Almera Tino V10 (2003 year). Manual — part 219
SLC283B
Oil Pressure Check
NLLC0042
JLC284B
SLC926-A
WARNING:
I
Be careful not to burn yourself, as the engine and oil may
be hot.
I
Oil pressure check should be done in “Neutral position”.
1.
Check oil level.
2.
Remove exhaust front tube.
3.
Remove oil pressure switch.
4.
Install pressure gauge.
5.
Install exhaust front tube.
6.
Start engine and warm it up to normal operating temperature.
7.
Check oil pressure with engine running under no-load.
Engine speed
rpm
Approximate discharge pressure
kPa (bar, kg/cm
2
, psi)
Idle speed
More than 140 (1.40, 1.43, 20.3)
2,000
More than 270 (2.69, 2.75, 39.1)
4,000
More than 430 (4.29, 4.38, 62.3)
If difference is extreme, check oil passage and oil pump
for oil leaks.
8.
After the inspections, install the oil pressure switch as follows.
a.
Remove the old sealant adhering to the switch and engine.
b.
Apply Genuine Liquid Gasket or equivalent to the thread and
tighten.
: 13 - 17 N·m (1.25 - 1.75 kg-m, 9 - 12 ft-lb)
Oil Pump
REMOVAL AND INSTALLATION
NLLC0043
I
When installing oil pump, apply engine oil to rotors.
Refer to EM-176, “Primary Timing Chain” for removal.
Reinstall all parts in the reverse order of removal.
ENGINE LUBRICATION SYSTEM
YD
Oil Pressure Check
LC-24
DISASSEMBLY AND ASSEMBLY
NLLC0044
JLC285B
JLC286B
JLC355B
OIL PUMP INSPECTION
NLLC0045
I
Install the inner rotor and outer rotor with the punched
marks on the pump cover side.
Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in)
Body to outer rotor radial clearance 1
0.114 - 0.260 (0.0045 - 0.0102)
Inner rotor to outer rotor tip clearance
2
Below 0.18 (0.0071)
Body to inner rotor axial clearance 3
0.050 - 0.090 (0.0020 - 0.0035)
Body to outer rotor axial clearance 4
0.030 - 0.190 (0.0012 - 0.0075)
Inner rotor to brazed portion of hous-
ing clearance 5
0.045 - 0.091 (0.0018 - 0.0036)
I
If the tip clearance (2) exceeds the limit, replace rotor set.
I
If body to rotor clearances (1, 3, 4, 5) exceed the limit,
replace oil pump body assembly.
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ENGINE LUBRICATION SYSTEM
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Oil Pump (Cont’d)
LC-25
JLC356B
JLC338B
REGULATOR VALVE INSPECTION
NLLC0046
1.
Visually inspect components for wear and damage.
2.
Check oil pressure regulator valve sliding surface and valve
spring.
3.
Coat regulator valve with engine oil. Check that it falls
smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump body.
JLC358B
4.
Check regulator valve to oil pump body clearance.
Clearance 6:
6 : 0.040 - 0.097 mm (0.0016 - 0.0038 in)
If it exceeds the limit, replace oil pump body.
ENGINE LUBRICATION SYSTEM
YD
Oil Pump (Cont’d)
LC-26
SLC287B
JLC288B
Changing Engine Oil
NLLC0074
WARNING:
I
Be careful not to burn yourself, as the engine oil is hot.
I
Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with
used oil. If skin contact is made, wash thoroughly with
soap or hand cleaner as soon as possible.
1.
Warm up engine, and check for oil leakage from engine com-
ponents.
2.
Stop engine and wait more than 10 minutes.
3.
Remove drain plug and oil filler cap.
4.
Drain oil and refill with new engine oil.
Oil Specification and Viscosity:
I
API grade CF-4
I
ACEA grade B1, B3
Refer to MA-20, “RECOMMENDED FLUIDS AND LUBRI-
CANTS”.
Refill oil capacity (Approximately):
Unit:
(Imp qt)
Drain and refill
Without oil filter
chang
e
4.9 (4 - 3/8
)
With oil filter
chang
e
5.2 (4 - 5/8
)
Dry engine (engine overhaul
) 6.3 (5 - 1/2
)
CAUTION:
I
Be sure to clean drain plug and install with new washer.
Drain plug:
: 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
I
The refill capacity depends on the oil temperature and
drain time. Use these specifications for reference only.
Always use the dipstick to determine when the proper
amount of oil is in the engine.
5.
Check oil level.
6.
Start engine and check area around drain plug and oil filter for
oil leakage.
7.
Run engine for a few minutes, then turn it off. After several
minutes, check oil level.
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ENGINE LUBRICATION SYSTEM
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Changing Engine Oil
LC-27
Oil Filter Bracket
NLLC0075
MBIB1012E
REMOVAL AND INSTALLATION
NLLC0075S01
1.
Remove the undercover.
2.
Steer the front wheel to the right.
3.
Remove the right splash cover.
4.
Remove the oil filter bracket bolt.
5.
Reinstall all removed parts in the reverse order of removal.
I
Insert the top mounting bolt to the oil filter bracket beforehand,
and set the oil filter bracket to the installation location.
MBIB1013E
Changing Oil Filter
NLLC0076
ENGINE LUBRICATION SYSTEM
YD
Oil Filter Bracket
LC-28
JLC290B
REMOVAL
NLLC0076S01
1.
Using a socket wrench [plane-to-plane width: 17 mm (0.67 in)],
loosen the oil filter approximately four turns.
JLC291B
2.
Drain the oil after matching the “DRAIN” arrow mark at the
bottom of the oil filter to the protrusion on the oil filter bracket.
I
Catch the oil with a pan or cloth.
CAUTION:
I
The drained oil flows over the right surface of the oil fil-
ter.
I
Completely wipe clean any engine oil remaining on the oil
filter or vehicle.
3.
Remove the oil filter.
JLC292B
4.
Remove the O-ring from the oil filter.
I
Push the O-ring in one direction, lift the slack part using
fingers, and remove the O-ring from the oil filter.
CAUTION:
Do not use wires or flat-bladed screwdrivers etc. as they may
cause damage to the oil filter.
INSTALLATION
NLLC0076S02
1.
Completely remove all foreign objects adhering to the inside of
the oil filter or O-ring mounting area (filter side and bracket
side).
2.
Install O-ring to the oil filter.
3.
Install the oil filter to the oil filter bracket.
: 20 - 24 N·m (2.0 - 2.5 kg-m, 15 - 18 ft-lb)
4.
After warming up the engine, check for engine oil leakage.
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ENGINE LUBRICATION SYSTEM
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Changing Oil Filter (Cont’d)
LC-29
Oil Cooler
NLLC0077
YLC050
REMOVAL AND INSTALLATION
NLLC0077S01
1.
Draining the coolant
Refer to LC-40, “Changing Engine Coolant”.
2.
Remove the exhaust front tube.
SLC359B
3.
Reinstall all removed parts in the reverse order of removal.
I
Confirm that no foreign objects are adhering to the installation
planes of the oil cooler or block.
I
Tighten the connecting bolt after aligning the stopper on the
cylinder block side with protrusion of the oil cooler.
ENGINE LUBRICATION SYSTEM
YD
Oil Cooler
LC-30
Service Data and Specifications (SDS)
OIL PRESSURE CHECK
=NLLC0048
Engine speed
rpm
Approximate discharge pressure
kPa (bar, kg/cm
2
, psi)
Idle speed
More than 140 (1.40, 1.43, 20.3)
2,000
More than 270 (2.69, 2.75, 39.1)
4,000
More than 430 (4.29, 4.38, 62.3)
REGULATOR VALVE INSPECTION
NLLC0049
Unit: mm (in)
Regulator valve to oil pump cover clearance
0.040 - 0.097 (0.0016 - 0.0038)
OIL PUMP INSPECTION
NLLC0050
Unit: mm (in)
Body to outer rotor radial clearance
0.114 - 0.260 (0.0045 - 0.0102)
Inner rotor to outer rotor tip clearance
Below 0.18 (0.0071)
Body to inner rotor axial clearance
0.050 - 0.090 (0.0020 - 0.0035)
Body to outer rotor axial clearance
0.030 - 0.190 (0.0012 - 0.0075)
Inner rotor to brazed portion of housing clearance
0.045 - 0.091 (0.0018 - 0.0036)
ENGINE OIL CAPACITY
NLLC0078
Unit:
(Imp qt)
Drain and refill (Approximately)
Without oil filter chang
e 4.9 (4-3/8
)
With oil filter chang
e 5.2 (4-5
/8)
Dry engine (engine overhaul
) 6.3 (5-1/2
)
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ENGINE LUBRICATION SYSTEM
YD
Service Data and Specifications (SDS)
LC-31
SEM164F
AEM080
Precautions
LIQUID GASKET APPLICATION PROCEDURE
NLLC0051
1.
Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2.
Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket.)
I
For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm
(0.157 to 0.197 in).
I
For areas except oil pan, be sure liquid gasket diameter is 2.0
to 3.0 mm (0.079 to 0.118 in).
3.
Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4.
Assembly should be done within 5 minutes after coating.
5.
Wait at least 30 minutes before refilling engine oil and engine
coolant.
Preparation
SPECIAL SERVICE TOOLS
NLLC0052
Tool number
Tool name
Description
EG17650301
Radiator cap tester
adapter
NT564
Adapting radiator cap tester to radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
ENGINE COOLING SYSTEM
YD
Precautions
LC-32
Cooling Circuit
NLLC0053
YLC046
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ENGINE COOLING SYSTEM
YD
Cooling Circuit
LC-33
System Check
NLLC0054
WARNING:
Never remove the radiator cap when the engine is hot; serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap and carefully remove it by
turning it a quarter turn to allow built-up pressure to escape
and then turn the cap all the way off.
CHECKING COOLING SYSTEM HOSES
NLLC0054S01
Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATOR
NLLC0054S02
Check radiator for mud or clogging. If necessary, clean radiator as
follows.
I
Be careful not to bend or damage the radiator fins.
I
When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, radiator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
1.
Apply water by hose to the back side of the radiator core ver-
tically downward.
2.
Apply water again to all radiator core surfaces once per
minute.
3.
Stop washing if any stains no longer flow out from the radia-
tor.
4.
Blow air into the back side of radiator core vertically downward.
I
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm
2
,
71 psi) and keep distance more than 30 cm (11.8 in).
5.
Blow air again into all the radiator core surfaces once per
minute until no water sprays out.
SLC755AC
CHECKING RADIATOR CAP
NLLC0054S03
To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm
2
, 11 - 14 psi)
Limit
59 kPa (0.59 bar, 0.6 kg/cm
2
, 9 psi)
SMA967B
Pull the negative pressure valve to open it.
Check that it closes completely when released.
I
Check the radiator cap negative pressure valve for contamina-
tion or damage to the valve seat.
I
Move the negative pressure valve to check for abnormalities to
the opening/shutting operation.
CAUTION:
I
Be sure to perform the inspections after cooling down the
engine.
I
Before connecting the radiator cap to the tester, apply
water or LLC to the cap sealing.
ENGINE COOLING SYSTEM
YD
System Check
LC-34
I
Replace the radiator cap if abnormalities are found with the
negative pressure valve, or if the valve opening pressure is out
of the standard range.
SLC756AA
CHECKING COOLING SYSTEM FOR LEAKS
NLLC0054S04
To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm
2
, 23 psi)
CAUTION:
I
Higher than the specified pressure may cause radiator
damage.
I
Be sure to perform the inspections after cooling down the
engine.
I
Use a hose adapter between the cap tester and filler neck
to prevent the radiator filler neck from deforming.
I
If any abnormalities are found, repair or replace the malfunc-
tioning parts.
Water Pump
REMOVAL AND INSTALLATION
NLLC0055
CAUTION:
I
When removing water pump assembly, be careful not to
get coolant on drive belt.
I
Water pump cannot be disassembled and should be
replaced as a unit.
I
After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
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ENGINE COOLING SYSTEM
YD
System Check (Cont’d)
LC-35
JLC294B
REMOVAL
NLLC0056
1.
Remove the undercover, splash cover (right), and accessory
belt.
2.
Drain engine coolant. Refer to LC-40, “Changing Engine Cool-
ant”.
3.
Support the bottom of the oil pan with a floor jack etc., and
remove the right engine mount bracket (front side of the
engine).
4.
Remove the water pump pulley.
I
Loosen the pulley bolts after fixing the pulley using a screw-
driver etc.
5.
Remove engine mount brackets.
6.
Remove the water pump.
INSPECTION
NLLC0057
I
Check for rust and contamination adhering to the water pump
and vane.
I
Turn the pump shaft by hand, and check that the pump turns
smoothly without looseness.
INSTALLATION
NLLC0058
I
Install the parts in the reverse order of removal.
I
Install the water pump pulley with the front mark (painted white,
used to prevent errors during assembly) facing the front of the
engine. Refer to the figure above.
ENGINE COOLING SYSTEM
YD
Water Pump (Cont’d)
LC-36
Thermostat
REMOVAL AND INSTALLATION
NLLC0059
YLC047
I
Be careful not to spill coolant over engine compartment.
Use a rag to absorb coolant.
1.
Drain engine coolant. Refer to LC-40, “Changing Engine Cool-
ant”.
2.
Remove exhaust manifold cover.
3.
Remove water inlet.
4.
Remove thermostat.
JLC300B
5.
Install thermostat with jiggle valve facing upward.
I
Carefully install the rubber ring to the flange of the
thermostat, making sure it does not slip out of place.
6.
After installation and refilling coolant, run engine for a few
minutes, and check for leaks.
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ENGINE COOLING SYSTEM
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Thermostat
LC-37
SLC252B
INSPECTION
NLLC0060
1.
Check valve seating condition at ordinary room temperatures.
It should seat tightly.
2.
Check valve opening temperature and maximum valve lift.
Standard
Valve opening temperature
Above 80 - 84°C (176 - 183°F)
Valve lift
More than 10 mm/95°C
(0.39 in/203°F)
3.
Then check if valve closes at 5°C (9°F) below valve opening
temperature.
ENGINE COOLING SYSTEM
YD
Thermostat (Cont’d)
LC-38
Radiator
COMPONENTS
NLLC0083
YLC048
REMOVAL AND INSTALLATION
NLLC0063
1. Remove under cover.
2. Drain coolant by removing lower radiator hose.
3. Disconnect radiator upper and lower hoses.
4. Remove radiator shroud.
5. Disconnect reservoir tank hose.
6. Remove radiator mounting bracket.
7. Remove radiator.
8. After repairing or replacing radiator, install any part removed in reverse order of removal.
When filling radiator with coolant, refer to LC-40, “Changing Engine Coolant”.
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ENGINE COOLING SYSTEM
YD
Radiator
LC-39
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