Almera Tino V10 (2003 year). Manual

VACUUM PUMP

EM-145

[YD]

Disassembly and Assembly

EBS00QFL

DISASSEMBLY

Push on chain guide lightly so that clearance between chain and chain guide part reaches 0 mm (0 in).
Then loosen chain guide mounting bolts.

Remove chain from rear cam sprocket and vacuum pump sprocket.

Remove rear cam sprocket.

Remove vacuum pump.

CAUTION:

Do not disassemble vacuum pump.

ASSEMBLY

Follow procedure below to install each part onto cylinder head rear
cover.

Install vacuum pump.

Temporarily fit chain guide.

MBIA0033E

Rear cam sprocket

Drive chain

Chain guide

Cylinder head rear cover

Vacuum pump

SBIA0171E

INJECTION TUBE AND FUEL INJECTOR

EM-147

[YD]

INJECTION TUBE AND FUEL INJECTOR

PFP:00018

Removal and Installation

EBS00QFM

CAUTION:

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

REMOVAL

Remove engine cover. Refer to

EM-160, "Removal and Installation"

Remove harness connector from fuel injector.

Remove spill hose.

Following steps below, remove injection tubes.

Put a paint mark or tag on injection tubes to identify each cylin-
der.

●

Use a fuel-resistant method.

Remove injection tubes in order of 2-1-4-3 individually.

CAUTION:

Be careful not to allow leaked fuel to contaminate engine
compartment. Especially, ensure to keep engine mount
insulator clear of fuel.
NOTE:
Removal procedure of fuel injector is shown right.

MBIA0011E

Spill tube

Eye-bolt

Spill tube gasket

Nozzle support

Fuel injector

O-ring

Nozzle gasket

Nozzle oil seal

Injection tube No. 1

10.

Injection tube No. 2

11.

Injection tube No. 3

12.

Injection tube No. 4

13.

Injection tube center

14.

Fuel rail assembly

SBIA0203E

EM-148

[YD]

INJECTION TUBE AND FUEL INJECTOR

Remove nozzle oil seal.

●

Using a slotted screwdriver, pry flange to remove oil seal.

NOTE:
Nozzle oil seal seals between fuel injector and rocker cover. If
only injection tube shall be removed and installed, nozzle oil
seal replacement is not required.

Remove rocker cover. Refer to

EM-160, "Removal and Installa-

tion"

Remove spill tube mounting bolts and nut.

●

Loosen bolts and nut to the reverse order of the shown in the
figure and remove then.

Following steps below, remove fuel injector.

Remove nozzle support.

Remove fuel injector. While rotating it to left and right, raise it to
remove.

CAUTION:

●

Handle fuel injector carefully without giving any impact.

●

Do not disassemble fuel injector.

If nozzle gasket remains in cylinder head, hook it with tip of a
slotted screwdriver and pull it out.

INSTALLATION

Following steps below, install fuel injector.

Install O-ring and nozzle gasket to fuel injector, and insert them into cylinder head.

Tighten injection tubes temporarily in the order of 3-4-1-2.

Be sure to fit nozzle support without looseness.

Tighten nozzle support bolts.

Loosen injection tubes in the order of 2-1- 4-3.

PBIC0944E

SBIA0205E

PBIC0759E

INJECTION TUBE AND FUEL INJECTOR

EM-149

[YD]

Connect spill tube.

●

Tighten fixing bolts and nut in the numerical order shown in
the figure.

NOTE:
Connection of spill tube gasket may be broken, even if it is tight-
ened to specified torque. It does not affect performance.

Carry out air tightness test for spill tube.

●

Connect a vacuum handy pump to spill connector. Check that
vacuum is retained while applying following vacuum.

●

If outside of standard, reconnect spill tube. (Replace gasket in
this case.)

Install rocker cover. Refer to

EM-160, "Removal and Installation"

Install nozzle oil seal.

●

Insert it straight until its flange fully contacts rocker cover.

CAUTION:

●

Check gutter spring in seal on fuel injector for missing.

Connect injection tubes individually to each cylinder in order of
3-4-1-2.

Connect spill hose.

Install remaining parts in reverse order of removal.

INSPECTION AFTER INSTALLATION

CONSULT-II service support has a force rail pressure increase function and can increase rail pressure to any
given pressure. Check for fuel leaks visually by increasing internal pressure using this function.

SBIA0205E

Standard

−

53.3 to

−

66.7 kPa (

−

533 to

−

667 mbar,

−

400 to

−

500 mmHg,

−

15.75 to

−

19.69 inHg)

JEF250Z

SBIA0203E

EM-150

[YD]

FUEL PUMP

PFP:17042

Removal and Installation

EBS00QFN

CAUTION:

●

Before removing and installing fuel pump, be sure to remove sprocket. Do not loosen or remove
installation nut in the center of fuel pump. If loosened or removed, replace fuel pump.

●

After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.

●

When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
surfaces with new engine oil.

●

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

REMOVAL

Remove RH engine mount insulator and bracket. Refer to

EM-197, "Removal and Installation"

Pull power steering reservoir tank out of brackets to move power steering piping.

CAUTION:

To avoid removing power steering reservoir tank out of brackets move it with power steering pip-
ing aside.

Remove RH front wheel.

Remove RH splash cover (combined with undercover)

Remove front exhaust tube.

Remove fuel hoses from fuel pump.

Washer

Fuel pump sprocket

Fuel pump

Spacer

Coupling

Sprocket nut

MBIA0012E

FUEL PUMP

EM-151

[YD]

Remove the harness connector from the fuel pump.

Remove injection tube center.

Remove front chain case.

●

Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.

●

Remove No. 6, 10 and 11 bolts with the rubber washer as
space is limited for pulling them out.

CAUTION:

●

While front chain case is removed, cover openings to
prevent entry of foreign material into engine.

●

Do not remove two mass dampers on the back of cover.

10. Set the No. 1 piston to TDC on its compression stroke.

●

Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
shown in the figure.

●

No position indicator is provided on the crankshaft pul-
ley.

●

When installing, color coded links on the secondary tim-
ing chain can be used as alignment marks. Marking may
not be necessary for removal; however, make alignment
marks as required because the alignment mark on fuel
pump sprocket may not be easy to see.

11. Remove chain tensioner.

Push the plunger of chain tensioner and keep it pressed with a
push pin.

JEM121G

SBIA0189E

SEM515G

JEM124G

EM-152

[YD]

FUEL PUMP

Using a hexagon-head wrench [face to face 5 mm (0.20 in)
SST], remove bolts to remove chain tensioner.

12. Remove timing chain slack guide.

●

Using a hexagon-head wrench [face to face 6 mm (0.24 in)
SST], remove bolt to remove timing chain slack guide.

13. Remove timing chain tension guide.

14. Remove secondary timing chain.

●

Timing chain alone can be removed without removing sprock-
ets.

15. Hold fuel pump sprocket and remove bolt.

Insert positioning stopper pin (SST) into the hole 6 mm (0.24 in)
in the diameter on the fuel pump sprocket.

Using a TORX wrench (SST), turn pump shaft little by little to
adjust the position of fuel pump sprocket so that the holes align.

Push positioning stopper pin (SST) through pump sprocket to
fuel pump spacer to hold pump sprocket.

SBIA0227E

SBIA0228E

JEM127G

MBIA0049E

FUEL PUMP

EM-153

[YD]

●

Insert the positioning stopper pin until its flange contacts the fuel
pump sprocket.

●

Remove the TORX wrench (SST).

16. Using a hexagon-head wrench [face to face 6 mm (0.24 in) SST]

remove tightening bolts of fuel pump sprocket and washer.

17. Using the sprocket holder (SST), hold the fuel pump sprocket to

prevent falling.

MBIA0050E

PBIC0945E

MBIA0074E

SBIA0217E

EM-154

[YD]

FUEL PUMP

●

As for the sprocket holder, install fuel pump mounting bolt
through hole of KV11106060 as shown in figure.

●

When the sprocket holder is installed, if the positioning stop-
per pin interferes, pull out the stopper pin approximately 10
mm (0.39 in), then install it.

●

After the sprocket holder is installed temporarily, insert the
extension bar (SST) and TORX socket in the three holes.
After positioning the holes, tighten the holder mounting bolts.

●

The thread length of the sprocket holder mounting bolts
should be approximately 15 mm (0.59 in).

●

Make sure that the a- and b-faces of the sprocket holder con-
tact the bottom side of the sprocket (small diameter side).

CAUTION:

Do not remove the sprocket holder until the fuel pump is
installed.

●

After the sprocket holder is installed, pull out the positioning
stopper pin (SST) from the fuel pump sprocket.

18. Using the extension bar [SST: whole length 43 mm (1.69 in)] and

the TORX socket (Q6-E12: commercially available), remove the
tightening bolts.

CAUTION:

Do not disassemble or adjust the fuel pump excepting the
following.

19. Remove the fuel pump toward the rear of the engine.

NOTE:
The seal washer of the tightening bolts cannot be reused.

CAUTION:

For removal, be careful not to drop the seal washer into the
engine.

SBIA0218E

MBIA0075E

SBIA0220E

MBIA0076E

FUEL PUMP

EM-155

[YD]

20. Remove adjusting shim.

21. Attach a suitable tool in the M8 bolt hole on coupling.

22. Loosen sprocket nut with the TORX wrench (SST).

23. Remove coupling with a suitable puller.

24. Remove spacer from fuel pump.

INSPECTION AFTER REMOVAL
Timing Chain

Check for cracks and excessive wear at roller links. Replace
chain if necessary.

INSTALLATION

Install new oil seal to the spacer.

Install fuel pump to the spacer.

MBIA0013E

MBIA0014E

SEM984C

MBIA0045E

EM-156

[YD]

FUEL PUMP

Install coupling to the fuel pump of spacer.

●

Using the TORX wrench (SST), tighten the sprocket nut to fix
the coupling.

Install adjusting shim.

●

For shim adjustment, measure dimension L (Distance
between front surface of the coupling and the fuel pump
flange) at 2 opposing points near the coupling bolt center. Use
the average of these two measurements to select the shim
grade that marked on adjusting shim.

●

The shim adjustment is required only when the fuel pump is
replaced.

Before the fuel pump is installed, check that the notch of its
spacer and the 6 mm (0.24 in) dia. hole on the body are aligned.

Insert the fuel pump to the mounting position from the rear side
of the engine, and install the tightening bolts with seal washer.

CAUTION:

Be careful not to drop the seal washer into the engine.

MBIA0013E

MBIA0077E

Part No. of adjusting shim

Grade number

Measuring dimension L mm (in)

16614 8H800

0.5 t

39.23 - 39.77 (1.5445 - 1.5657)

16614 8H810

1.0 t

38.76 - 39.23 (1.5260 - 1.5445)

16614 8H860

1.2 t

38.57 - 38.76 (1.5185 - 1.5260)

16614 8H820

1.6 t

38.18 - 38.57 (1.5031 - 1.5185)

MBIA0016E

MBIA0017E

FUEL PUMP

EM-157

[YD]

Using the extension bar (SST) and the TORX socket, tighten the
mounting bolts of the fuel pump.

Remove the sprocket holder (SST).

Using the TORX wrench (SST), turn the pump shaft gradually to
adjust the position of the flange. Then, insert the positioning
stopper pin (SST) to the 6 mm (0.24 in) dia. hole of the fuel
pump sprocket through the pump flange and the pump body.

10. Remove the TORX wrench (SST)

11. Using the hexagon wrench [face to face 6 mm (0.24 in) (SST)],

tighten the sprocket tightening bolts.

●

When the washer of the fuel pump sprocket install it with the
marking “F” facing the front of the engine.

12. Pull out the positioning stopper pin (SST).

SBIA0220E

MBIA0049E

PBIC0945E

EM-158

[YD]

FUEL PUMP

13. Install secondary timing chain.

●

When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the chain.

14. Install timing chain tension guide.

●

The upper bolt has a longer shank than the lower bolt.

15. Using a hexagon-head wrench [face to face 6 mm (0.24 in)

SST], install timing chain slack guide.

16. Install chain tensioner.

Push the plunger of the chain tensioner. While holding it with a
push pin, install the chain tensioner.

Using a hexagon-head wrench [face to face 5 mm (0.20 in)
SST], tighten bolts.

Pull out the push pin. holding the plunger.

●

Check again that the alignment marks on the sprockets
and the colored alignment marks on the timing chain are
aligned.

MBIA0030E

SBIA0228E

SBIA0227E

FUEL PUMP

EM-159

[YD]

17. Install front chain case.

Install tension guide on the back surface of front chain case.

●

Hold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.

Apply Genuine Liquid Gasket or equivalent (Refer to

EM-110,

"Precautions for Liquid Gasket"

.) on both ends of arched area

(locations where rear chain case is adjoined) as shown in the
figure.

Install front chain case.

●

When installing, align dowel pin on oil pump case with the pin
hole.

●

Install No. 6, 10 and 11 bolts with the rubber washer to the
front chain case.

Tighten fixing bolts in the numerical order shown in the figure.

After tightening all the bolts, re-tighten in the same order.

18. Install injection tube center.

19. Install the harness connector to fuel pump.
20. Install fuel hoses to fuel pump.

21. Hereafter, install in the reverse order of removal.

SBIA0189E

JEF370Y

JEM121G

EM-160

[YD]

ROCKER COVER

PFP:13264

Removal and Installation

EBS00QFO

REMOVAL

Remove engine cover. Refer to the figure at right.

Remove harness connector from fuel injector.

Remove injection tube. Refer to

EM-147, "Removal and Installa-

tion"

PBIC0760E

Nozzle oil seal

Oil filler cap

Gasket

Rocker cover

MBIA0018E

Almera Tino V10 (2003 year). Manual - part 206