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Almera Tino V10 (2003 year). Manual - part 208

PRIMARY TIMING CHAIN

EM-177

[YD]

MBIA0027E

Fuel pump

Chain tensioner

Slack guide

Camshaft sprocket

Fuel pump sprocket

Tension guide

EM-178

[YD]

PRIMARY TIMING CHAIN

REMOVAL

Remove engine and transaxle. Refer to

EM-197, "Removal and Installation"

Remove transaxle from engine. place engine onto engine stand (SST). Refer to

EM-201, "Disassembly

and Assembly"

Remove oil pan. Refer to

EM-137, "Removal and Installation"

Remove oil filter bracket. Refer to LC-28, “Oil Filter Bracket”.

Remove injection tube and fuel injector. Refer to

EM-147, "Removal and Installation"

Remove secondary timing chain and associated parts. Refer to

EM-171, "Removal and Installation"

When removing rear chain case, remove camshaft sprockets. Refer to

EM-162, "Removal and Installa-

tion"

Remove crankshaft pulley.

Hold crankshaft pulley with the pulley holder (SST).

Loosen crankshaft pulley fixing bolt and pull out the bolt approx-
imately 10 mm (0.39 in).

Using pulley puller (SST), remove crankshaft pulley.

●

Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.

Remove oil pump housing.

●

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

●

Use seal cutter (SST) etc. for removal.

10. Remove front oil seal from oil pump housing.

●

Punch out the seal off from the back surface of the oil pump
using a flat-bladed screwdriver.

●

Be careful not to damage the oil pump housing.

Chain guide

Spacer

Front chain case

10.

Crankshaft pully

11.

Front oil seal

12.

Oil pump housing

13.

Primary timing chain

14.

Oil pump drive spacer.

15.

Crankshaft sprocket

16.

Secondary timing chain

17.

Rear chain case

18.

Power steering pump

JEM131G

JEM132G

JEM133G

PRIMARY TIMING CHAIN

EM-179

[YD]

11. Remove chain tensioner.

●

When removing chain tensioner, push the sleeve of chain
tensioner and keep it pressed with a push pin, etc.

12. Remove timing chain slack guide.

13. 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 fuel pump sprocket
to fuel pump body to hold pump sprocket, and remove bolt.

14. Remove primary timing chain with fuel pump sprocket and

crankshaft sprocket.

15. Remove chain guide and tension guides.

16. Remove fuel pump.

17. Remove power steering pump.

JEM134G

MBIA0049E

PBIC0945E

MBIA0079E

MBIA0080E

EM-180

[YD]

PRIMARY TIMING CHAIN

18. Remove camshaft sprockets.

●

Loosen the camshaft sprockets installation bolts by fixing the
hexagonal portion of the camshaft.

19. Remove rear chain case.

●

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

●

Use seal cutter (SST) for removal.

INSPECTION AFTER REMOVAL
Timing Chain

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

JEM159G

SBIA0211E

SEM984C

PRIMARY TIMING CHAIN

EM-181

[YD]

INSTALLATION

Install rear chain case.

Apply a continuous bead of Genuine Liquid Gasket or eqivalent
on locations shown in the figure. Refer to

EM-110, "Precautions

for Liquid Gasket"

A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by starting and ending
at areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protruding
from the case surface.

Install four O-rings to the grooves of the cylinder block and fuel
pump bracket.

MBIA0031E

SBIA0212E

JEM141G

EM-182

[YD]

PRIMARY TIMING CHAIN

Install rear chain case.

●

When installing, align the dowel pin with the pin hole.

Tighten bolts in the numerical order shown in the figure.

●

Install the following four types of bolts, referring to the figure.

●

The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).

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

Install power steering pump.

Install fuel pump.

●

Before installing, make sure the notch on the fuel pump flange
and the hole 6 mm (0.24 in) in diameter on the pump body are
aligned.

Install chain guide and tension guides.

Install crankshaft sprocket, aligning it with the crankshaft key on
the far side.

Install primary timing chain with fuel pump sprocket.

●

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

●

Install fuel pump sprocket washer with the surface marked “F”
(front mark) facing the front of the engine.

Install timing chain onto power steering pump sprocket and
through chain guide.

16 mm (0.63 in)

: Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22

20 mm (0.79 in)

: Bolt No. 3, 4, 6, 9, 10, 11, 13, 14

25 mm (0.98 in)

: Bolt No. 12, 15

35 mm (1.38 in)

: Bolt No. 5, 7, 8

SBIA0211E

MBIA0080E

MBIA0079E

PRIMARY TIMING CHAIN

EM-183

[YD]

Use the positioning stopper pin (SST) to hold the fuel pump
sprocket and install the bolt.

●

Using a TORX wrench (SST), turn the pump shaft little by little
to adjust the position of the pump flange. Insert positioning
stopper pin (SST) into the hole 6 mm (0.24 in) in diameter on
the fuel pump sprocket so that the stopper pin goes through
the pump flange to the pump body. While the stopper pin is in
place, install the bolt.

Install timing chain slack guide.

10. Install chain tensioner.

●

Push the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin, etc., install the chain
tensioner.

●

After installation, pull out the push pin holding the plunger.

●

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

11. Install front oil seal to oil pump housing.

●

Using a suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.

●

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

12. Install chain case cover (for opening for power steering pump

removal/installation) to oil pump.

●

Apply a continuous bead of Genuine Liquid Gasket or equiv-
alent as shown in the figure. Refer to

EM-110, "Precautions

for Liquid Gasket"

●

Apply liquid gasket on oil pump-side surface.

MBIA0049E

PBIC0945E

JEM134G

MBIA0047E

JEM143G

EM-184

[YD]

PRIMARY TIMING CHAIN

13. Install oil pump housing.

Apply a continuous bead of Genuine Liquid Gasket or equiva-
lent on locations shown in the figure. Refer to

EM-110, "Precau-

tions for Liquid Gasket"

A: Leave the start and end areas of the bead slightly protruding
from the surface.
B: Apply liquid gasket along upper end surface of oil pump hous-
ing.

Install oil pump drive spacer to crankshaft.

●

Install with the front mark (punched mark) facing the front of
the engine.

Install O-ring into the groove of rear chain case.

Install oil pump housing.

●

When installing, align the inner rotor in the direction of the two
facing flats of the oil pump drive spacer.

●

When installing, align the dowel pin with the pin hole.

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

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

14. Check gaps on upper oil pan mounting surface.

●

Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:

●

If the measured value is out of the above range, install again.

15. Install crankshaft pulley.

Install crankshaft pulley to crankshaft.

Hold crankshaft pulley with the pulley holder (SST).

Tighten bolt to 20 to 29 N·m (2.0 to 3.0 kg-m,15 to 21 ft-lb).

Put an alignment mark on crankshaft pulley that aligns with one
of the punched marks on the bolt.

Tighten fixing bolt another 60

- 66

[target: 60

(turn by one

notch)].

16. Install secondary timing chain and the associated parts.

Refer to

EM-174, "INSTALLATION"

JEM144G

JEM145G

JEM133G

Oil pump housing and rear chain case:

Standard

: – 0.14 to 0.14 mm (– 0.0055 to 0.0055 in)

Rear chain case and cylinder block:

Standard

: – 0.25 to 0.13 mm (– 0.0098 to 0.0051 in)

JEM146G

JEM147G

PRIMARY TIMING CHAIN

EM-185

[YD]

17. Install in the reverse order of removal hereafter.

EM-186

[YD]

CYLINDER HEAD

PFP:11041

On-Vehicle Service

EBS00QFT

CHECKING COMPRESSION PRESSURE

Warm up engine thoroughly. Then, stop it.

Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer to

EC-971,

"Basic Inspection"

●

Do not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and
for error detection at the end of this operation.

Disconnect the negative battery cable.

To prevent fuel from being injected during inspection, remove
fuse [ECCS (20A)] from fuse box on the left side of engine com-
partment.

Remove glow plugs from all the cylinders. Refer to

EM-142,

"Removal and Installation"

CAUTION:

●

Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.

●

Carefully remove glow plugs to prevent any damage or
breakage.

●

Handle with care to avoid applying any shock to glow
plugs.

Install adapter to installation holes of glow plugs and connect
compression gauge for diesel engine.

Connect battery negative terminal.

Set the ignition switch to “START” and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.

●

Always use a fully-charged battery to obtain specified engine
speed.

Unit: kPa (bar, kg/cm

, psi)/rpm

●

When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.

●

If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.

●

If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.

–

If compression pressure becomes normal after applying oil, piston ring may be worn or damaged.
Check piston ring for malfunction. If any, replace piston ring.

–

If compression pressure is still low after applying oil, valve may be malfunctioning. Check valve for mal-
function. If contact malfunction is found, replace valve or valve seat.

●

If compression pressure in adjacent two cylinders is low after applying oil, pressure may be leaking
from gasket. In this case, replace cylinder head gasket.

Complete this operation as follows.

Turn the ignition switch to “OFF”.

Disconnect negative battery cable.

MBIA0019E

: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)

Standard

Minimum

Difference limit between

cylinders

2,991 (29.9, 30.5, 2,434)/

200

2,452 (24.52, 25.0, 356)/

200

490 (4.90, 5.0, 71)/200

SEM112G

CYLINDER HEAD

EM-187

[YD]

Install glow plug and install all the parts removed in step 4.

Install fuse [ECCS (20A)].

Connect negative battery cable.

Using CONSULT-II make sure no error code is indicated for items of self-diagnosis.

Removal and Installation

EBS00QFU

CAUTION:

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

REMOVAL

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

Remove the following parts.

●

Rocker cover (Refer to

EM-160, "Removal and Installation"

●

Air cleaner and air duct (Refer to

EM-119, "Removal and Installation"

●

Vacuum pump (Refer to

EM-143, "Removal and Installation"

●

Injection tube, spill tube and fuel injector (Refer to

EM-147, "Removal and Installation"

●

Intake manifold (Refer to

EM-123, "Removal and Installation"

●

Exhaust manifold and turbocharger (Refer to

EM-128, "Removal and Installation"

●

Secondary timing chain (Refer to

EM-171, "Removal and Installation"

●

Camshaft (Refer to

EM-162, "Removal and Installation"

PBIC0946E

Glow plug

Cylinder head assembly

Cylinder head bolt

Gasket

Engine coolant temperature sensor

Gasket

Water outlet

Glow plate

EM-188

[YD]

CYLINDER HEAD

Remove cylinder head assembly.

●

Loosen and remove mounting bolts in the reverse order
shown in the figure.

●

Lift up the cylinder head assembly to avoid interference with
dowel pins located between the block and head, and remove
cylinder head assembly.

CAUTION:

Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of the cylinder
head, or, place wood blocks beneath both ends of the cyl-
inder head to keep the cylinder bottom from any contact.

●

For glow plug removal, the following shall be noted.

CAUTION:

●

To avoid breakage, do not remove glow plug unless necessary.

●

Perform continuity test with glow plug installed.

●

Keep glow plug from any impact. (Replace if dropped from a height 10 cm (3.94 in) or higher.)

●

Do not use air impact wrench.

INSPECTION AFTER REMOVAL
Cylinder Head Bolt Deformation

●

Using micrometer, measure the outer diameters d1 and d2 of
bolt thread as shown in the figure.

●

If the necking point can be identified, set it as measuring point
d2.

●

Calculate the difference between d1 and d2.

●

If out of the limit, replace cylinder head bolt.

Cylinder Head-to-block Difference Check

●

After installing cylinder head, measure dimension from the front
end surface of cylinder block to that of cylinder head.

●

If the difference is out of the range, check fitting of dowel pins
and cylinder head.

INSTALLATION

Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts.

Install cylinder head gasket.

●

Cylinder head gasket to be installed is selected by its thick-
ness through the following procedure.

–

When replacing gasket alone

• Install a gasket with same thickness as that of the one

removed.

• Identify the thickness of gasket by the number of cut-outs on

the rear RH side.

JEM149G

Limit

: 0.15 mm (0.0059 in)

JEM171G

Standard

: 23.53 - 24.07 mm (0.9264 - 0.9476 in)

JEM172G

MBIA0020E

CYLINDER HEAD

EM-189

[YD]

*: Measured with head bolts tightened

• Gasket thickness can be identified at the location shown in

the figure by the numbers of cut-outs before removal.

–

When the following parts have been repaired/replaced:

●

With cylinder block upper surface and/or crankshaft pin journal ground.

●

With cylinder block, pistons, connecting rods, and/or crankshaft replaced.

Set piston at a point close to TDC.

Set a dial gauge at the location as shown in the figure. Turning crankshaft gradually, set the gauge scale
to “0” where the piston protrusion is maximized.

Move the dial gauge stand so that the tip of dial gauge can contact the cylinder block. Read the difference.

Measure at two locations per cylinder, that is eight locations for four cylinders. Select gasket based on the
maximum protrusion of eight measurements.

*: Measured with head bolts tightened

Gasket thickness* mm (in)

Number of grade

Number of cut-outs

0.900 (0.0354)

0.925 (0.0364)

0.950 (0.0374)

0.975 (0.0384)

1.000 (0.0394)

1.025 (0.0404)

PBIC0682E

SEM507G

Piston protrusion

mm (in)

Gasket thickness* mm (in)

Identification

Number of cut-outs

Less than 0.255 (0.0100)

0.900 (0.0354)

Less than 0.255 - 0.280 (0.0100 - 0.0110)

0.925 (0.0364)

Less than 0.280 - 0.305 (0.0110 - 0.0120)

0.950 (0.0374)

Less than 0.305 - 0.330 (0.0120 - 0.0130)

0.975 (0.0384)

Less than 0.330 - 0.355 (0.0130 - 0.0140)

1.000 (0.0394)

More than 0.355 (0.0140)

1.025 (0.0404)

EM-190

[YD]

CYLINDER HEAD

Apply a continuous bead of Genuine Liquid Gasket or equivalent
on the surface shown in the figure.
A: Apply bead so that it does not protrude into oil passage. Refer
to

EM-110, "Precautions for Liquid Gasket"

B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.

Apply so that the portion marked * comes at an external loca-

tion but cannot be viewed externally after engine is assembled.

Install cylinder head assembly.

●

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

Apply engine oil to bolt threads and seat surfaces.

Tighten bolts to 35 to 44 N·m (3.5 to 4.5 kg-m, 26 to 32 ft-lb).

Tighten 180

to 185

[target: 180

] (angular tightening).

Loosen completely to 0 N·m (0 kg-m, 0 in-lb) in the reverse order
of that shown in the figure.

Tighten bolts to 35 to 44 N·m (3.5 to 4.5 kg-m, 26 to 32 ft-lb).

Tighten 90

to 95

[target: 90

] (angular tightening)

Tighten another 90

to 95

[target: 90

] (angular tightening).

●

When an angle wrench is not used, paint an alignment
mark on the head of cylinder head bolt and cylinder head
surface before tightening. Check the angle with a protrac-
tor.

Install glow plug.

●

To avoid damage, glow plugs should be removed only
when required.

●

Handle with care to avoid applying shock. When dropped
from approx. 100 mm (3.94 in) or higher, always replace
with a new one.

●

Before installing, remove carbon depositing on mounting hole of glow plug with a reamer.

Install engine coolant temperature sensor and thermal transmitter.

JEM167G

JEM149G

JEM166G

CYLINDER HEAD

EM-191

[YD]

Disassembly and Assembly

EBS00QFV

CAUTION:

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

DISASSEMBLY

Remove adjusting shims and valve lifters.

●

Check the installation positions, and keep them to avoid being
confused.

Remove valve.

●

Using valve spring compressor, compress valve spring. Using
magnetic hand, remove valve collets.

Remove valve spring retainers and valve springs.

Remove valves as pressing valve stems toward combustion
chamber.

●

Before removing the valve, check the valve guide clearance.
Refer to

EM-193, "Valve Guide Clearance"

●

Check installation positions, and keep them to avoid being
confused.
NOTE:
Refer to the figure for intake and exhaust valve positions.
Intake and exhaust valve driving cams are provided alter-
nately for each camshaft.

SBIA0194E

SBIA0195E

SBIA0196E