Almera Tino V10 (2003 year). Manual — part 205
EXHAUST MANIFOLD AND TURBOCHARGER
EM-129
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REMOVAL
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 and air inlet pipe. Refer to
EM-119, "Removal and Installation"
.
4.
Remove engine undercover.
5.
Remove radiator upper and lower hoses. Refer to LC-39, “Radiator”.
6.
Remove radiator and radiator fan. Refer to LC-39, “Radiator”.
7.
Remove air inlet pipe.
8.
Disconnect exhaust front tube.
9.
Remove catalyst. Refer to
EM-126, "Removal and Installation"
.
10. Remove exhaust manifold cover.
11. Remove insulator.
12. Each wiring and piping (disconnect/move)
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, oil return tube
MBIA0006E
EM-130
[YD]
EXHAUST MANIFOLD AND TURBOCHARGER
13. Loosen exhaust manifold mounting nuts in the reverse order
specified in the figure.
14. Rotate the exhaust manifold and turbocharger assembly so that
the rear side (EGR tube mounting side) faces upward. And then
pull out the assembly from between the engine and the air con-
ditioning piping.
CAUTION:
Be careful not to deform each turbocharger piping when pulling
out the assembly.
INSTALLATION
●
When a stud bolt is pulled out, tighten it to the following torque:
●
Tighten the exhaust manifold mounting nuts in the following procedure:
1.
Tighten the nuts in the order specified in the figure.
2.
Re-tighten the nuts 1 to 4.
3.
Install the gasket so that the alignment protrusion faces the No.
4 port.
4.
Install in reverse order of removal.
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust emission leaks.
JEM266G
: 12.7 - 16.7 N·m (1.3 - 1.7 kg-m, 9 - 12 ft-lb)
JEM266G
EXHAUST MANIFOLD AND TURBOCHARGER
EM-131
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Disassembly and Assembly
EBS00QFG
MBIA0007E
1.
Exhaust manifold
2.
Gasket
3.
Oil return tube
4.
Oil feed tube
5.
Turbocharger
EM-132
[YD]
EXHAUST MANIFOLD AND TURBOCHARGER
REMOVAL
1.
After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
CAUTION:
Do not disassemble or adjust the turbocharger body.
2.
When a stud bolt is pulled out, tighten it to the following torque:
INSPECTION AFTER REMOVAL
Surface Distortion
Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.
1.
Exhaust manifold
2.
Gasket
3.
Oil return tube
4.
Turbocharger
MBIA0008E
: 24 - 27 N·m (2.4 - 2.8 kg-m, 18 - 20 ft-lb)
Limit
: 0.3 mm (0.012 in)
JEM267G
EXHAUST MANIFOLD AND TURBOCHARGER
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Turbocharger
EBS00QFH
CAUTION:
When the compressor wheel turbine wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary failure:
MBIA0009E
MBIA0010E
Suction side
: Between turbocharger and air cleaner
Exhaust side
: Between turbocharger and catalyst
EM-134
[YD]
EXHAUST MANIFOLD AND TURBOCHARGER
ROTOR SHAFT CLEARANCE
●
Check that the rotor shaft rotates smoothly without any resis-
tance when it is rotated by your fingertips.
●
Check that the rotor shaft is not loose when it is moved vertically
or horizontally.
ROTOR SHAFT END PLAY
Place a dial gauge at the rotor shaft end in the axial direction to mea-
sure the end play.
TURBINE WHEEL
●
Check that there is no oil adhesion.
●
Check that there is no carbon accumulation.
●
Check that blades of the turbine wheel are not bent or broken.
●
Check that the turbine wheel does not interfere with the turbine
housing.
COMPRESSOR WHEEL
●
Check that there is no oil adhesion inside the air inlet.
●
Check that the compressor wheel does not interfere with the
compressor housing.
●
Check that the wheel is not bent or broken.
Standard
: 0.086 - 0.117 mm (0.0034 - 0.0046 in)
PBIC0727E
Standard
: 0.036 - 0.090 mm (0.0014 - 0.0035 in)
PBIC0728E
PBIC0729E
PBIC0730E
EXHAUST MANIFOLD AND TURBOCHARGER
EM-135
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TURBOCHARGER BOOST CONTROL ACTUATOR
●
Connect the handy vacuum pump to the actuator, and check
that the rod strokes smoothly in compliance with the following
pressure.
●
Pressure to be applied at actuator part to move rod end as fol-
lows:
Standard (Pressure/rod stroke amount):
YD22DDT engine
: 131.24 - 136.56 kPa (1,312.4 - 1,365.6 mbar, 984 -
1,024 mmHg, 38.7 - 40.3 inHg) / 0.38 mm (0.0150 in)
: 155.44 - 164.76 kPa (1,554.4 - 1,647.6 mbar, 1,166 -
1,236 mmHg, 45.9 - 48.7 inHg) / 4.0 mm (0.157 in)
YD22DDTi engine
: 52.0 - 54.6 kPa (520 - 546 mbar, 390 - 410 mmHg,
15.306 - 16.094 inHg) / 0.2 mm (0.0079 in)
: 32.0 - 40.0 kPa (320 - 400 mbar, 240 - 300 mmHg, 9.42
- 11.78 inHg) / 5.0 mm (0.197 in)
PBIC0941E
EM-136
[YD]
EXHAUST MANIFOLD AND TURBOCHARGER
TROUBLE DIAGNOSIS OF TURBOCHARGER
Preliminary check:
●
Check that the engine oil level is between MIN and MAX of the dipstick. (When the engine oil amount is
more than MAX, the oil flows into the inlet duct through the blow-by gas passage, and the turbocharger is
misjudged failure.)
●
Ask the customer if he/she always runs the vehicle in idle engine speed to cool the oil down after driving.
●
Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.
●
If no malfunction is found after the unit inspections, judge that the turbocharger body has no failure. Check
the other parts again.
A: Large possibility
B: Medium possibility
C: Small possibility
Inspection item
Inspection result
Symptom
(when each inspection item meets each inspection result)
Oil leakage
Smoke
Noise
Insufficient power/
acceleration failure
Turbine wheel
Oil leaks
C
A
C
C
Carbon is accumulated
C
A
B
B
Friction with housing
C
B
A
B
Blades are bent or broken
A
A
Compressor wheel
Inside the air inlet is seriously con-
taminated by oil.
B
B
Friction with housing
C
B
A
B
Blades are bent or broken
A
A
After checking both turbine and
compressor, inspect rotor shaft
end play.
There is resistance when the rotor
shaft is rotated by your fingertips.
C
C
B
The rotor shaft sometimes does not
rotate by your fingertips.
A
There is too much play in the bear-
ing.
C
C
B
C
Oil return port
Carbon or sludge is accumulated in
the waste oil hole.
C
A
C
C
OIL PAN AND OIL STRAINER
EM-137
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OIL PAN AND OIL STRAINER
PFP:11110
Removal and Installation
EBS00QFI
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
When removing the transaxle, first remove the crankshaft position sensor from the assembly.
Be careful not to damage sensor edges and signal plate teeth.
1.
Remove engine undercover.
2.
Drain engine oil. Refer to LC-27, “Changing Engine Oil”.
3.
Remove A/C compressor bracket.
4.
Remove lower oil pan bolts. Loosen bolts in the reverse order of
that shown in the figure.
MBIA0029E
1.
Rear plate cover
2.
Oil pan upper
3.
Oil strainer
4.
Drain plug
5.
Oil pan lower
6.
Crankshaft position sensor
JEM114G
EM-138
[YD]
OIL PAN AND OIL STRAINER
5.
Remove lower oil pan.
a.
Insert Tool between upper oil pan and lower oil pan.
●
Be careful not to damage aluminum mating surface.
●
Do not insert screwdriver, or oil pan flange will be
deformed.
b.
Slide Tool by tapping on the side of the Tool with a hammer.
c.
Remove lower oil pan.
6.
Remove oil strainer.
7.
Remove front exhaust tube and its support.
8.
Set a suitable transmission jack under transaxle and hoist
engine with engine slinger. Refer to
.
9.
Remove front and rear engine mounting nuts and bolts.
10. Remove center member.
11. Remove crankshaft position sensor from transaxle.
12. Remove rear plate cover.
SEM544G
SEM545G
JEM553G
MBIA0048E
OIL PAN AND OIL STRAINER
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13. Remove catalyst rear diffuser. Refer to
.
14. Loosen bolts in reverse order of illustration to remove upper oil
pan.
15. Remove four engine - to - transaxle bolts using a universal
socket. (Commercial Service Tool).
16. Remove upper oil pan.
●
Insert Tool (Seal cutter) between upper oil pan and cylinder
block. Slide tool by tapping on the side of the tool with a ham-
mer. Remove oil pan.
●
Be careful not to damage aluminum mating surface.
●
Do not insert screwdriver, or oil pan flange will be
deformed.
●
Be careful to prevent No.15 and 16 bolts from falling into
transaxle case.
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSTALLATION
1.
Install upper oil pan in the order below.
a.
Use a scraper to remove old liquid gasket from mating surfaces.
●
Also remove old liquid gasket from mating surface of cyl-
inder block, front cover and lower oil pan.
●
Remove old liquid gasket from the bolt hole and thread.
b.
Apply a continuous bead of liquid gasket to mating surface of
aluminum oil pan.
●
Use Genuine Liquid Gasket or equivalent.
JEM116G
SEM365EA
JEM117G
SEM159F
EM-140
[YD]
OIL PAN AND OIL STRAINER
c.
Apply Genuine Liquid Gasket or equivalent to areas shown in
the figure.
●
At the 8 bolt holes marked
, liquid gasket should be
applied on the rims of the holes.
●
Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
or 4.5 to 5.5 mm (0.177 to 0.217 in) wide. (Be careful that
the diameter of the liquid gasket bead is different around
the front.)
●
Attaching should be done within 5 minutes after coating.
d.
Install upper oil pan.
●
Tighten bolts in numerical order to specified torque.
●
Bolt dimensions vary depending on the installation location. Refer to the following and use appropriate
bolts.
●
The shank length under the bolt neck above is the length of the threaded part (pilot portion not
included).
2.
Install the four engine-to-transaxle bolts. Refer to
EM-137, "Removal and Installation"
.
3.
Install rear plate cover.
4.
Install A/C compressor bracket.
5.
Install drive belts.
6.
Install center member.
7.
install front and rear engine mounting insulator nuts and bolts.
8.
Install crankshaft position sensor.
9.
Install front exhaust tube and its support.
10. Install oil strainer.
11. Install lower oil pan.
a.
Use a scraper to remove old liquid gasket from mating surfaces.
●
Also remove old liquid gasket from mating surface of
upper oil pan.
JEM118G
JEM116G
M6 x 30 mm (1.18 in)
: Bolt No. 15, 16
M8 x 25 mm (0.98 in)
: Bolt No. 3, 4, 9, 10
M8 x 60 mm (2.36 in)
: Bolt No. 1, 2, 5, 6, 7, 8,
11, 12, 13, 14
: 57 - 65 N-m (5.9 - 6.7 kg-m, 43 - 48 ft-lb)
MBIA0048E
SEM493G
OIL PAN AND OIL STRAINER
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b.
Apply a continuous bead of liquid gasket to mating surface of
lower oil pan.
●
Use Genuine Liquid Gasket or equivalent.
●
Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
●
Attaching should be done within 5 minutes after coating.
12. Install oil pan drain plug.
●
Refer to illustration of components parts for installation direc-
tion of washer.
13. Install in the reverse order of removal after this step.
●
Pour engine oil or start engine at least 30 minutes after
oil pan is installed.
INSPECTION AFTER INSTALLATION
Check for leakage of engine oil when engine is warmed.
SEM159F
SEM494G
JEM114G
EM-142
[YD]
GLOW PLUG
GLOW PLUG
PFP:22401
Removal and Installation
EBS00QFJ
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1.
Disconnect harness connector from glow plate.
2.
Remove glow nut to remove glow plate.
3.
Remove glow plug.
CAUTION:
●
When removing or installing, do not use such tools as an air impact wrench.
●
Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
1.
Remove adhered carbon from glow plug installation hole with a reamer.
2.
Install glow plug.
3.
Install remaining parts in reverse order of removal.
SBIA0165E
1.
Glow plate
2.
Glow harness
3.
Glow nut
4.
Cap
5.
Glow plug
VACUUM PUMP
EM-143
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VACUUM PUMP
PFP:41920
Removal and Installation
EBS00QFK
INSPECTION BEFORE REMOVAL
1.
Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
●
Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way con-
nector.
2.
Start engine and measure generated vacuum at idle speed.
●
If out of standard, check for air suction in vacuum route, and measure again.
●
If still outside of standard, replace vacuum pump.
REMOVAL
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 and air cleaner case. Refer to
EM-119, "Removal and Installation"
.
4.
Disconnect harness connector from fuel injector.
5.
Remove injection tube. Refer to
EM-147, "Removal and Installation"
.
6.
Remove fuel injector oil seal.
7.
Remove rocker cover. Refer to
EM-160, "Removal and Installation"
.
8.
Remove air inlet pipes. Refer to
EM-128, "Removal and Installation"
.
9.
Remove exhaust manifold cover.
10. Disconnect electronic EGR volume control valve water hose and harness.
11. Disconnect heater hose.
12. Remove EGR tube.
13. Disconnect vacuum hose from vacuum pump side.
MBIA0046E
Standard
: – 86.6 to – 101.3 kPa (– 866 to – 1,013 mbar, – 650 to – 760 mmHg, – 25.59 to –
29.92 inHg)
EM-144
[YD]
VACUUM PUMP
14. Remove camshaft position sensor.
15. Remove cylinder head rear cover plate.
16. Loosen and remove the installation bolts in rear cam sprocket.
●
Loosen rear cam sprocket installation bolts by fixing the hexagonal portion of the camshaft.
17. Remove vacuum pump and cylinder head rear cover assembly.
●
Remove and install vacuum pump, sprocket, drive chain and
chain guide as an assembly.
●
Loosen mounting bolts in reverse order shown in figure.
●
Do not remove any bolts not shown in figure. (Especially
never remove M6 bolts on vacuum pump.)
●
Use seal cutter (special service tool) or other suitable tool to
remove.
INSTALLATION
1.
Install vacuum pump and cylinder head rear cover assembly
onto cylinder head. Refer to
EM-143, "Removal and Installation"
.
●
Camshaft sprocket and camshaft need mating angle when
installing to cylinder head.
●
Apply Genuine Liquid Gasket or equivalent (Refer to
"Precautions for Liquid Gasket"
.) to area shown in the figure.
●
Attaching should be done with in 5 minutes after coating.
2.
Tighten mounting bolts in order shown in the figure.
3.
Install rear cam sprocket mounting bolts by fixing the hexagonal
portion of the camshaft.
4.
Tighten rear cam sprocket mounting bolts.
●
Check if the chain tension is excessive.
5.
Install cylinder head rear cover plate.
●
Apply Genuine Liquid Gasket or equivalent (Refer to
"Precautions for Liquid Gasket"
.) to area shown in the figure.
●
Attaching should be done with in 5 minutes after coating.
CAUTION:
Never start engine with vacuum circuit being open. If
engine is started and vehicle is running while vacuum
pump is open (with vacuum hose disconnected), PCV flow
rate will increase and engine may be damaged.
6.
Install in reverse order of removal after this step.
●
When vacuum hose is connected, insert it securely by at least
15 mm (0.59 in).
INSPECTION AFTER INSTALLATION
Check generated vacuum satisfies the specification at idle speed. Refer to
.
SBIA0167E
SBIA0167E
SBIA0169E
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