Almera Tino V10 (2003 year). Manual — part 200
CAMSHAFT
EM-49
[QG]
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●
Thickness of new adjusting shim is indicated with stamped
mark on its back.
10. Install selected adjusting shim to valve lifter.
CAUTION:
Install shim with its stamp mark facing the valve lifter.
11. Using camshaft pliers (special service tool), compress valve spring to remove lifter stopper (special ser-
vice tool).
12. Turn crankshaft a couple of times by hand.
13. Check that valve clearance is within standards.
Stamped mark
Thickness of shim
200
202
:
:
298
2.00 mm (0.0787 in)
2.02 mm (0.0795 in)
:
:
2.98 mm (0.1173 in)
Setting of adjusting shim thickness (at factory)
: Thickness 2.00 to 2.98 mm (0.0787 - 0.1173 in) [spacing of 0.02 mm (0.0008 in)] 50 types
MBIB0230E
EM-50
[QG]
TIMING CHAIN
TIMING CHAIN
PFP:13028
Removal and Installation
EBS00QEJ
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1.
Place vehicle on lift.
MBIA0044E
1.
Cylinder head front cover
2.
Camshaft sprocket (INT)
3.
Washer
4.
Camshaft sprocket (EXH)
5.
Chain tensioner
6.
Chain slack guide
7.
O-ring
8.
Power steering pump adjusting bar
9.
Crankshaft pulley
10. Front oil seal
11. Front cover
12. Chain tension guide
13. Dowel pin
14. Timing chain
15. Oil pump drive spacer
16. Crankshaft sprocket
17. O-ring (with collar)
18. Auxiliary bolt of cylinder head
TIMING CHAIN
EM-51
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2.
Disconnect battery ground cable.
3.
Remove undercover, front RH wheel and RH splash cover.
4.
Drain engine coolant from radiator and cylinder block. Refer to LC-18, “Changing Engine Coolant”.
5.
Drain engine oil from oil pan.
6.
Remove drive belt. Refer to
EM-15, "Removal and Installation"
.
7.
Remove power steering pump from adjusting bar.
8.
Remove alternator. SC-24, “Charging System”.
9.
Remove ignition coils. Refer to
EM-27, "Removal and Installation"
.
10. Remove rocker cover. Refer to
EM-32, "Removal and Installation"
.
11. Remove oil level gauge.
12. Remove exhaust front tube. Refer to FE-11, “Exhaust System”.
13. Remove center member.
14. Remove gusset.
15. Remove rear plate (lower) (A/T models).
16. Remove oil pan and oil strainer. Refer to
EM-25, "Removal and Installation"
.
17. For safe operation, and to reduce load to mount insulator, install removed center member again.
18. Remove engine front-side (right side of vehicle) engine mount. Refer to
EM-70, "Removal and Installation"
.
a.
Remove any parts that cause difficulties for operation around mount, or perform transfer.
b.
Support cylinder block bottom surface with a transmission jack.
CAUTION:
●
When applying jack, use a wooden block to avoid damage to oil pan mounting surface.
●
While performing following operations, support engine front-side with jack.
c.
Separate engine mounting insulator and bracket.
d.
Remove engine mounting bracket.
19. Remove cylinder head front cover.
●
Move harness which was previously fixed on front surface.
20. Remove auxiliary bolts of cylinder head.
21. Set the No. 1 cylinder to the compression TDC.
a.
Turn the crankshaft pulley clockwise, and align the timing indica-
tor of the gear case to the timing mark of the crankshaft pulley.
PBIC0557E
PBIC0750E
EM-52
[QG]
TIMING CHAIN
b.
Make sure that the camshaft sprocket mating mark is in the
position shown in the figure.
●
If the mating mark is not in position, turn the crankshaft pulley
once more and position it.
22. Remove crankshaft pulley with the following procedure:
a.
Secure crankshaft counter weight with handle of a hammer, and
loosen crankshaft pulley bolts.
CAUTION:
Take care to prevent foreign material from entering the
engine.
b.
Remove crankshaft pulley using crankshaft pulley puller (com-
mercial service tool).
CAUTION:
●
Hook tab onto back of crankshaft pulley only.
●
Do not remove crankshaft pulley bolt. Fully loosen, and
then use it as support point.
NOTE:
If oil pan is not removed, remove crankshaft pulley as follows.
i.
Remove rear plate (lower).
ii.
Engage drive plate ring gear with a flat-head screwdriver to fix
crankshaft in position, and loosen crankshaft pulley bolt.
iii.
Remove crankshaft pulley using crankshaft pulley puller (com-
mercial service tool).
23. Remove water pump pulley and idler pulley bracket assembly.
MBIB0194E
PBIC0565E
KBIA1437E
KBIA1438E
TIMING CHAIN
EM-53
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24. Remove front cover with the following procedure:
a.
To increase freedom of front cover posture during removal/
installation, pull oil pump drive spacer out through front oil seal.
●
Pull it straight out using long-nose priers or two flat-bladed
screwdrivers.
CAUTION:
Be careful not to damage side of oil pump drive spacer and
front oil seal lip.
b.
Remove power steering pump adjusting bar.
c.
Remove front cover carefully.
●
Remove mounting bolts A - E shown in figure.
NOTE:
Bolts C and E have been removed in step b.
CAUTION:
●
When removing, be careful not to damage or bend front
end of cylinder head gasket. Also after peeling off con-
tact face between front cover and gasket, their surfaces
shall be smooth.
●
If cylinder head gasket is damaged, replace it with new
one.
d.
Remove O-rings from front cover and cylinder block.
25. Pull two dowel pins for front cover out of cylinder block.
●
Heat them with industrial dryer sufficiently, then pull them out
using locking pliers.
NOTE:
This operation is performed as preparation operation for front
cover installation. This operation can be performed after
removal of timing chain.
26. If front oil seal is need to be replaced, remove it from front cover.
●
Insert a flat-bladed screwdriver in notch on oil seal mounting
point, and lift oil seal to remove.
NOTE:
Remove timing chain and its related parts with the following pro-
cedure:
27. Secure intake camshaft sprocket in most advanced position. Refer to
.
NOTE:
Removal of timing chain and related parts is described in following steps.
28. Remove chain tensioner. Refer to
.
29. Remove camshaft sprocket. Refer to
.
CAUTION:
After this step is completed, do not rotate crankshaft and camshaft separately in order to prevent
interference between valve and piston.
PBIC0566E
EMD0850D
PBIC0567E
PBIC0558E
EM-54
[QG]
TIMING CHAIN
30. Remove timing chain, timing chain slack guide and tension guide.
31. Remove crankshaft sprocket.
INSPECTION AFTER REMOVAL
Timing Chain
Check timing chain for cracks or serious wear. If a malfunction is
detected, replace it.
INSTALLATION
CAUTION:
●
Use a scraper to completely remove all liquid gasket adhering to mounting surface. De-grease and
clean with white gasoline.
●
After installation, wipe off any protruding liquid gasket.
1.
Install timing chain and its related parts with the following procedure:
●
For aligning positions for each sprocket and timing chain, and
installed condition of their related parts, refer to figure.
●
Install each sprocket with its mating mark facing engine front
side.
a.
Install timing chain and crankshaft sprocket.
●
Make sure that crankshaft key points straight up (No.1 cylin-
der is at TDC).
●
Hook timing chain on front end of camshaft so that it will not
fall off.
b.
Install timing chain slack guide and tension guide.
c.
Install camshaft sprocket. Refer to
.
d.
Install chain tensioner. Refer to
.
e.
Make sure again that mating marks are properly aligned.
f.
Temporarily install oil pump drive spacer, crankshaft pulley, and crankshaft pulley mounting bolt so that
crankshaft can be rotated.
g.
Install oil pump drive spacer, crankshaft pulley, and crankshaft pulley mounting bolts temporarily. Rotate
crankshaft clockwise several times to make sure it rotates normally. Refer to
.
h.
Rotate crankshaft clockwise several times, and check that there is no unusual condition.
i.
Remove parts temporarily installed in step f.
PBIC0282E
KBIA1398E
TIMING CHAIN
EM-55
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2.
Install front oil seal to front cover.
●
Install it so that identification letters on oil seal will face toward
front side of the engine.
●
Using an oil seal drift (commercial service tool), press oil seal
in until it is flush with end surface of mounting position.
●
Make sure that oil seal outer circumference is free from dam-
age and burr.
3.
Install front cover with the following procedure:
a.
Install O-ring to cylinder block.
b.
Using a flat-bladed screwdriver, apply a continuous bead of liq-
uid gasket to contact surface between cylinder head gasket
lower surface and cylinder block (2 locations shown in figure).
Use Genuine Liquid Gasket or equivalent.
c.
Apply a continuous bead of liquid gasket to back surface of front
cover (location shown in figure).
CAUTION:
●
Do not apply liquid gasket to groove A shown in figure.
●
Especially for locations indicated by * mark in figure,
strictly observe application range of liquid gasket.
d.
Apply liquid gasket to top surface of front cover lightly and
evenly.
Use Genuine Liquid Gasket or equivalent.
e.
Install O-ring to back surface of front cover.
f.
With socket of oil pump inner rotor placed on crankshaft top sur-
face (clearance between front cover top surface and cylinder
head gasket lower surface is secured), move front cover close to
cylinder block. (Right side in figure)
g.
Lift front cover at an angle and install it to mounting position so
that front cover will come in contact with both cylinder head gas-
ket lower surface and cylinder block front surface at the same
time. (Right side in figure)
CAUTION:
●
During work, be sure not to damage cylinder head gas-
ket.
●
When installing, avoid discontinuous bead of liquid gas-
ket caused by allowing it to adhere to an unnecessary area.
PBIC0530E
PBIC0561E
PBIC0562E
PBIC0563E
EM-56
[QG]
TIMING CHAIN
h.
Install front cover with mounting bolts temporarily so that front
cover will not move.
i.
Press fit dowel pin into cylinder block through front cover.
j.
Tighten front cover mounting bolts temporarily.
●
A [M6 x 20 mm (0.79 in)], B [M6 x 40 mm (1.57 in)], C [M8 x
70 mm (2.76 in)], D [M6 x 73 mm (2.87 in)]
●
Bolt C also secures power steering pump adjusting bar.
●
Bolt E [M6 x 12 mm (0.47 in)] is for installing power steering
pump adjusting bar.
k.
Tighten cylinder head auxiliary bolts (M6) temporarily.
l.
Tighten front cover mounting bolts and cylinder head auxiliary
bolts to specified torque.
4.
Install oil pump drive spacer.
●
When installing, align with flat of oil pump inner rotor.
●
If they are not aligned, rotate inner rotor with a flat-bladed
screwdriver to align them.
CAUTION:
Be careful not to damage oil seal lips.
5.
Install water pump pulley and idler pulley bracket assembly.
6.
Install crankshaft pulley.
●
When installing it, make sure that front oil seal lip is not inverted and garter spring is in position.
●
For direction of mounting bolt washer, refer to “Component Parts Location”.
●
With same procedure as “removal”, secure crankshaft, and tighten mounting bolts.
7.
Install cylinder head front cover.
●
Apply liquid gasket to cylinder head front cover.
●
Use Genuine Liquid Gasket or equivalent.
8.
Install engine front mounting bracket.
9.
Install remaining parts in the reverse order of removal.
INSPECTION AFTER INSTALLATION
●
In order to allow liquid gasket to be cured, perform inspection at least 30 minutes after the last step in
which parts sealed with liquid gasket are installed.
●
With engine warmed up, check each part for engine oil leakage.
PBIC0564E
EMD0850D
PBIC0566E
PBIC0968E
OIL SEAL
EM-57
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OIL SEAL
PFP:00100
Removal and Installation of Valve Oil Seal
EBS00QEK
REMOVAL
1.
Remove camshaft. Refer to
.
2.
Remove adjusting shim (if so equipped) and valve lifters. Refer
to
.
3.
To prevent valve from falling inside cylinder, turn crankshaft until
cylinder with oil seal to be removed is at top dead center.
CAUTION:
When rotating crankshaft, be careful that timing chain is not
caught by front cover.
4.
Using valve spring compressor (special service tool), remove valve collect. Then remove valve spring and
valve spring retainer.
5.
Remove valve oil seal using valve oil seal puller (special service
tool).
INSTALLATION
1.
Apply engine oil on new valve oil seal joint and seal lip.
2.
Using valve oil seal drift (special service tool), press fit valve oil
seal to height shown in figure.
3.
Perform steps in the reverse order of removal for the following
operations.
SEM914F
SEM909F
SEM910F
EM-58
[QG]
OIL SEAL
Removal and Installation of Front Oil Seal
EBS00QEL
REMOVAL
1.
Remove the following parts:
●
RH undercover (with splash cover)
●
Drive belt; Refer to
EM-15, "Removal and Installation"
.
●
Crankshaft pulley; Refer to
.
2.
Using flat-head screwdriver, remove front oil seal.
CAUTION:
Be careful not to damage front timing chain cover and crankshaft.
INSTALLATION
1.
Apply engine oil on new front oil seal.
2.
Using a suitable drift, press fit until the height of front oil seal is
level with the mounting surface.
●
Suitable drift: outer diameter 50 mm (1.97 in), inner diameter
44 mm (1.73 in).
CAUTION:
●
Be careful not to damage front cover and crankshaft.
●
Press oil seal straight so that it is not curling up or
inclined.
3.
Perform steps in the reverse order of removal for the following
operations.
Removal and Installation of Rear Oil Seal
EBS00QEM
REMOVAL
1.
Remove transaxle assembly. Refer to MT-19 (5MT) (RS5F50A), MT-21 (5MT) (RS5F70A) and
(AUTOMATIC TRANSAXLE).
2.
Remove flywheel or drive plate. Refer to
.
3.
Using flat-head screwdriver, remove rear oil seal.
CAUTION:
Be careful not to damage mounting surface.
INSTALLATION
1.
Using a suitable drift, press rear oil seal to rear oil seal retainer.
●
Suitable drift: outer diameter 102 mm (4.02 in), inner diameter
90 mm (3.54 in).
CAUTION:
●
Do not touch grease applied on oil seal lip
●
Be careful not to damage rear oil seal retainer and crank-
shaft.
●
Press in straight to avoid causing any burrs or tilting of
oil seal.
SEM912F
SEM715A
SEM097F
OIL SEAL
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Press rear oil seal into rear oil seal retainer so that is
does not project from the end.
2.
Perform steps in the reverse order of removal for the following operations.
KBIA1401E
EM-60
[QG]
CYLINDER HEAD
CYLINDER HEAD
PFP:11041
On-Vehicle Service
EBS00QEN
CHECKING COMPRESSION PRESSURE
1.
Warm up engine thoroughly. Then, stop it.
2.
Release fuel pressure. Refer to
EC-52, "FUEL PRESSURE RELEASE"
(WITH EURO-OBD),
(WITHOUT EURO-OBD).
3.
Remove ignition coil and spark plug from each cylinder.
Refer to IGNITION COIL
EM-27, "Removal and Installation"
and SPARK PLUG
.
4.
Connect engine tachometer (not required in use of CONSULT-II).
5.
Disconnect fuel injector harness connector so that no fuel is injected.
6.
Install compression tester with adapter onto spark plug hole.
●
Use compression gauge whose picking up end inserted to spark
plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise,
it may be caught by cylinder head during removal.
7.
With accelerator pedal fully depressed, turn ignition switch to
“START” for cranking. When the gauge pointer stabilizes, read
the compression pressure and engine rpm. Perform these steps
to check each cylinder.
Compression pressure
[kPa (bar, kg/cm
2
, psi)/rpm]
CAUTION:
Always use a fully changed battery to obtain specified engine speed.
●
If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine speed
again with normal battery gravity.
●
If compression pressure is below minimum value, check valve clearances and parts associated with com-
bustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gas-
ket). After the checking, measure compression pressure again.
●
If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug hole
of the cylinder to re-check it for compression.
–
If the added engine oil improves the compression, the piston rings may be worn out or damaged. Check
the piston rings and replace if necessary.
–
If the compression pressure remains at low level despite the addition of engine oil, the valves may be mal-
functioning. Check the valves for damage. Replace the valve or valve seat accordingly.
●
If two adjacent cylinders have respectively low compression pressure and their compression remains low
even after the addition of engine oil, the gaskets are leaking. In such a case, replace the cylinder head
gaskets.
8.
Install spark plug, ignition coil and harness connectors.
KBIA1402E
Standard
1,324 (13.24, 13.5, 192)
Limit
1,128 (11.28, 11.5, 164)
Difference limit among cylinders
98 (0.98, 1.0, 14)
SEM387C
CYLINDER HEAD
EM-61
[QG]
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Removal and Installation
EBS00QEO
REMOVAL
1.
Release fuel pressure. Refer to
EC-52, "FUEL PRESSURE RELEASE"
(WITH EURO-OBD),
(WITHOUT EURO-OBD).
2.
Remove undercover.
3.
Drain engine coolant. Refer to LC-18, “Changing Engine Coolant”.
4.
Remove the following components and related parts:
●
Intake manifold and intake manifold collector. Refer to
EM-18, "Removal and Installation"
.
●
Exhaust manifold and catalytic converter. Refer to
EM-21, "Removal and Installation"
.
●
Ignition coil. Refer to
EM-27, "Removal and Installation"
.
●
Rocker cover. Refer to
EM-32, "Removal and Installation"
.
●
Camshaft. Refer to
EM-35, "Removal and Installation"
.
●
Alternator bracket. Refer to SC-24, “Charging System”.
5.
Remove cylinder head loosening bolts in reverse order shown in
the figure.
6.
Remove cylinder head gasket.
PBIC0972E
1.
Rear engine slinger
2.
Cylinder head bolt
3.
Washer
4.
Auxiliary bolt of cylinder head
5.
Cylinder head gasket
6.
Cylinder head assembly
SEM900F
EM-62
[QG]
CYLINDER HEAD
INSTALLATION
1.
Apply liquid gasket to positions shown in figure, then install cyl-
inder head gasket.
●
Use Genuine Liquid Gasket or equivalent.
2.
Install cylinder head assembly, tighten bolts (1) to (10) in numer-
ical order shown in figure with the following procedure:
CAUTION:
●
Be sure to install washers between bolts and cylinder
head.
●
In step “d”, loosen bolts in the reverse order of that indi-
cated in figure.
a.
Apply new engine oil to threads and seating surface of mounting
bolts.
b.
Tighten all bolts to 29.4 N·m (3.0 kg-m, 22 ft-lb).
c.
Tighten all bolts to 58.8 N·m (6.0 kg-m, 43 ft-lb).
d.
Completely loosen to 0 N·m (0 kg-m, 0 ft-lb).
e.
Tighten all bolts to 27.4 - 31.4 N·m (2.8 to 3.2 kg-m, 21 to 23 ft-
lb).
f.
Turn all bolts 50 to 55 degrees (target: 50 degrees) clockwise.
CAUTION:
Check and confirm the tightening angle by using angle
wrench (special service tool). Avoid judgment by visual
inspection without the tool.
PBIC0573E
SEM900F
SEM877A
PBIC0574E
CYLINDER HEAD
EM-63
[QG]
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3.
Tighten cylinder auxiliary bolts (11) to (14) in numerical order
shown in figure.
●
Pay attention to shank length under bolt head. [11: 20 mm
(0.79 in), 12 - 14: 25 mm (0.98 in)]
Disassembly and Assembly
EBS00QEP
CAUTION:
●
When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
surface with new engine oil.
●
Apply new engine oil to threads and seat surface when installing cylinder head, camshaft
sprocket, crankshaft pulley and camshaft bracket.
●
Attach tags to valve lifters so as not to mix them up.
DISASSEMBLY
1.
Remove adjusting shim (if so equipped) and valve lifter.
●
Confirm installation point.
SEM900F
PBIC0973E
1.
Cylinder head
2.
Valve (INT)
3.
Valve (EXH)
4.
Valve seat
5.
Engine coolant temperature sensor
6.
Copper washer
7.
Spark plug tube
8.
Spark plug
EM-64
[QG]
CYLINDER HEAD
2.
Remove valve collet.
●
Compress valve spring with valve spring compressor (special
service tool). Remove valve collet with magnet driver.
3.
Remove valve spring retainer and valve spring.
4.
Push valve stem to combustion chamber side, and remove
valve.
●
Inspect valve guide clearance before removal. Refer to
.
●
Confirm installation point.
5.
Remove valve oil seal with valve oil seal puller (special service
tool).
6.
Remove valve spring seat.
7.
When valve seat must be replaced, refer to
.
8.
When valve guide must be replaced, refer to
.
9.
Remove spark plug with spark plug wrench (commercial service
tool).
10. Remove engine coolant temperature sensor.
CAUTION:
Do not shock it.
11. Remove spark plug tube, as necessary.
●
Using a pair of pliers, pull spark plug tube out of cylinder head.
CAUTION:
●
Take care not to damage cylinder head.
●
Once removed, a spark plug tube will be deformed and cannot be reused. Do not remove it
unless absolutely necessary.
ASSEMBLY
1.
Install valve guide. Refer to
EM-66, "VALVE GUIDE REPLACEMENT"
.
2.
Install valve seat. Refer to
EM-68, "VALVE SEAT REPLACEMENT"
.
3.
Install valve oil seal.
●
Install with valve oil seal drift (special service tool) to match
dimension in illustration.
4.
Install valve spring seat.
5.
Install valve.
●
Install larger diameter to intake side.
6.
Install valve spring.
7.
Install valve spring retainer.
PBIC1015E
SEM909F
PBIC0576E
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