Almera Tino V10 (2003 year). Manual — part 198
AIR CLEANER AND AIR DUCT
EM-17
[QG]
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Changing Air Cleaner Element
EBS00QE8
The viscous paper type filter does not need cleaning between
renewals.
SMA373C
EM-18
[QG]
INTAKE MANIFOLD
INTAKE MANIFOLD
PFP:14003
Removal and Installation
EBS00QE9
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the coolant when the engine is hot.
1.
Release fuel pressure.
Refer to
EC-52, "FUEL PRESSURE RELEASE"
(WITH EURO-OBD),
(WITHOUT EURO-OBD).
2.
Remove air duct and air cleaner case.
Refer to
EM-16, "Removal and Installation"
.
3.
Disconnect harness on engine top surface, and move it aside.
4.
Disconnect fuel injector/fuel tube assembly from intake manifold, and move it aside.
●
It is not necessary to disconnect fuel hose.
5.
Disconnect the following vacuum hoses.
6.
Disconnect blow-by hose (between intake manifold collector and rocker cover).
KBIA1363E
1.
Electric throttle control actuator
2.
Gasket
3.
Intake manifold collector
4.
EVAP canister purge volume control
solenoid valve
5.
Vacuum hose
6.
Vacuum hose
7.
Hose clamp
8.
Intake manifold support (front)
9.
Harness bracket
10. Vacuum hose
11. Intake manifold
12. PCV hose
13. Gasket
14. Vacuum hose
15. Gasket
16. Intake manifold support (rear)
17. Harness bracket
18. Intake manifold support (engine rear)
19. Grounding wire
INTAKE MANIFOLD
EM-19
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7.
Loosen mounting bolts in reverse order shown in figure to
remove electric throttle control actuator.
CAUTION:
●
Do not shock it.
●
Do not disassembly and adjusting.
NOTE:
Remove intake manifold collector and electronic throttle control
as a single assembly, then remove electronic throttle control
itself.
8.
Remove bolt on cylinder head side of intake manifold collector.
9.
Loosen intake manifold collector nuts and bolts in reverse of the
order shown in the figure.
●
Do not remove intake manifold collector at this stage.
10. Move harness, which is fixed on intake manifold support, with bracket.
11. Remove intake manifold supports (rear, front, engine rear).
12. Loosen nuts and bolts in reverse order shown in the figure, and
remove intake manifold from cylinder head.
13. Disconnect intake manifold collector from intake manifold, and
pull out between engine and body.
PBIC0534E
KBIA1365E
KBIA1366E
PBIC0535E
EM-20
[QG]
INTAKE MANIFOLD
INSPECTION AFTER REMOVAL
Surface Distortion
●
Using straightedge and feeler gauge, inspect surface distortion
of intake manifold collector and intake manifold surface.
INSTALLATION
●
Install in the reverse order of removal paying attention to the following.
Tightening Intake Manifold
●
Temporarily attach before installing intake manifold collector.
●
Tighten in numerical order as shown in the figure.
Tightening Intake Manifold Collector
●
Temporarily attach before installing intake manifold.
●
Tighten in numerical order as shown in the figure.
Installation of Electric Throttle Control Actuator
●
Tighten mounting bolts for electric throttle control actuator in
numerical order shown in figure.
CAUTION:
When electric throttle control actuator is replaced, perform
idle air volume learning.
●
Refer to BASIC SERVICE PROCEDURE,
(WITH EURO-OBD),
(WITHOUT EURO-OBD).
Limit
: 0.1 mm (0.004 in)
PBIC0536E
PBIC0535E
KBIA1366E
: 17.7 - 21.6 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
PBIC0534E
EXHAUST MANIFOLD AND CATALYTIC CONVERTER
EM-21
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EXHAUST MANIFOLD AND CATALYTIC CONVERTER
PFP:14004
Removal and Installation
EBS00QEA
MBIA0035E
1.
Heated oxygen sensor 1
2.
Ground nut
3.
Gasket
4.
Stud bolt
5.
Exhaust manifold and catalytic con-
verter assembly
6.
Support
7.
Exhaust manifold cover
8.
Heated oxygen sensor harness
bracket
EM-22
[QG]
EXHAUST MANIFOLD AND CATALYTIC CONVERTER
REMOVAL
1.
Remove undercover.
2.
Disconnect exhaust front tube from catalytic converter. Refer to FE-11, “Exhaust System”.
3.
Remove exhaust manifold support from both sides of catalytic converter.
4.
Disconnect heated oxygen sensor harness connector.
5.
Remove heated oxygen sensors.
●
Follow below steps to remove each heated oxygen sensor.
1.
Heated oxygen sensor 1 (bank 2)
2.
Ground nut
3.
Heated oxygen sensor 1 (bank 1)
4.
Stud bolt
5.
Gasket
6.
Exhaust manifold and catalytic con-
verter assembly
7.
Support
8.
Heated oxygen sensor 2 (bank 1)
9.
Heated oxygen sensor 2 (bank 2)
10.
Heated oxygen sensor harness
bracket
11. Exhaust manifold cover
MBIA0036E
EXHAUST MANIFOLD AND CATALYTIC CONVERTER
EM-23
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●
Using heated oxygen sensor wrench, remove heated oxygen
sensor.
CAUTION:
●
Be careful not to damage heated oxygen sensor.
●
When using heated oxygen sensor wrench, tighten to the
middle of specified torque because length of tool may
induce sight indication increase. (Do not tighten to the
maximum specified torque)
●
Do not over torque the heated oxygen sensor. Doing so
may cause damage to the heated oxygen sensor, result-
ing in the MI coming on.
6.
Remove exhaust manifold cover.
7.
Loosen mounting nuts in reverse order shown in figure to
remove exhaust manifold and catalytic converter assembly.
INSPECTION AFTER REMOVAL
Surface Distortion
●
Use a reliable straightedge and feeler gauge to check the flat-
ness of exhaust manifold fitting surface.
INSTALLATION
●
Install in the reverse order of removal after this step.
●
Tighten mounting nuts for exhaust manifold and catalytic con-
verter assembly in order shown in figure.
●
Before installing exhaust manifold support, apply liquid gasket to
contact surface on engine side.
Use Genuine Liquid Gasket or equivalent.
Installation of Heated Oxygen Sensor
CAUTION:
●
Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen
sensor, resulting in the MI coming on.
PBIC0541E
PBIC0542E
Limit
: 0.3 mm (0.012 in)
PBIC0543E
PBIC0542E
EM-24
[QG]
EXHAUST MANIFOLD AND CATALYTIC CONVERTER
Disassembly and Assembly
EBS00QEB
M/T MODELS
A/T MODELS
DISASSEMBLY
1.
Remove catalytic converter cover.
2.
Disconnect exhaust manifold and catalytic converter.
CAUTION:
Be careful not to damage catalytic converter.
ASSEMBLY
●
Assemble in reverse order of disassembly.
YEM049
1.
Exhaust manifold
2.
Catalytic converter
3.
Catalytic converter cover
PBIC0546E
1.
Exhaust manifold
2.
Gasket
3.
Converter cap
4.
Wire mesh washer
5.
Catalytic converter cover
6.
Catalytic converter
7.
Heated oxygen sensor harness
bracket
OIL PAN AND OIL STRAINER
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OIL PAN AND OIL STRAINER
PFP:11110
Removal and Installation
EBS00QEC
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
1.
Remove engine RH undercover.
2.
Drain engine oil. Refer to LC-8, “Changing Engine Oil”.
3.
Remove exhaust front tube. Refer to FE-11, “Exhaust System”.
4.
Using a transmission jack, be sure to support the bottom of
transsexual, and remove center member.
5.
Remove gusset and engine rear plate (lower) [A/T vehicle].
6.
Loosen and remove mounting nuts and bolts in reverse order
shown in figure.
MBIA0037E
1.
Oil strainer
2.
Washer
3.
Drain plug
4.
Oil pan
SEM067F
SEM072F
EM-26
[QG]
OIL PAN AND OIL STRAINER
7.
Insert Tool (Seal cutter) between oil pan and cylinder block.
Slide tool by tapping on the side of the tool with a hammer.
Remove oil pan.
8.
Remove oil strainer.
INSTALLATION
1.
Install oil strainer.
NOTE:
Gasket and O-ring are not used for sealed area with oil pump.
2.
Install oil pan drain plug.
●
Referring to “Components”, install drain plug washer.
3.
Apply a continuous bead of liquid gasket to position shown in figure.
Use Genuine Liquid Gasket or equivalent.
4.
Tighten mounting nuts and bolts in order shown in figure.
●
Install mounting nuts and bolts as follows.
5.
Install center member.
Refer to ENGINE ASSEMBLY,
.
6.
Install remaining parts in the reverse order of removal.
INSPECTION AFTER INSTALLATION
●
Check for leakage of engine oil when engine is warmed.
●
Pour engine oil or start engine at least 30 minutes after oil pan is installed.
SEM365EA
PBIC0549E
Mounting bolt:
[Shank length under
head 10 mm (0.39 in)]
: Nos. 1 - 10, 13, 14
[Shank length under
head 12 mm (0.47 in)]
: Nos. 11, 12
SEM072F
IGNITION COIL
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IGNITION COIL
PFP:22448
Removal and Installation
EBS00QED
REMOVAL
1.
Remove ignition coil harness connector from ignition coil.
2.
Remove ignition coil.
CAUTION:
●
Do not shock it.
●
Do not disassemble it.
INSTALLATION
●
Install in the reverse order of removal.
MBIA0038E
1.
Ignition coil
2.
Spark plug
3.
Rocker cover
EM-28
[QG]
SPARK PLUG (CONVENTIONAL)
SPARK PLUG (CONVENTIONAL)
PFP:22401
Removal and Installation
EBS00QEE
REMOVAL
1.
Disconnect ignition coil harness connector from ignition coil.
2.
Remove ignition coil.
3.
Remove spark plugs with a spark plug wrench (commercial ser-
vice tool).
Spark plug
INSPECTION AFTER REMOVAL
Check spark plug gap. Adjust or replace if necessary.
●
Use a wire brush for cleaning, if necessary.
INSTALLATION
Install in the reverse order of removal, paying attention to the following.
Make
NGK
Champion
Standard type
LFR5A-11
REC10YC4
Hot type
LFR4A-11
—
Cold type
LFR6A-11
—
SMA581C
Standard
: 1.0 - 1.1 mm (0.039 - 0.043 in)
SMA476
Spark plug:
: 19.6 - 29.4 N·m (2.0 - 3.0 kg-m, 15 - 21 ft-lb)
FUEL INJECTOR AND FUEL TUBE
EM-29
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FUEL INJECTOR AND FUEL TUBE
PFP:16600
Removal and Installation
EBS00QEF
CAUTION:
●
Apply new engine oil when installing the parts that specified to do so in the figure.
●
Do not remove or disassembly parts unless instructed as shown in the figure.
REMOVAL
1.
Release fuel pressure. Refer to
EC-52, "FUEL PRESSURE RELEASE"
(WITH EURO-OBD),
(WITHOUT EURO-OBD).
2.
Disconnect harness for fuel injector, and move it aside.
3.
Remove fuel hose.
CAUTION:
After removal, install blind plug to fuel hose to prevent the fuel from draining.
4.
Remove fuel tube and injector assembly with the following pro-
cedure:
a.
Loosen mounting bolts in reverse order shown in figure.
b.
Pull out fuel injector/fuel tube assembly toward engine rear side.
MBIA0039E
1.
Fuel tube
2.
Fuel feed hose
3.
O-ring
4.
Clip
5.
Fuel injector
6.
Intake manifold
PBIC0617E
EM-30
[QG]
FUEL INJECTOR AND FUEL TUBE
CAUTION:
Do not touch fuel injector nozzle with intake manifold or other parts.
5.
Remove fuel injector from fuel tube.
●
Release clip and remove it.
●
Pull fuel injector straight out of fuel tube.
CAUTION:
●
Be careful not to damage nozzle part.
●
Avoid any impact such as a dropping.
●
Do not disassemble or adjust it.
INSTALLATION
1.
When installing O-ring to fuel injector, follow instructions described below.
CAUTION:
●
Handle O-ring with bare hands. Never wear gloves.
●
Lubricate O-ring with new engine oil.
●
Do not clean O-ring with solvent.
●
Make sure that O-ring and its mating part are free of foreign material.
●
Be careful not to scratch it with a tool or fingernails during installation. Also be careful not to
twist or stretch O-ring. If O-ring is stretched while being attached, do not insert it into fuel tube
immediately.
●
Insert O-ring straight into fuel tube. Do not angle or twist it.
2.
Install fuel injector to fuel tube with the following procedure.
a.
Insert clip into clip mounting groove on fuel injector.
●
Insert clip so that lug “A” of fuel injector matches notch “A” of
the clip.
CAUTION:
●
Do not reuse clip. Replace it with a new one.
●
Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b.
Insert fuel injector into fuel tube with clip attached.
●
Insert it while matching it to the axial center.
●
Insert fuel injector so that lug “B” of fuel tube matches notch
“B” of the clip.
●
Make sure that fuel tube flange is securely fixed in flange fix-
ing groove on clip.
c.
Make sure that installation is complete by checking that fuel
injector does not rotate or come off.
PBIC0620E
PBIC1021E
FUEL INJECTOR AND FUEL TUBE
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3.
Tighten mounting bolts in two steps in numerical order shown in
figure.
4.
Install fuel feed hose.
CAUTION:
Install hose clamp avoiding interference with bulge, and
securely tighten it
5.
Install remaining parts in the reverse order of removal.
INSPECTION AFTER INSTALLATION
●
Check for fuel leakage with following procedure.
1.
Turn ignition switch ON (do not start engine), and check connections for leakage by applying fuel pressure
to fuel piping.
2.
Start engine, and re-check connections for fuel leakage by increasing engine speed.
1st step : 11.8 - 13.7 N·m (1.2 - 1.4 kg-m, 9 - 10 ft-lb)
2nd step : 16.7 - 23.5 N·m (1.7 - 2.4 kg-m, 12 - 17 ft-lb)
PBIC0617E
EM-32
[QG]
ROCKER COVER
ROCKER COVER
PFP:13264
Removal and Installation
EBS00QEG
CAUTION:
Apply new engine oil when installing the parts that specified to do so in the figure.
REMOVAL
1.
Move harnesses on top surface and right side of rocker cover, and move them aside.
2.
Remove ignition coil. Refer to
EM-27, "Removal and Installation"
.
3.
Disconnect PCV hoses on rocker cover side.
4.
If necessary, remove PCV control valve.
5.
If necessary, remove intake valve timing control solenoid valve and camshaft position sensor (PHASE).
CAUTION:
●
Do not shock it.
●
Do not disassemble it.
●
Tip of camshaft position sensor (PHASE) generates strong magnetic fields. Keep it away from
metal particles or objects affected by magnetic fields.
MBIA0040E
1.
PCV hose
2.
Rocker cover
3.
Grommet
4.
PCV control valve
5.
PCV hose
6.
Intake valve timing control solenoid
valve
7.
O-ring
8.
Oil filter cap
9.
Gasket
10. Gasket
11. Rocker cover oil seal
12. Gasket
13. O-ring
14. Camshaft position sensor (PHASE)
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