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Almera Tino V10 (2003 year). Manual - part 203

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-97

[QG]

SPARK PLUG

CYLINDER HEAD

Unit: mm (in)

VALVE
Valve Dimensions

Unit: mm (in)

Valve Clearance

Shim Type

Unit: mm (in)

*: At a temperature of approximately 20

C (68

Shimless Type

Make

NGK

Champion

Type

Standard

LFR5A-11

REC10YC4

Hot

LFR4A-11

—

Cold

LFR6A-11

—

Plug gap

1.0 - 1.1 mm (0.039 - 0.043 in)

Standard

Limit

Head surface distortion

Less than 0.03 (0.0012)

0.1 (0.004)

Height

117.9 (4.642)

—

Valve head diameter “D”

Intake

29.9 - 30.2 (1.177 - 1.189)

Exhaust

24.9 - 25.2 (0.980 - 0.992)

Valve length “L”

Intake

92.00 - 92.50 (3.6220 - 3.6417)

Exhaust

92.37 - 92.87 (3.6366 - 3.6563)

Valve stem diameter “d”

Intake

5.465 - 5.480 (0.2152 - 0.2157)

Exhaust

5.445 - 5.460 (0.2144 - 0.2150)

Valve seat angle “

”

′

- 44

′

Valve margin “T”

0.8 - 0.14 (0.031 - 0.055)

Valve margin “T” limit

More than 0.5 (0.020)

Valve stem end surface grinding limit

0.2 (0.008)

SEM188

For adjusting

For checking

Hot

Cold* (reference data)

Hot

Intake

0.304 - 0.416 (0.012 - 0.016)

0.25 - 0.33 (0.010 - 0.013)

0.21 - 0.47 (0.008 - 0.019)

Exhaust

0.348 - 0.472 (0.014 - 0.019)

0.32 - 0.40 (0.013 - 0.016)

0.30 - 0.56 (0.012 - 0.022)

Hot

Cold* (reference data)

Intake

0.32 - 0.40 (0.013 - 0.016)

0.24 - 0.32 (0.009 - 0.013)

Exhaust

0.33 - 0.41 (0.013 - 0.016)

0.26 - 0.34 (0.010 - 0.013)

EM-98

[QG]

SERVICE DATA AND SPECIFICATIONS (SDS)

*: At a temperature of approximately 20

C (68

Available Shims

Thickness

mm (in)

Identification mark

2.00 (0.0787)

200

2.02 (0.0795)

202

2.04 (0.0803)

204

2.06 (0.0811)

206

2.08 (0.0819)

208

2.10 (0.0827)

210

2.12 (0.0835)

212

2.14 (0.0843)

214

2.16 (0.0850)

216

2.18 (0.0858)

218

2.20 (0.0866)

220

2.21 (0.0870)

221

2.22 (0.0874)

222

2.23 (0.0878)

223

2.24 (0.0882)

224

2.25 (0.0886)

225

2.26 (0.0890)

226

2.27 (0.0894)

227

2.28 (0.0898)

228

2.29 (0.0902)

229

2.30 (0.0906)

230

2.31 (0.0909)

231

2.32 (0.0913)

232

2.33 (0.0917)

233

2.34 (0.0921)

234

2.35 (0.0925)

235

2.36 (0.0929)

236

2.37 (0.0933)

237

2.38 (0.0937)

238

2.39 (0.0941)

239

2.40 (0.0945)

240

2.41 (0.0949)

241

2.42 (0.0953)

242

2.43 (0.0957)

243

2.44 (0.0961)

244

2.45 (0.0965)

245

2.46 (0.0969)

246

2.47 (0.0972)

247

2.48 (0.0976)

248

2.49 (0.0980)

249

2.50 (0.0984)

250

2.51 (0.0988)

251

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-99

[QG]

Valve Spring

2.52 (0.0992)

252

2.53 (0.0996)

253

2.54 (0.1000)

254

2.55 (0.1004)

255

2.56 (0.1008)

256

2.57 (0.1012)

257

2.58 (0.1016)

258

2.59 (0.1020)

259

2.60 (0.1024)

260

2.61 (0.1028)

261

2.62 (0.1031)

262

2.63 (0.1035)

263

2.64 (0.1039)

264

2.65 (0.1043)

265

2.66 (0.1047)

266

2.68 (0.1055)

268

2.70 (0.1063)

270

2.72 (0.1071)

272

2.74 (0.1079)

274

2.76 (0.1087)

276

2.78 (0.1094)

278

2.80 (0.1102)

280

2.82 (0.1110)

282

2.84 (0.1118)

284

2.86 (0.1126)

286

2.88 (0.1134)

288

2.90 (0.1142)

290

2.92 (0.1150)

292

2.94 (0.1157)

294

2.96 (0.1165)

296

2.98 (0.1173)

298

Thickness

mm (in)

Identification mark

AEM236

Free height

mm (in)

40.0 (1.57)

Pressure N (kg, lb) at height

mm (in)

147.5 - 166.3 (15.04 - 16.96, 33.2 - 37.4) at 23.64 (0.9307)

Out-of-square

mm (in)

Less than 1.80 (0.0709)

EM-100

[QG]

SERVICE DATA AND SPECIFICATIONS (SDS)

Valve Lifter

Unit: mm (in)

Standard

Valve lifter outer diameter

29.960 - 29.975 (1.1795 - 1.1801)

Lifter guide inner diameter

30.000 - 30.021 (1.1811 - 1.1819)

Clearance between lifter and lifter guide

0.025 - 0.061 (0.0010 - 0.0024)

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-101

[QG]

Available Valve Lifter (Shimless Type)

Thickness mm (in)

Identification Mark

3.000 (0.1181 in)

3.020 (0.1189 in)

3.040 (0.1197 in)

3.060 (0.1205 in)

3.080 (0.1213 in)

3.100 (0.1220 in)

3.120 (0.1228 in)

3.140 (0.1236 in)

3.160 (0.1244 in)

3.180 (0.1252 in)

3.200 (0.1260 in)

3.220 (0.1268 in)

3.240 (0.1276 in)

3.260 (0.1283 in)

3.280 (0.1291 in)

3.300 (0.1299 in)

3.320 (0.1307 in)

3.340 (0.1315 in)

3.360 (0.1323 in)

3.380 (0.1323 in)

3.400 (0.1339 in)

3.420 (0.1346 in)

3.440 (0.1354 in)

3.460 (0.1362 in)

3.480 (0.1370 in)

3.500 (0.1378 in)

3.520 (0.1386 in)

3.540 (0.1394 in)

3.560 (0.1402 in)

3.580 (0.1409 in)

3.600 (0.1417 in)

3.620 (0.1425 in)

3.640 (0.1433 in)

3.660 (0.1441 in)

3.680 (0.1449 in)

EM-102

[QG]

SERVICE DATA AND SPECIFICATIONS (SDS)

Valve Guide

Unit: mm (in)

PBIC1077E

Intake

Exhaust

Standard

Service

Standard

Service

Valve guide

Outer diameter

9.523 - 9.534

(0.3749 - 0.3754)

9.723 - 9.734

(0.3828 - 0.3832)

9.523 - 9.534

(0.3749 - 0.3754)

9.723 - 9.734

(0.3828 - 0.3832)

Inner diameter
(Finished size)

5.500 - 5.515 (0.2165 - 0.2171)

Cylinder head valve guide hole diameter

9.475 - 9.496

(0.3730 - 0.3739)

9.685 - 9.696

(0.3813 - 0.3817)

9.475 - 9.496

(0.3730 - 0.3739)

9.685 - 9.696

(0.3813 - 0.3817)

Interference fit of valve guide

0.027 - 0.059

(0.0011 - 0.0023)

0.027- 0.049

(0.0011 - 0.0019)

0.027 - 0.059

(0.0011 - 0.0023)

0.027- 0.049

(0.0011 - 0.0019)

Stem to guide clearance

0.020 - 0.050 (0.0008 - 0.0020)

0.040 - 0.070 (0.0016 - 0.0028)

Valve deflection limit (Dial gauge read-
ing)

0.2 (0.008)

Projection length “L”

11.5 - 11.7 (0.453 - 0.461)

MEM096A

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-103

[QG]

Valve Seat

Unit: mm (in)

CAMSHAFT AND CAMSHAFT BEARING

Unit: mm (in)

Dia

27.8 - 28.0 (1.094 - 1.102)

29.5 - 29.7 (1.161 - 1.169)

31.9 - 32.1 (1.256 - 1.264)

31.500 - 31.516 (1.2402 - 1.2408)

24.5 - 24.7 (0.9646 - 0.9724)

26.500 - 26.516 (1.043 - 1.0439)

26.2 - 26.4 (1.031 - 1.039)

SEM573DA

SEM574DA

Standard

Camshaft runout [TIR*]

Less than 0.02 (0.0008)

Cam height “A”

Intake

40.217 - 40.407 (1.5833 - 1.5908)

Exhaust

39.205 - 39.395 (1.5435 - 1.5510)

Outer diameter of camshaft journal

No. 1

27.935 - 27.955 (1.0998 - 1.1006)

No. 2, 3, 4, 5

23.935 - 23.955 (0.9423 - 0.9431)

SEM671

EM-104

[QG]

SERVICE DATA AND SPECIFICATIONS (SDS)

*: Total indicator reading

CYLINDER BLOCK

Unit: mm (in)

PISTON, PISTON RING AND PISTON PIN
Available Piston

Unit: mm (in)

Inner diameter of camshaft bracket

No .1

28.000 - 28.021 (1.1024 - 1.1032)

No.2, 3, 4, 5

24.000 - 24.021 (0.9449 - 0.9457)

Camshaft journal clearance

0.045 - 0.086 (0.0018 - 0.0034)

Camshaft end play

Intake

0.070 - 0.143 (0.0028 - 0.0056)

Exhaust

0.115 - 0.188 (0.0045 - 0.0074)

Standard

Limit

Surface flatness

Less than 0.03 (0.0012)

0.1 (0.004)

Height “H” (nominal)

213.95 - 214.05 (8.4232 - 8.4271)

—

Cylinder bore
inner diameter

Standard

Grade No. 1

80.000 - 80.010

(3.1496 - 3.1500)

0.2 (0.008)

Grade No. 2

80.010 - 80.020

(3.1500 - 3.1504)

Grade No. 3

80.020 - 80.030

(3.1504 - 3.1508)

Out-of-round (X

−

Less than 0.015 (0.0006)

—

Taper (A

−

Less than 0.01 (0.0004)

—

Difference in inner diameter between cylinders

0.05 (0.0020)

0.2 (0.008)

SEM171D

Standard

SEM882E

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-105

[QG]

Piston Ring

Unit: mm (in)

Piston Pin

Unit: mm (in)

CONNECTING ROD

Unit: mm (in)

*: After installing in connecting rod

CRANKSHAFT

Unit: mm (in)

Piston skirt diame-
ter “A”

Standard

Grade No. 1

79.965 - 79.975

(3.1482 - 3.1486)

Grade No. 2

79.975 - 79.985

(3.1486 - 3.1490)

Grade No. 3

79.985 - 79.995

(3.1490 - 3.1494)

0.5 (0.002) oversize (service)

80.215 - 80.245

(3.1581 - 3.1592)

1.0 (0.039) oversize (service)

80.465 - 80.495

(3.1679 - 3.1691)

“a” dimension

42.3 (1.665)

Piston pin hole inner diameter

18.993 - 18.999

(0.7478 - 0.7480)

Piston to bore clearance

0.025 - 0.045 (0.0010 - 0.0018)

Standard

Limit

Side clear-
ance

Top

0.040 - 0.080

(0.0016 - 0.0031)

0.110 (0.0043)

2nd

0.030 - 0.070 (0.0012 - 0.0028)

0.100 (0.0039)

Oil ring

0.045 - 0.155

(0.0018 - 0.0061)

—

End gap

Top

0.20 - 0.39 (0.0079 - 0.0154)

0.54 (0.0213)

2nd

0.32 - 0.56

(0.0126 - 0.0220)

0.67 (0.0264)

Oil (rail ring)

0.20 - 0.69 (0.0079 - 0.0272)

0.95 (0.0374)

Piston pin outer diameter

18.989 - 19.001 (0.7476 - 0.7481)

Piston pin to piston clearance

0.002 - 0.006 (0.0001 - 0.0002)

Piston pin to connecting rod bush-
ing clearance

Standard

0.005 - 0.017 (0.0002 - 0.0007)

Limit

0.023 (0.0009)

Center distance

140.45 - 140.55 (5.5295 - 5.5335)

Bend [per 100 (3.94)]

Limit

0.15 (0.0059)

Torsion [per 100 (3.94)]

Limit

0.30 (0.0118)

Connecting rod bushing inner diameter* (small end)

19.000 - 19.012 (0.7480 - 0.7485)

Connecting rod big end inner diameter

43.000 - 43.013 (1.6929 - 1.6934)

Side clearance

Standard

0.20 - 0.470 (0.0079 - 0.0185)

Limit

0.50 (0.0197)

Main journal dia. “Dm”

Grade No. 0

49.956 - 49.964 (1.9668 - 1.9671)

Grade No. 1

49.948 - 49.956 (1.9665 - 1.9668)

Grade No. 2

49.940 - 49.948 (1.9661 - 1.9665)

EM-106

[QG]

SERVICE DATA AND SPECIFICATIONS (SDS)

*: Total indicator reading

MAIN BEARING
Standard size

Unit: mm (in)

Undersize

Unit: mm (in)

Bearing Clearance

Unit: mm (in)

CONNECTING ROD BEARING
Standard Size

Unit: mm (in)

Undersize

Unit: mm (in)

Pin journal dia. “Dp”

Grade No. 0

39.968 - 39.974 (1.5735 - 1.5738)

Grade No. 1

39.962 - 39.968 (1.5733 - 1.5735)

Grade No. 2

39.956 - 39.962 (1.5731 - 1.5733)

Out-of-round (X

−

Standard

Less than 0.003 (0.0001)

Limit

Less than 0.005 (0.0002)

Taper (A

−

Standard

Less than 0.004 (0.0002)

Limit

Less than 0.005 (0.0002)

Runout [TIR*]

Standard

Less than 0.04 (0.0016)

Limit

Less than 0.05 (0.002)

Free end play

Standard

0.060 - 0.260 (0.0024 - 0.0102)

Limit

0.3 (0.012)

Grade No.

Thickness

Identification color

1.826 - 1.830 (0.0719 - 0.0720)

Black

1.830 - 1.834 (0.0720 - 0.0722)

Red

1.834 - 1.838 (0.0722 - 0.0724)

Green

1.838 - 1.842 (0.0724 - 0.0725)

Yellow

1.842 - 1.846 (0.0725 - 0.0727)

Blue

Thickness

0.25 (0.0098)

1.960 - 1.964 (0.0772 - 0.0773)

0.50 (0.0197)

2.085 - 2.089 (0.0821 - 0.0822)

Main bearing clearance

Standard

0.020 - 0.044 (0.0008 - 0.0017)

Limit

0.1 (0.004)

Grade No.

Thickness

Identification color or number

1.503 - 1.506 (0.0592 - 0.0593)

Black

1.506 - 1.509 (0.0593 - 0.0594)

Red

1.509 - 1.512 (0.0594 - 0.0595)

Green

Grade No.

Thickness

Identification color or number

0.08 (0.0031)

1.542 - 1.546 (0.0607 - 0.0609)

—

0.12 (0.0047)

1.562 - 1.566 (0.0615 - 0.0617)

—

0.25 (0.0098)

1.627 - 1.631 (0.0641 - 0.0642)

—

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-107

[QG]

Bearing Clearance

Unit: mm (in)

MISCELLANEOUS COMPONENTS

Unit: mm (in)

*: Total indicator reading

Tightening Torque

EBS00QEW

*1: Parts to be tightened in particular orders.
1)-: Order of tightening when tightening two or more times separately.

Unit: N·m (kg-m, ft-lb)

Unit: N·m (kg-m, in-lb)*

Connecting rod bearing clear-
ance

Standard

0.014 - 0.039 (0.0006 - 0.0015)

Limit

0.1 (0.004)

Flywheel runout [TIR*]

Less than 0.1 (0.004)

Camshaft sprocket runout [TIR*]

Intake

Less than 0.2 (0.008)

Exhaust

Less than 0.15 (0.0059)

Mass air flow sensor

8.4 - 10.8 (0.9 - 1.1, 75 - 95)*

Resonator

3.8 - 4.5 (0.39 - 0.45, 34 - 39)*

Air cleaner case lower

3.8 - 4.5 (0.39 - 0.46, 34 - 39)*

Intake manifold

16.7 - 23.5 (1.7 - 2.4, 13 - 17)

Intake manifold collector

7.0 - 9.5 (0.71 - 0.97, 62 - 84)*

Intake manifold support

16.7 - 23.5 (1.7 - 2.4, 13 - 17)

Electric throttle control actuator

17.7 - 21.6 (1.8 - 2.2, 13 - 15)

Exhaust manifold

25.5 - 29.4 (2.6 - 2.9, 19 - 21)

Exhaust manifold cover

6.3 - 8.3 (0.64 - 0.85, 56 - 73)*

Heated oxygen sensor

58.8 - 78.4 (6.0 - 7.9, 44 - 57)

Ground nut

79.4 (8.1, 59)

Oil pan

6.28 - 8.34 (0.64 - 0.85, 56 - 73)*

Oil pan drain plug

29.4 - 39.2 (3.0 - 3.9, 22 - 28)

Oil strainer

6.28 - 8.34 (0.64 - 0.85, 56 - 73)*

Ignition coil

3.8 - 5.0 (0.38 - 0.51, 33 - 44)*

Spark plug

19.6 - 29.4 (2.0 - 3.0, 15 - 21)

Fuel tube

11.8 - 13.7 (1.2 - 1.4, 9 - 10)

16.7 - 23.5 (1.7 - 2.4, 12 - 17)

Rocker cover

2.0 - 3.9 (0.20 - 0.40, 17.4 - 34.7)*

Intake valve timing control solenoid valve

6.3 - 8.3 (0.64 - 0.85, 56 - 73)*

Camshaft position sensor (PHASE)

7.2 - 10.8 (0.73 - 1.1, 64 - 95) *

Camshaft sprocket (INT)

78.4 - 88.2 (8.0 - 9.0, 58 - 65)

Camshaft sprocket (EXH)

98.1 - 127.5 (10.0 - 13.0, 73 - 94)

Camshaft bracket

2.0 (0.2, 18) *

5.9 (0.6, 52) *

9.0 - 11.8 (0.92 - 1.20, 80 - 104)*

Crankshaft pulley

132.4 - 152.0 (14.0 - 15.0, 98 - 112)

Front cover

6.92 - 9.5 (0.71 - 0.96, 62 - 84)*

Timing chain tension guide

15.7 - 20.6 (1.6 - 2.1, 12 - 15)

EM-108

[QG]

SERVICE DATA AND SPECIFICATIONS (SDS)

Cylinder head

29.4 (3.0, 22)

58.8 (6.0, 43)

0 (0.0, 0)

27.4 - 31.4 (2.8 - 3.2, 21 - 23)

- 55

(Angle tightening)

Cylinder head front cover

7.0 - 9.5 (0.72 - 0.96, 62 - 84)*

Flywheel (M/T)

83.4 - 93.2 (8.5 - 9.5, 62 - 68)

Drive plate (A/T)

93.2 - 103 (9.5 - 10.5, 69 - 75)

Connecting rod bearing cap

13.72 - 15.68 (1.4 - 1.5, 10.2 - 11.5)

- 40

(Angle tightening)

Knock sensor

20.6 - 26.5 (2.1 - 2.7, 15 - 20)

Crankshaft position sensor (POS)

7.2 - 10.8 (0.8 - 1.1, 64 - 95)*

Rear oil seal retainer

6.3 - 8.3 (0.65 - 0.84, 56 - 73)*

Signal plate

7.6 - 9.2 (0.78 - 0.93, 68 - 81)*

PRECAUTIONS

EM-109

[YD]

[YD]

PRECAUTIONS

PFP:00001

Precautions for Drain Coolant

EBS00QEX

●

Drain coolant when engine is cooled.

Precautions for Disconnecting Fuel Piping

EBS00QEY

●

Before starting work, make sure no fire or spark producing items are in the work area.

●

Release fuel pressure before disassembly.

●

After disconnecting pipes, plug openings to stop fuel leakage.

Precautions for Removal and Disassembly

EBS00QEZ

●

When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.

●

Exercise maximum care to avoid damage to mating or sliding surfaces.

●

Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.

●

Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.

●

When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.

Precautions for Inspection, Repair and Replacement

EBS00QF0

●

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.

Precautions for Assembly and Installation

EBS00QF1

●

Use torque wrench to tighten bolts or nuts.

●

When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.

●

Replace with new gasket, packing, oil seal or O-ring.

●

Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.

●

Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.

●

Release air within route after draining coolant.

●

After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.

Parts Requiring Angular Tightening

EBS00QF2

●

Use an angle wrench for the final tightening of the following engine parts:

–

Cylinder head bolts

–

Main bearing cap bolts

–

Connecting rod cap nuts

–

Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)

●

Do not use a torque value for final tightening.

●

The torque value for these parts are for a preliminary step.

●

Ensure thread and seat surfaces are clean and coated with engine oil.

EM-110

[YD]

PRECAUTIONS

Precautions for Liquid Gasket

EBS00QF3

REMOVAL OF LIQUID GASKET SEALING

●

After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.

CAUTION:

Be careful not to damage the mating surfaces.

●

In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the liquid gasket is applied.

CAUTION:

If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.

LIQUID GASKET APPLICATION PROCEDURE

Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.

●

Remove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.

Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.

Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.

Apply the gasket without breaks to the specified location with the
specified dimensions.

●

If there is a groove for the liquid gasket application, apply the
gasket to the groove.

●

As for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read this service manual.

●

Within five minutes of gasket application, install the mating com-
ponent.

●

If the liquid gasket protrudes, wipe it off immediately.

●

Do not retighten after the installation.

●

After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.

CAUTION:

If there are specific instructions in this service manual, observe
them.

PBIC0275E

PBIC0003E

EMA0622D

SEM159F

PREPARATION

EM-111

[YD]

PREPARATION

PFP:00002

Special Service Tools

EBS00QF4

Tool number
Tool name

Description

ST0501S000
Engine stand assembly
1 ST05011000
Engine stand
2 ST05012000
Base

Disassembling and assembling

KV10106500
Engine stand shaft

KV11105900
Engine sub-attachment

Used with KV10106500

KV10115600
Valve oil seal drift

Installing valve oil seal
Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
Unit: mm (in)

KV10107902
Valve oil seal puller
1 KV10116100
Valve oil seal puller adapter

Removing valve oil seal

KV11103000
Injection pump drive gear puller

Removing crankshaft pulley

NT042

NT028

NT799

NT603

NT605

NT676

EM-112

[YD]

PREPARATION

KV101056S0
Ring gear stopper
1 KV10105630
Adapter
2 KV10105610
Plate

Preventing crankshaft from rotating
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)

KV101151S0
Lifter stopper set
1 KV10115110
Camshaft pliers
2 KV10115120
Lifter stopper

Changing valve lifter shims

ST16610001
Pilot bushing puller

Removing crankshaft pilot bushing

KV10111100
Seal cutter

Removing steel oil pan and rear timing chain
case

WS39930000
Tube presser

Pressing the tube of liquid gasket

KV10112100
Angle wrench

Tightening bolts for bearing cap, cylinder
head, etc.

KV10109300
Pulley holder

a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.

Tool number
Tool name

Description

NT617

NT041

NT045

NT046

NT052

NT014

NT628

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