Almera Tino V10 (2003 year). Manual

ROCKER COVER

EM-161

[YD]

Remove fuel injector oil seal.

●

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

Remove rocker cover.

●

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

INSTALLATION

Apply 3.0 mm (0.118 in) dia. of Genuine Liquid Gasket or equiv-
alent (Refer to

EM-110, "Precautions for Liquid Gasket"

.) on

locations shown in the figure.

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

●

Re-tighten to the same torque in the same order as above.

Install nozzle oil seal.

●

Insert it straight until flange fully contacts cylinder head.

Install remaining parts in reverse order removal.

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

INSPECTION AFTER INSTALLATION

Start engine and increase engine speed to check for fuel leak.

PBIC0944E

MBIA0078E

JEM248G

MBIA0078E

EM-162

[YD]

CAMSHAFT

PFP:13001

Removal and Installation

EBS00QFP

CAUTION:

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

●

This engine will have a different valve arrangement from normal
DOHC 4-valve type engines. As both camshafts on this engine
have intake and exhaust camshafts, in this chapter they are
named as follows:

●

Refer to the figure for intake and exhaust valve arrangement.
(The camshafts have, alternately, either an intake valve or an
exhaust valve.)

REMOVAL

Drain engine coolant. Refer to LC-40, “Changing Engine Coolant”.

Remove air duct. Refer to

EM-119, "Removal and Installation"

Remove rocker cover. Refer to

EM-160, "Removal and Installation"

Remove vacuum pump. Refer to

EM-143, "Removal and Installation"

Remove injection tube and fuel injector. Refer to

EM-147, "Removal and Installation"

Remove secondary timing chain. Refer to

EM-171, "Removal and Installation"

SBIA0177E

Camshaft bracket

Camshaft (right side)

Camshaft (left side)

Camshaft sprocket (right side)

Camshaft sprocket (left side)

Adjusting shim

Valve lifter

Cylinder head

Camshaft (Right side)

: Intake manifold side

Camshaft (Left side)

: Exhaust manifold side

SBIA0178E

CAMSHAFT

EM-163

[YD]

Set the No. 1 cylinder at TDC on its compression stroke.

Remove the camshaft stroke.

●

Loosen the camshaft gear installation bolt by fixing the hexag-
onal portion of the camshaft.

Remove the camshaft.

●

Place distinguishing marks on the right and left sides with
paint.

●

Loosen and remove the installation bolt in reverse order
shown in the figure.

10. Remove the adjusting shim and valve lifter.

●

Remove by taking notice of the installation position, and place
outside engine in order to prevent confusion.

INSPECTION AFTER REMOVAL
Visual Check of Camshaft

●

Check the camshaft for one sided wear or scratches.

●

Replace the camshaft if there are abnormalities.

Camshaft Runout

●

Prepare V-block on a flat surface and secure camshaft journals
No. 2 and No. 5.

●

Set the dial gauge vertically on journal No. 3.

●

Rotate camshaft in one direction by hand, then read needle
movement on dial indicator. (Total indicator reading)

Height of Cam Nose

Measure by using a micrometer.

JEM159G

JEM160G

Limit

: 0.02 mm (0.0008 in)

JEM161G

Standard:

Intake

: 39.505 - 39.695 mm (1.5553 - 1.5628 in)

Exhaust

: 39.905 - 40.095 mm (1.5711 - 1.5785 in)

SEM549A

EM-164

[YD]

CAMSHAFT

Camshaft Oil Clearance

Measure by using a micrometer.

Camshaft Bracket Inner Diameter

●

Install camshaft bracket and tighten bolts to the specified torque.

●

Measure inner diameter of camshaft bracket using an inside
micrometer.

Camshaft Oil Clearance Calculations

(Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal outer diameter)

●

If it exceeds the standard value, refer to the standard value of each unit, then replace the camshaft and/or
cylinder head.

NOTE:
As the camshaft bracket is manufactured with the cylinder head, it is impossible to replace only the camshaft
bracket.

Camshaft End Play

●

Set the dial gauge to the front end of the camshaft. Measure the
end play by moving the camshaft in the direction of the axle.

●

If end play exceeds the limit, replace camshaft and measure
camshaft end play again.

●

If end play still exceeds the limit after replacing camshaft,
replace cylinder head.

Camshaft journal outer diameter:

Standard:

No. 1

: 30.435 - 30.455 mm

(1.1982 - 1.1990 in)

No. 2, 3, 4, 5

: 23.935 - 23.955 mm

(0.9423 - 0.9431 in)

SEM012A

Camshaft bracket inner diameter:

Standard:

No. 1

: 30.500 - 30.521 mm

(1.2008 - 1.2016 in)

No. 2, 3, 4, 5

: 24.000 - 24.021 mm

(0.9449 - 0.9457 in)

JEM162G

Standard

: 0.045 - 0.086 mm (0.0018 - 0.0034 in)

Standard

: 0.070 - 0.148 mm (0.0028 - 0.0058 in)

Limit

: 0.24 mm (0.0094 in)

PBIC0366E

CAMSHAFT

EM-165

[YD]

Camshaft Sprocket Runout

Install sprocket on camshaft.

Measure camshaft sprocket runout.

If it exceeds the limit, replace camshaft sprocket.

Visual Inspection of Valve Lifter and Adjusting Shim

●

Check lifter side for any signs of wear or damage. Replace if
there are any abnormalities.

●

Check cam nose contact and sliding surfaces for wear and
scratches. Replace if there are any abnormalities.

Valve Lifter Outer Diameter

Measure the outer diameter of the valve lifter with a micrometer.

Valve Lifter Bore Diameter

Measure the bore diameter of the cylinder head valve lifter with an
inside micrometer.

Valve Lifter Clearance Calculations

(Clearance) = (Valve lifter bore diameter) – (Valve lifter outer diameter)

If it exceeds the standard value, refer to the outer diameter and bore diameter standard values and replace
valve lifter and/or cylinder head.

Runout (Total indicator reading):

: Less than 0.15 mm (0.0059 in)

JEM164G

SEM160D

Standard

: 29.960 - 29.975 mm (1.1795 - 1.1801 in)

SEM961E

Standard

: 30.000 - 30.021 mm (1.1811 - 1.1819 in)

PBIC0367E

Standard

: 0.025 - 0.061 mm (0.0010 - 0.0024 in)

EM-166

[YD]

CAMSHAFT

INSTALLATION

Install the valve lifter and adjusting shim.

●

Make sure that these are installed in the same position as before the removal process.

Install the camshaft.

●

Identify camshafts by the paint position and screw hole at the
rear end.

●

Install so that dowel pins are positioned in the directions
shown in the figure.

Install camshaft brackets.

●

Install correctly, identifying brackets by the journal No. and
front mark on top surface.

Tighten bolts in the order shown in the figure according to the
following procedure:

Tighten to 1.96 N·m (0.2 kg-m, 17 in-lb).

●

Make sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.

Tighten to 5.88 N·m (0.6 kg-m, 52 in-lb).

Tighten to 12 to 13 N·m (1.2 to 1.4 kg-m, 9 to 10 ft-lb).

Install camshaft sprockets.

●

Camshaft sprockets are commonly used for RH and LH.

●

Align camshaft sprocket and dowel pin on camshaft, and
install.

●

Holding the hexagonal part of camshaft with a wrench, tighten bolt securing camshaft sprocket.

Before installing spill tube after installing secondary timing chain, check and adjust valve clearance. Refer
to

EM-167, "Valve Clearance"

Hereafter, install in the reverse order of removal.

Camshaft
RH

: Paint is at position A without screw hole.

Camshaft LH

: Paint is at position B with screw hole.

JEM173G

SEM516G

JEM175G

JEM160G

CAMSHAFT

EM-167

[YD]

Valve Clearance

EBS00QFQ

INSPECTION

●

When the camshaft or parts in connection with valves are
removed or replaced, and a malfunction has occurred (poor
starting, idling, or other malfunction) due to the mis adjustment
of the valve clearance, inspect as follows.

●

Inspect and adjust when the engine is cool (at normal tempera-
ture).

●

Be careful of the intake and exhaust valve arrangement. The
valve arrangement is different from that in a normal engine.

NOTE:
The camshafts have, alternately, either an intake valve or an
exhaust valve. (Refer to illustration)

Drain engine coolant. Refer to LC-40, “Changing Engine Coolant”.

Remove air duct and air inlet pipe. Refer to

EM-119, "Removal and Installation"

Remove rocker cover. Refer to

EM-160, "Removal and Installation"

Remove vacuum pump. Refer to

EM-143, "Removal and Installation"

Remove injection tube and fuel injector. Refer to

EM-147, "Removal and Installation"

Remove secondary timing chain. Refer to

EM-171, "Removal and Installation"

Check valve clearance while engine is cold and not running.

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

●

Turn crankshaft pulley clockwise so that the knock pin on
camshaft LH faces straight above. (No position indicator, etc.
is provided on the crankshaft pulley.)

Put an alignment mark with paint, etc. on the crankshaft pulley
and on the oil pump as an angle indicator.

While referring to the figure, measure the valve clearance
marked in the table below.

●

The injection order is 1-3-4-2.

SBIA0178E

SBIA0179E

JEM177G

Measuring point

No. 1

No. 2

No. 3

No. 4

INT

EXH

INT

EXH

INT

EXH

INT

EXH

When the No. 1
cylinder is in the
TDC

SBIA0180E

EM-168

[YD]

CAMSHAFT

●

Measure the valve clearance using a fine feeler gauge when
the engine is cool (at normal temperature).

10. Set the No. 4 cylinder at TDC by rotating the crankshaft clock-

wise once.

11. While referring to the figure, measure the valve clearance

marked in the table below.

12. If the valve clearance is outside the specification, adjust as fol-

lows.

ADJUSTMENTS

●

Remove the adjusting shim for parts which are outside the spec-
ified valve clearance.

Remove the spill tube. Refer to

EM-147, "Removal and Installa-

tion"

Extract the engine oil on the upper side of the cylinder head (for
the air blowing in step 7).

Rotate the crankshaft to face the camshaft for adjusting shims
that are to be removed upward.

Grip the camshaft with camshaft pliers, them using the camshaft
as a support point, push the adjusting shim downward to com-
press the valve spring.

CAUTION:

Do not damage the camshaft, cylinder head and the outer
circumference of the valve lifter.

Valve clearance (Cold):

Standard:

Intake

: 0.24 - 0.32 mm (0.0094 - 0.0126 in)

Exhaust

: 0.26 - 0.34 mm (0.0102 - 0.0134 in)

SBIA0181E

Measuring point

No. 1

No. 2

No. 3

No. 4

INT

EXH

INT

EXH

INT

EXH

INT

EXH

When the No. 4
cylinder is in the
TDC

SBIA0182E

SBIA0183E

SBIA0184E

CAMSHAFT

EM-169

[YD]

With the valve spring in a compressed state, remove the cam-
shaft pliers by securely setting the outer circumference of the
valve lifter with the end of the lifter stopper.

●

Hold the lifter stopper by hand until the shim is removed.

CAUTION:

Do not retrieve the camshaft pliers forcefully, as the cam-
shaft will be damaged.

Move the rounded hole of the adjusting shim to the front with a
very thin screwdriver or like that.

●

When the adjusting shim on the valve lifter will not rotate
smoothly, restart from step 4 to release the end of the lifter
stopper from touching the adjusting shim.

Remove the adjusting shim from the valve lifter by blowing air
through the rounded hole of the shim with an air gun.

CAUTION:

To prevent any remaining oil from being blown around,
thoroughly wipe the area clean and wear protective gog-
gles.

Remove the adjusting shim by using a magnetic hand.

Measure the thickness of the adjusting shim using a micrometer.

●

Measure near the center of the shim (the part that touches the
camshaft).

10. Select the new adjusting shim from the following methods.

SBIA0185E

SBIA0186E

SBIA0187E

Calculation method of the adjusting shim thickness:

R = Thickness of removed shim

N = Thickness of new shim

M = Measured valve clearance

Intake

N = R + [M - 0.28 mm (0.0010 in)]

Exhaust

N = R + [M - 0.30 mm (0.0118 in)]

FEM032

EM-170

[YD]

CAMSHAFT

●

New adjusting shims have the thickness stamped on the rear
side.

●

Shims are available in 33 size from 2.10 mm (0.0827 in) to
2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in).

11. Fit the selected adjusting shim to the valve lifter.

CAUTION:

Place the stamped side of the adjusting shim to the valve
lifter.

12. Compress the valve spring using the camshaft pliers and

remove the lifter stopper.

13. Rotate the crankshaft 2 to 3 turns by hand.

14. Confirm that the valve clearance is within the specification.

Valve clearance:

*: Approximately 80

C (176

15. Install remaining parts in reverse order of removal.

Stamped mark

Shim thickness mm (in)

2.10
2.12

·
·
·

2.74

2.10 (0.0827)
2.12 (0.0835)

·
·
·

2.74 (0.1079)

JEM184G

SEM552G

Item

Cold

Hot* (Reference data)

Intake

0.24 -0.32 (0.0094 - 0.0126)

0.274 - 0.386 (0.0108 - 0.0152)

Exhaust

0.26 - 0.34 (0.0102 - 0.0134)

0.308 - 0.432 (0.0121 - 0.0170)

SECONDARY TIMING CHAIN

EM-171

[YD]

SECONDARY TIMING CHAIN

PFP:13028

Removal and Installation

EBS00QFR

CAUTION:

●

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

●

For preparative work for removing/installing secondary timing chain to remove/install fuel pump. Refer to

EM-150, "FUEL PUMP"

●

To prepare for removing/installing secondary timing chain to remove/install camshaft. Refer to

EM-162,

"Removal and Installation"

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.

MBIA0028E

EM-172

[YD]

SECONDARY TIMING CHAIN

Remove front chain case.

●

Move power steering fluid reservoir tank from the bracket.

●

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.

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
supply pump sprocket may not be easy to see.

Remove chain tensioner.

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

JEM121G

SBIA0189E

SEM515G

JEM124G

SECONDARY TIMING CHAIN

EM-173

[YD]

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

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.

Remove timing chain tension guide.

Remove secondary timing chain.

●

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

INSPECTION AFTER REMOVAL
Timing Chain

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

SBIA0227E

SBIA0228E

JEM127G

SEM984C

EM-174

[YD]

SECONDARY TIMING CHAIN

INSTALLATION

Install secondary timing chain.

●

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

Install timing chain tension guide.

●

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

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

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, etc. 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

SECONDARY TIMING CHAIN

EM-175

[YD]

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.

Hereafter, install in the reverse order of removal.

SBIA0189E

JEF370Y

JEM121G

EM-176

[YD]

PRIMARY TIMING CHAIN

PFP:13028

Removal and Installation

EBS00QFS

CAUTION:

●

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.

Almera Tino V10 (2003 year). Manual - part 207