Almera Tino V10 (2003 year). Manual — part 209

CYLINDER HEAD

EM-193

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Valve Dimension

Check dimensions of each valve. For dimensions, refer to SDS,

EM-

224, "VALVE"

.

When valve head has been worn down to 1 mm (0.039 in) in margin
thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.

Valve Guide Clearance

●

Perform the inspection before removing valve guides.

●

Check that the valve stem diameter is within specifications.

●

Push valve approximately 25 mm (0.98 in) toward combustion
chamber, move valve toward dial indicator to measure valve
movement.

●

Valve guide clearance is 1/2 of movement on dial indicator.

●

If the measured value exceeds the limit, replace valve guide.

Valve Guide Replacement

●

When removing valve guide, replace it with oversized [0.2 mm
(0.0008 in)] valve guide.

1.

Heat cylinder head to 110 to 130

°

C (230 to 266

°

F) in oil bath.

2.

Using valve guide drift, tap valve guides out from the combus-
tion chamber side.

SEM188A

Standard:

Intake

: 0.020 - 0.053 mm (0.0008 - 0.0021 in)

Exhaust

: 0.040 - 0.073 mm (0.0016 - 0.0029 in)

Limit:

Intake

: 0.08 mm (0.0031 in)

Exhaust

: 0.10 mm (0.0039 in)

PBIC0414E

SEM008A

SEM931C

EM-194

[YD]

CYLINDER HEAD

3.

Remove cylinder head valve guide hole.

4.

Heat cylinder head to 110 to 130

°

C (230 to 266

°

F) in oil bath.

5.

Using valve guide drift, press fit valve guides from camshaft
side, referring to the dimension shown in the figure.

6.

Using valve guide reamer, perform reaming to the press-fitted
valve guides.

Valve Seat Contact

●

Before starting this check, confirm that the dimension of valve
guide and valves are as specified.

●

Apply red lead primer on contacting surfaces of valves seat and
of valve face to examine the conditions of contacting surfaces.

●

Check that the paint on contacting surfaces is continuous along
the entire circumference.

●

If there are abnormal indications, grind the valve and check the
contact again. If abnormal indications still persist, replace valve
seat.

Valve Seat Replacement

●

When removing valve seat, replace it with oversized [0.5 mm (0.020 in)] valve seat.

1.

Cut valve seat to make it thin, and pull it out.

Valve guide hole diameter (for service parts):

: 10.175 - 10.196 mm (0.4006 - 0.4014 in)

SEM932C

Projection “L”

: 10.4 - 10.6 mm (0.409 - 0.417 in)

JEM156G

Reaming specifications:

Intake and Exhaust

6.000 - 6.018 mm (0.2362 - 0.2369 in)

FEM072

SBIA0322E

CYLINDER HEAD

EM-195

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2.

Machine cylinder head inner diameter at valve seat installation
position.

3.

Heat cylinder head to approximately 110 to 130

°

C (230 to

266

°

F) in oil bath.

4.

After cooling valve seats sufficiently with dry ice, press fit it to cylinder head.

CAUTION:

Do not touch the cooled valve seats directly by hand.

5.

Using valve seat cutter, finish processing referring to the dimen-
sions shown in the figure.

CAUTION:

When using valve seat cutter, grasp cutter handle with both
hands, press cutter onto contacting face all around, and cut
thoroughly. If cutter is pressed unevenly or repeatedly, the
valve seat surface may be damaged.

6.

Using compound, perform valve fitting.

7.

Check again to make sure that contacting status is satisfactory.
For details, refer to

EM-194, "Valve Seat Contact"

.

Machining dimension:

Intake

30.500 - 30.516 mm (1.2008 - 1.2014 in)

Exhaust

29.500 - 29.516 mm (1.1614 - 1.1620 in)

SEM795A

FEM075

MBIA0021E

EM-196

[YD]

CYLINDER HEAD

8.

Use a depth gauge to measure the distance between the mount-
ing surface of the cylinder head spring seat and the valve stem
end. If the distance is shorter than specified, repeat step 5
above to adjust it. If it is longer, replace the valve seat with a
new one.

Valve Spring Squareness

Position a straightedge to valve spring, turn the spring, and measure
the maximum clearance value between top surface of spring and the
straightedge.

Valve Spring Dimensions and Valve Spring Pressure Load

Using valve spring tester, check the following.

Valve seat resurface limit “L”:

Intake

: 36.53 - 36.98 mm (1.4382 - 1.4559 in)

Exhaust

: 36.53 - 37.01 mm (1.4382 - 1.4571 in)

JEM253G

Limit

: 1.5 mm (0.059 in)

PBIC0080E

Free length

: 44.74 mm (1.7614in)

Installation height

: 32.82 mm (1.2921 in)

Installation load

: 184 - 208 N

(18.77 - 21.22 kg, 41.4 - 46.8 lb)

Height during
valve open

: 24.82 mm (0.9772 in)

Load with valve
open

: 320 - 360 N

(32.65 - 36.73 kg, 71.9 - 80.9 lb)

SEM113

ENGINE ASSEMBLY

EM-197

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ENGINE ASSEMBLY

PFP:10001

Removal and Installation

EBS00QFW

MBIA0022E

1.

Rear engine mounting insulator

2.

Rear engine mounting bracket

3.

RH engine mounting insulator

4.

RH engine mounting bracket

5.

Front engine mounting bracket

6.

Front engine mounting insulator

7.

Center member

8.

LH engine mounting insulator

EM-198

[YD]

ENGINE ASSEMBLY

WARNING:

●

Situate vehicle on a flat and solid surface.

●

Place chocks at front and back of rear wheels.

●

For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.

CAUTION:

●

Always be careful to work safely, avoid forceful or uninstructed operations.

●

Do not start working until exhaust system and coolant are cool enough.

●

If items or work required are not covered by the engine main body section, refer to the applicable
sections.

●

Always use the support point specified for lifting.

●

Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.

●

For supporting points for lifting and jacking point at rear axle, refer to GI-43, “Lifting Points and
Tow Truck Towing”.

REMOVAL

Preparation

1.

Remove engine hood.

2.

Drain coolant from radiator drain plug.

3.

Remove the following parts.

●

LH/RH undercover

●

LH/RH front wheel

1.

Rear engine mounting insulator

2.

Rear engine mounting bracket

3.

RH engine mounting insulator

4.

RH engine mounting bracket

5.

Front engine mounting bracket

6.

Front engine mounting insulator

7.

Center member

8.

LH engine mounting insulator

9.

LH engine mounting bracket

MBIA0023E

ENGINE ASSEMBLY

EM-199

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●

Battery

●

Engine cover

●

Auxiliary drive belt; Refer to

EM-118, "Removal and Installation"

.

●

Air duct and air cleaner case assembly; Refer to

EM-119, "Removal and Installation"

.

●

Alternator and brackets

●

Radiator and radiator fan assembly; Refer to LC-39, “Radiator”.

4.

Disconnect engine room harness from the engine side and set it aside for easier work.

5.

Disconnect all the body-side vacuum hoses and air hoses at engine side.

Engine room LH

6.

Disconnect fuel feed and return hoses, and plug it to prevent fuel from draining.

7.

Disconnect heater hose, and install plug it to prevent engine coolant from draining.

8.

Remove clutch operating cylinder from transaxle, and move it aside.

9.

Disconnect shift cable from transaxle. (6M/T vehicle)

Engine room RH

10. Remove air conditioner compressor with piping connected from engine. Temporarily secure it on body

with a rope to avoid putting load on it.

Vehicle underbody

11. Remove exhaust front tube.

12. Disconnect two hoses from power steering pump and plug to stop fluid.

13. Remove MT control rod and support rod. (5M/T vehicle).

14. Remove ABS sensor from brake caliper.

15. Remove brake caliper with piping connected from steering knuckle. Temporarily secure it on body with a

rope to avoid load on it.

16. Remove LH/RH drive shafts ; Refer to AX-11, “Removal”.

Removal

17. Install engine slingers into front right of cylinder head and rear

left of cylinder head.

18. Lift up vehicle to appropriate level where work can be performed

efficiently. Using two transmission jacks, securely support
engine oil pan and bottom surface of transaxle.

CAUTION:

●

Make sure that support is stable with the use of safety blocks.

19. Install hooks of lifting chain into engine slingers and tighten chain so that engine still remains on transmis-

sion jacks without being lifted up.

20. Remove engine mount insulator RH.

21. Remove through-bolt of engine mount insulator LH.
22. Remove bolts securing center member at front and rear.

Slinger bolts:

: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)

SBIA0191E

SEM189G

EM-200

[YD]

ENGINE ASSEMBLY

23. Carefully lower transmission jacks in accordance with the lower-

ing pace of the hoist, and remove engine and transaxle assem-
bly from vehicle.

CAUTION:

●

While working, check that no parts of engine assembly
interfere with adjacent parts on the vehicle.

●

While working, make sure that parts requiring disconnec-
tion are not left connected, and that no parts interfere
with vehicle.

●

to prevent vehicle from falling down, perform operation
carefully so that the center of gravity of the vehicle will
not shift.

24. Remove center member.

CAUTION:

●

Before starting removal operation, first place the assembly on a level surface and securely sup-
port the bottom surface with wood blocks Using a hoist, lift engine slingers and make sure the
assembly is stable.

25. Separate engine and transaxle.

INSTALLATION

Install in the reverse order of removal.

●

Do not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.

●

When installation directions are specified, install parts according to the direction marks on them referring
to components illustration.

●

Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.

INSPECTION AFTER INSTALLATION

●

Before starting engine check the levels of coolant, lubrications and working oils. If less than required
quantity, fill to the specified level.

●

Before starting engine, bleed air from fuel piping. Refer to FE-18, “Bleeding Fuel Filter”.

●

Run engine to check for unusual noise and vibration.

●

Warm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel and
exhaust gas.

●

Bleed air from passages in pipes and tubes of applicable lines.

JEM190G

CYLINDER BLOCK

EM-201

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CYLINDER BLOCK

PFP:11010

Disassembly and Assembly

EBS00QFX

MBIA0015E

EM-202

[YD]

CYLINDER BLOCK

CAUTION:

Apply new engine oil to parts marked in illustration before installation.

DISASSEMBLY

1.

Remove engine assembly from the vehicle, then separate engine and transaxle. Refer to

EM-197,

"ENGINE ASSEMBLY"

.

2.

Remove clutch cover and disk. Refer to CL-22 (5MT),

CL-16

(6MT).

3.

Install engine to engine stand as follows.

a.

Remove flywheel.

b.

Secure ring gear with ring gear stopper, then loosen mounting
bolts with TORX bit (size: Q6T55 E9, Commercial Service Tools)
and remove them. As an alternative method hold the crankshaft
pulley with a pulley holder (SST) to remove the flywheel.

CAUTION:

Do not disassemble flywheel.

c.

Install engine sub-attachment to the rear side of cylinder block.

●

Align knock pins on cylinder block with pin holes on attach-
ment to install.

NOTE:
Installation bolts are part of engine sub-attachment.

d.

Install engine attachment.

NOTE:
Use commercially available M12 (0.47 in) mounting bolts and
nuts (4 sets) with strength grade of 9T (minimum).

1.

Rear oil seal retainer

2.

Oil pressure switch

3.

Coppet washer

4.

Oil jet relief valve

5.

Cylinder block

6.

Top ring

7.

Second ring

8.

Oil ring

9.

Oil jet

10.

Piston pin

11.

Snap ring

12.

Piston

13.

Main bearing

14.

Thrust bearing

15.

Connecting rod

16.

Key

17.

Connecting rod bearing

18.

Connecting rod cap

19.

Connecting rod nut

20.

Main bearing

21.

Crankshaft

22.

Main bearing cap

23.

Pilot bush

24.

Flywheel

25.

Drain plug

26.

Rear oil seal

SBIA0199E

JEM192G

CYLINDER BLOCK

EM-203

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e.

Hoist engine and install it to the engine stand.

NOTE:
It is possible to set engine sub-attachment and engine attach-
ment to engine stand at first, then install engine later.

●

Commercial engine stand can be used.

NOTE:
The figure shows an example of general-purpose engine stand
that can hold mating surface of transmission with drive plate and
rear plate removed.

4.

Drain engine oil and coolant from inside engine.

5.

Remove the following parts and related parts. (Only major parts are listed.)

●

Intake manifold (Refer to

EM-123, "Removal and Installation"

.)

●

Exhaust manifold and turbocharger (Refer to

EM-128, "Removal and Installation"

.)

●

Rocker cover (Refer to

EM-160, "Removal and Installation"

).

●

Injection tube and fuel injector (Refer to

EM-147, "Removal and Installation"

.)

●

Oil pan and oil strainer (Refer to

EM-137, "Removal and Installation"

.)

●

Water pump (Refer to LC-35, “Water Pump”.)

●

Thermostat and water piping (Refer to LC-37, “Thermostat”.)

●

Vacuum pump (Refer to

EM-143, "Removal and Installation"

.)

●

Secondary timing chain (Refer to

EM-171, "Removal and Installation"

)

●

Primary timing chain (Refer to

EM-176, "Removal and Installation"

.)

●

Fuel pump (Refer to

EM-150, "Removal and Installation"

.)

●

Camshaft (Refer to

EM-162, "Removal and Installation"

.)

●

Cylinder head (Refer to

EM-187, "Removal and Installation"

.)

●

Oil cooler (Refer to LC-30, “Oil Cooler”.)

●

Accessory, accessory bracket and mount brackets

6.

Remove fuel supply pump bracket.

JEM193G

PBIC0085E

EM-204

[YD]

CYLINDER BLOCK

7.

If they need to be replaced, replace pilot bushing.

●

Using pilot bushing puller, remove the bushing from rear edge
of crankshaft.

8.

Remove rear oil seal retainer.

●

Insert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer.

9.

Remove rear oil seal from rear oil seal retainer.

●

Punch out with a flat-bladed screwdriver.

●

Be careful not to damage rear oil seal retainer.

10. Remove piston and connecting rod assembly.

●

Before removing piston and connecting rod assembly, check
connecting rod side clearance.
Refer to

EM-214, "CONNECTING ROD SIDE CLEARANCE"

.

a.

Move crankshaft pin to be removed to approximately BDC.

b.

Remove connecting rod caps.

c.

Using the grip of a hammer, press the piston and connecting rod
assembly out to cylinder head side.

CAUTION:

When removing the piston and connecting rod assembly,
prevent the big end of the connecting rod from interfering
with the oil jet.

11. Remove connecting rod bearings from connecting rods and

caps.

●

Keep them by cylinder to avoid confusion.

12. Remove piston rings from pistons using piston ring expander.

CAUTION:

●

When removing, prevent pistons from being damaged.

●

Do not expand piston rings excessively. This may dam-
age the piston rings.

SEM500G

JEM195G

FEM086

JEM196G

CYLINDER BLOCK

EM-205

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13. Remove pistons from connecting rods.

a.

Using long nose pliers, remove snap rings.

b.

Using industrial dryer, heat pistons up to 60 to 80

°

C (140 to

176

°

F).

c.

Using rod with outer diameter of 26 mm (1.02 in), press piston
pins out.

14. Remove main bearing cap bolts.

●

With a TORX socket (size: E-14,Commercial Service Tool),
loosen main bearing cap bolts in several stages in the reverse
order of that shown in the figure and remove them.

●

Before loosening main bearing cap bolts, measure crankshaft
side clearance. Refer to

EM-213, "CRANKSHAFT SIDE

CLEARANCE"

.

15. Remove main bearing caps.

●

Using main bearing cap bolts, remove by rocking bearing cap
back and forth.

16. Remove crankshaft.

17. Remove main bearings and thrust bearings from cylinder block

and main bearing caps.

●

Check the correct installation locations of removed parts.
Store them so they do not get mixed up.

18. Remove oil jet.

19. Remove oil jet relief valve.

JEM197G

PBIC0089E

EMM0072D

JEM200G

JEM201G

EM-206

[YD]

CYLINDER BLOCK

ASSEMBLY

1.

Blow air sufficiently to inside coolant passage, oil passage,
crankcase and cylinder bore to remove foreign matter.

2.

Install oil jet relief valve.

3.

Install oil jet.

●

Align knock pin on back of oil jet with hole on block when
installing oil jet.

4.

Install main bearings and thrust bearings.

a.

Remove contamination, dust and oil from bearing mounting
positions on cylinder block and main bearing caps.

b.

Install thrust bearings on both sides of No. 3 housing on cylinder
block.

●

Install thrust bearings with oil groove facing to crankshaft arm
(outside).

c.

Being careful with the direction, install main bearings.

●

Install main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the main cap side.

●

While installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply oil to rear surfaces, but clean them
completely.

●

Align stopper notches on bearings to install them.

●

Check that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.

5.

Install crankshaft to cylinder block.

●

Make sure crankshaft rotates smoothly by hand.

6.

Install main bearing caps.

●

Identify main bearing caps by the punched mark. Install cor-
rectly matching the journal No.on the bearing cap and the
journal with the front mark facing forward.

●

Main bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.

7.

Check the main bearing cap bolts for deformation.
Refer to

EM-220, "MAIN BEARING CAP BOLT DEFORMA-

TION"

.

PBIC0389E

JEM224G

JEM213G

JEM225G

CYLINDER BLOCK

EM-207

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8.

Tighten the main bearing cap bolts according to the following
procedure:

a.

Apply engine oil to the threaded part and seat surface of each
bolt.

b.

Tighten to 24 to 30 N·m (2.5 to 3.1 kg-m, 18 to 22 ft-lb) in the
numerical order shown in the figure.

c.

Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (When using a protractor)

d.

Then, tighten 90

°

to 95

°

[target: 90

°

].

●

Always use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.

●

After tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.

●

Check crankshaft end side clearance. Refer to

EM-213,

"CRANKSHAFT SIDE CLEARANCE"

.

9.

Check the outer diameter of connecting rod bolts. Refer to

EM-

221, "CONNECTING ROD BOLT DEFORMATION"

.

10. Install pistons to connecting rod.

a.

Using long nose pliers, install snap rings to grooves on piston rear side.

●

Fit snap rings correctly into grooves.

b.

Install pistons to connecting rods.

●

Using industrial dryer, heat pistons up to approx. 60 to 70

°

C (140 to 158

°

F) until piston pin can be

pressed down by finger touch. Then insert piston pins into piston and connecting rod from front side of
piston toward rear.

●

Assemble piston and connecting rod with front mark of piston
crown and cylinder No. stamped on connecting rod being
positioned as shown in the figure.

c.

Install snap rings to front side of pistons.

●

Refer to above step a for precaution on snap ring installation.

●

After installation, check connecting rods for smooth move-
ment.

11. Use piston ring expander to install piston rings.

CAUTION:

When installing, prevent piston from being damaged.

●

Install top ring and second ring with stamped surfaces facing
upward.

●

Install rings so that three closed gap position 120

°

apart one

another.

●

Closed gaps do not need to face in a specific directions, as long as each are positioned 120

°

apart.

JEM200G

JEM226G

MBIA0024E

Identification stamp:

Top ring

: RTop

Second ring

: R2ND

JEM228G

EM-208

[YD]

CYLINDER BLOCK

12. Install connecting rod bearings to connecting rods and caps.

●

While installing connecting rod bearings, apply engine oil to
bearing surfaces (inside). Do not apply oil to rear surfaces,
but clean them completely.

●

Align stoppers on connecting rod bearings with connecting
rod stopper notches to install connecting rod bearings.

13. Install piston and connecting rod assembly to crankshaft.

●

Move crankshaft pin to be assembled to BDC.

●

Align cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.

●

Using piston ring compressor, install piston and connecting
rod assembly with front mark on piston crown facing toward
the front side of engine.

CAUTION:

When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with oil
jet.

14. Install connecting rod caps and mounting nuts.

●

Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.

●

Make sure that the front mark on connecting rod cap faces
towards the front of the engine.

15. Tighten connecting rod nuts according to the following proce-

dure:

a.

Apply engine oil on bolt threads and seat surface of nuts.

b.

Tighten to 29 to 30 N·m (2.9 to 3.1 kg-m, 21 to 22 ft-lb).

c.

Loosen completely to 0 N·m (0 kg-m, 0 in-lb).

d.

Tighten to 19 to 20 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).

e.

Tighten 120

°

to 125

°

[target: 120

°

]. (angular tightening)

●

Always use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.

●

After tightening nuts, check that crankshaft rotates smoothly.

●

Check connecting rod side clearance. Refer to

EM-214,

"CONNECTING ROD SIDE CLEARANCE"

.

16. Force fit rear oil seal into rear oil seal retainer.

●

Using a drift [105 mm (4.13 in) dia.], force fit so that the
dimension is as specified in the figure.

●

Avoid inclined fitting. Force fit perpendicularly.

●

Do not touch lips of oil seal. Make sure seal surfaces are
free foreign materials.

JEM229G

JEM230G

MBIA0024E

JEM231G

JEM232G