTION:
●
When checking belt deflection immediately after installa-
tion, first adjust it to the specified value. Then, after turn-
ing the crankshaft two turns or more, re-adjust to the
specified value to avoid variation in deflection between
pulleys.
●
Tighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
*: When engine is cold.
Tension Adjustment
EBS00QF9
●
Adjust belts with the parts shown below.
CAUTION:
●
When a new belt is installed as a replacement, adjust it to the value specified under “New” value
because of insufficient adaptability with pulley grooves.
●
If the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
●
When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid vari-
ation in deflection between pulleys.
●
Make sure the belts are fully fitted into the pulley grooves during installation.
●
Handle with care to avoid smearing the belts with oil or cooling water etc.
●
Do not twist or bend the belts with strong force.
JEM249G
Applied belt
Belt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New
Adjusted
Limit for re-adjusting
Air conditioner compressor belt
4 - 5 (0.16 - 0.20)
6 - 7 (0.24 - 0.28)
8.5 (0.335)
Alternator and water pump belt
9.0 - 10.5 (0.354 - 0.413)
11.0 - 12.5 (0.433 - 0.492)
16.5 (0.650)
Applied belt
Belt adjustment method
Air conditioner compressor belt
Adjusting bolt on idler pulley
Alternator water pump belt
Adjusting bolt on alternator
EM-118
[YD]
DRIVE BELTS
AIR CONDITIONER COMPRESSOR BELT
1.
Remove RH splash cover (with undercover attached).
2.
Loosen idler pulley lock nut (A).
3.
Turn adjusting bolt (B) to adjust.
●
Refer to
EM-117, "Checking Drive Belts"
.
4.
Tighten lock nut (A).
ALTERNATOR AND WATER PUMP BELT
1.
Loosen adjusting lock nut (C).
2.
Loosen alternator fixing bolts (D) (each on front and rear).
3.
Turn adjusting bolt (E) to adjust.
●
Refer to
.
4.
Tighten nut (C) and bolt (D) in this order.
Removal and Installation
EBS00QFA
REMOVAL
1.
Loosen each belt. Refer to
.
2.
Remove air conditioner compressor belt.
3.
Remove alternator and water pump belt.
INSTALLATION
1.
Install each belt on pulley in reverse order of removal.
2.
Adjust belt tension. Refer to
.
3.
Tighten nuts and bolts provided for adjustment to the specified torque.
4.
Check again that each belt tension is as specified.
Nut A:
: 31 - 39 N·m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)
JEM251G
Nut C:
: 19 - 24 N·m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
Bolt D:
: 44 - 57 N·m (4.4 - 5.9 kg-m, 32 - 42 ft-lb)
AIR CLEANER AND AIR DUCT
EM-119
[YD]
C
D
E
F
G
H
I
J
K
L
M
A
EM
AIR CLEANER AND AIR DUCT
PFP:16500
Removal and Installation
EBS00QFB
REMOVAL
1.
Remove mass air flow sensor harness clamp.
2.
Remove harness connector from mass air flow sensor.
3.
Remove air duct, air cleaner case/ mass air flow sensor.
●
Add marks as necessary for easier installation.
4.
Remove mass air flow sensor from air cleaner case.
CAUTION:
Handle mass air flow sensor with following cares.
●
Do not shock it.
●
Do not disassemble it.
●
Do not touch its sensor.
INSTALLATION
1.
Attach each joint aligning marks put at removal. Screw clamps firmly.
2.
Install in the reverse order of removal.
CHANGING AIR CLEANER ELEMENT
1.
Remove air cleaner case.
MBIA0032E
1.
Air cleaner case (upper)
2.
Clamp
3.
Air duct
4.
Mass air flow sensor
5.
Grommet
6.
Air duct side
7.
Air cleaner case (lower)
8.
Air cleaner element
EM-120
[YD]
AIR CLEANER AND AIR DUCT
2.
Remove clips and lift up air cleaner upper case.
3.
Remove air cleaner element.
CHARGE AIR COOLER
EM-121
[YD]
C
D
E
F
G
H
I
J
K
L
M
A
EM
CHARGE AIR COOLER
PFP:14461
Removal and Installation
EBS00QFC
REMOVAL
1.
Remove front bumper. Refer to BT-7, “Body Front End”.
2.
Remove battery and tray (with fusible link and fuse box).
3.
Remove air cleaner and air duct. Refer to
EM-119, "Removal and Installation"
.
4.
Remove air inlet hose and tube.
5.
Remove charge air cooler.
6.
Remove and install with bottom bracket as an assembly.
MBIA0001E
1.
Hose clamp
2.
Air inlet hose
3.
Air inlet tube
4.
Charge air cooler
5.
Bracket
EM-122
[YD]
CHARGE AIR COOLER
CAUTION:
When removing charge air cooler, close opening on turbocharger and on intake manifold with shop
cloth or other suitable material.
INSPECTION AFTER REMOVAL
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
●
Be careful not to deform core fins.
INSTALLATION
Pay attention to identification mark and direction when installing air inlet hose and tubes. Refer to
.
INTAKE MANIFOLD
EM-123
[YD]
C
D
E
F
G
H
I
J
K
L
M
A
EM
INTAKE MANIFOLD
PFP:14003
Removal and Installation
EBS00QFD
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the coolant when the engine is hot.
1.
Drain engine coolant. Refer to LC-40, “Changing Engine Coolant”.
2.
Remove engine cover. Refer to
EM-160, "Removal and Installation"
3.
Remove air duct. Refer to
EM-119, "Removal and Installation"
.
4.
Remove air inlet hose and pipe. Refer to
EM-121, "Removal and Installation"
.
5.
Remove exhaust manifold cover.
6.
Disconnect electronic EGR volume control valve water hoses and harness.
7.
Disconnect heater hose.
8.
Remove EGR tube.
MBIA0002E
1.
Fuel gallery
2.
Water hose
3.
Electronic EGR volume control valve
4.
Gasket
5.
EGR passage
6.
EGR support
7.
Water pipe
8.
EGR tube
9.
Intake manifold
EM-124
[YD]
INTAKE MANIFOLD
9.
Remove injection tube center. Refer to
EM-147, "Removal and Installation"
.
10. Remove water pipe.
11. Remove fuel hose.
●
To prevent fuel from flowing out, plug the opening of the hose with a blind plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
12. Loosen bolts and nuts in the reverse order of that shown in the
figure.
13. Remove electronic EGR volume control valve from intake mani-
fold.
INSPECTION AFTER REMOVAL
Surface Distortion
●
Check distortion on the mounting surface with a straightedge
and feeler gauge.
INSTALLATION
Following instructions below, install in reverse order of removal.
1.
Install electronic EGR volume control valve.
●
Handle with care avoiding any shocks.
●
Do not disassemble or adjust.
2.
Install intake manifold.
●
Tighten fixing bolts and nuts in numerical order as shown in the figure.
●
When stud bolts come off, install with the following torque.
PBIC0719E
Limit
: 0.1 mm (0.004 in)
PBIC0723E
: 10 - 11 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)
INTAKE MANIFOLD
EM-125
[YD]
C
D
E
F
G
H
I
J
K
L
M
A
EM
3.
Install water hose.
●
Install water hose by referring to identification marks avoiding
twisting.
●
When an insert stopper is not provided with the pipe, insert
the hose up to dimension A. When the pipe is shorter than
dimension A, insert hose fully until it reaches the end.
●
When an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
●
When marking is provided on the pipe, insert hose until it cov-
ers half of the marking.
4.
Install remaining parts in reverse order of removal.
5.
Before starting engine, bleed air from fuel piping. Refer to FE-
18, “Bleeding Fuel Filter”.
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
Dimension A
: 25 - 30 mm (0.984 - 1.181 in)
MBIA0081E
EM-126
[YD]
CATALYST
CATALYST
PFP:20905
Removal and Installation
EBS00QFE
MBIA0003E
1.
Insulator
2.
Catalyst
3.
Catalyst rear diffuser
4.
Gasket
CATALYST
EM-127
[YD]
C
D
E
F
G
H
I
J
K
L
M
A
EM
REMOVAL
1.
Remove engine undercover.
2.
Drain engine coolant. Refer to LC-40, “Changing Engine Coolant”.
3.
Remove radiator upper and lower hoses.
4.
Remove radiator and radiator fan. Refer to LC-39, “Radiator”.
5.
Remove insulators.
6.
Remove water inlet pipe.
7.
Disconnect exhaust front tube.
8.
Remove catalyst.
CAUTION:
Do not disassemble.
Install two locking pins into both sides of the catalyst. Be careful not to confuse locking pins with insulator
mounting bolts.
INSTALLATION
Install in reverse order of removal.
●
Pushing gussets against the oil pan and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque.
1.
Insulator
2.
Catalyst
3.
Catalyst rear diffuser
4.
Gasket
MBIA0004E
Catalyst locking pin
: Flange bolt (black)
Insulator mounting bolt
: Washer bolt (silver or yellow)
EM-128
[YD]
EXHAUST MANIFOLD AND TURBOCHARGER
EXHAUST MANIFOLD AND TURBOCHARGER
PFP:14004
Removal and Installation
EBS00QFF
MBIA0005E
1.
Electronic EGR volume control valve 2.
Gasket
3.
EGR tube
4.
Air inlet pipe
5.
Exhaust manifold and turbocharger
assembly
6.
Oil return hose
7.
Turbo insulator
8.
Exhaust manifold insulator
9.
Air inlet pipe
10.
Oil feed tube
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст