Almera Tino V10 (2003 year). Manual

CYLINDER BLOCK

EM-209

[YD]

17. Install rear oil seal and retainer assembly.

●

Apply a continuous bead of liquid gasket to rear oil seal and
retainer assembly as shown in the figure.

18. Press fit pilot bushing into flywheel.

●

Using drift with outer diameter of 19 mm (0.75 in), press fit
pilot bushing until it stops.

19. Install fuel supply pump bracket.

●

Align the bracket with the dowel pins on the block to install.

●

The two bolts used for dowel pins have a longer shanks than
the other two.

20. Install parts to the engine in the reverse order of disassembly.

21. Remove engine from engine stand in the reverse order of

assembly.

22. Install flywheel.

●

When installing flywheel to crankshaft, be sure to correctly
align crankshaft side dowel pin and flywheel side dowel pin-
hole.

JEM233G

JEM234G

PBIC0762E

PBIC0952E

EM-210

[YD]

CYLINDER BLOCK

●

There is a mating mark on the clutch cover side, Refer it dur-
ing installation.

●

Holding ring gear with ring stopper (SST), tighten securing bolts with TORX bit (size: Q6T55 E9, Com-
mercial Service Tool).

●

Tighten bolts uniformly in a crisscross manner.

How to Select Piston and Bearing

EBS00QFY

DESCRIPTION

●

The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.

●

For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.

●

For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.

HOW TO SELECT PISTON
When Using New Cylinder Block

Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.

Select the piston of the same grade.

●

The part No. of piston is specified together with the piston pin as
an assembly.

PBIC0981E

Selection points

Selection parts

Selection items

Selection methods

Between cylinder block to
crankshaft

Main bearing

Main bearing grade (bearing
thickness)

Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)

Between crankshaft to connect-
ing rod

Connecting rod bearing

Connecting rod bearing grade
(bearing thickness)

Combining service grades for
connecting rod bearing and
crankshaft pin outer diameter
determine connecting rod bear-
ing selection.

Between cylinder block to pis-
ton

Piston and piston pin assembly
The piston is available together
with piston pin as an assembly.

Piston grade (piston outer
diameter)

Piston grade = cylinder bore
grade (inner diameter of bore)

JEM208G

CYLINDER BLOCK

EM-211

[YD]

When Re-using an Old Cylinder Block

Measure cylinder block bore inner diameter.

Referring to “Cylinder block bore inner diameter” in “Piston
Selection Table”, determine the bore grade.

Select the piston of the same grade.

Piston Selection Table

Unit: mm (in)

HOW TO SELECT CONNECTING ROD BEARING
When Using a New Crankshaft and Connecting Rod

Identify the pin diameter grade (No. 0, 1, or 2) on front surface of
crankshaft.

Select the connecting rod bearings of the same grade.

●

There is no grading for the inner diameter of the big end of the
connecting rod.

When Re-using the Removed Crankshaft and Connecting Rod

Measure the inner diameter of the big end of the connecting rod and make sure it is within the specified
range.

Measure the outer diameter of the crankshaft pin.

Determine the crankshaft pin grade by comparing the measurement with the values under the column
“Crankshaft pin outer diameter” of the table below.

Choose the bearings of the same grade.

Selection Table of connecting Rod Bearing

Unit: mm (in)

MBIA0025E

Grade (punched)

Cylinder bore
inner diameter

86.000 - 86.010(3.3858 - 3.3862)

86.010 - 86.020(3.3862 - 3.3866)

86.020 - 86.030(3.3866 - 3.3870)

Piston outer
diameter

85.928 - 85.942(3.3830 - 3.3835)

85.938 - 85.952(3.3834 - 3.3839)

85.948 - 85.962(3.3838 - 3.3843)

JEM215G

Connecting rod big end inner diameter

55.000 - 55.013 (2.1654 - 2.1659)

Crankshaft pin outer diameter

Grade (punched)

0 (no punching)

51.968 - 51.974

(2.0460 - 2.0462)

●

Bearing grade No.

●

Bearing thickness

●

Oil clearance

●

Identification color

STD 0

1.492 - 1.496

(0.0587 - 0.0589)

0.031 - 0.061

(0.0012 - 0.0024)

Black

EM-212

[YD]

CYLINDER BLOCK

Under Size Bearing Usage

●

If bearing clearance is out of specifications for connecting rod bearings in standard size, use under size
bearings.

●

When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft pins to adjust clearance to specification.

Connecting Rod Bearing Under Size list

Unit: mm (in)

CAUTION:

When grinding the crankshaft journal to use an under size bear-
ing, avoid damaging the fillet R.

HOW TO SELECT MAIN BEARING
When Using a New Cylinder Block and Crankshaft

Identify the bearing housing grade (No. 0, 1, or 2) on LH surface
at the rear of the cylinder block, and locate the applicable grade
on the “Grade” row in the table below.

Identify the journal grade (No. 0, 1, or 2) on the front surface of
the crankshaft, and locate the applicable grade under the
“Grade” column on the table.

The main bearing to be used (STD 0 to STD 4) can be located
in the cell where the row and column cross.

When Re-using Removed Cylinder Block and Crankshaft

Measure the inner diameter of cylinder block main bearing hous-
ing.

Locate the applicable cell where the measurement falls, on
“Inner diameter of cylinder block main bearing housing” row on
the table.

Measure the outer diameter of the crankshaft journal.

Locate the applicable cell where the measurement falls, under
“Crankshaft journal outer diameter” column on the table.

The main bearing to be used (STD 0 to STD 4) can be located in
the cell where the row and column cross.

51.961 - 51.968

(2.0457 - 2.0460)

●

Bearing grade No.

●

Bearing thickness

●

Oil clearance

●

Identification color

STD 1

1.496 - 1.500

(0.0589 - 0.0591)

0.031 - 0.061

(0.0012 - 0.0024)

Brown

51.954 - 51.961

(2.0454 - 2.0457)

●

Bearing grade No.

●

Bearing thickness

●

Oil clearance

●

Identification color

STD 2

1.500 - 1.504

(0.0591 - 0.0592)

0.031 - 0.061

(0.0012 - 0.0024)

Green

Size

Thickness

US 0.08 (0.0031)

1.536 - 1.540 (0.0605 - 0.0606)

US 0.12 (0.0047)

1.556 - 1.560 (0.0613 - 0.0614)

US 0.25 (0.0098)

1.621 - 1.625 (0.0638 - 0.0640)

Standard dimension R

: 1.5 - 1.7 mm (0.0591 - 0.0669 in)

JEM216G

JEM208G

JEM215G

CYLINDER BLOCK

EM-213

[YD]

Main Bearing Grade Table

Unit: mm (in)

Under Size Bearing Usage

●

If bearing clearance is out of specifications for connecting rod bearings in standard size, use under size
bearings.

●

When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft journals to adjust clearance to specification.

Main Bearing Under Size List

Unit: mm (in)

CAUTION:

When grinding crank journals to use undersize bearings, keep
corners radius of fillet. (All journals)

Inspection After Disassembly

EBS00QFZ

CRANKSHAFT SIDE CLEARANCE

●

Using dial indicator, measure crankshaft travel amount by mov-
ing the crankshaft forward or backward.

●

If the value exceeds the limit, replace thrust bearings with new
ones and measure again.
If the measurement exceeds the limit again, replace crankshaft
with a new one.

Inner diameter of cylinder block main bearing housing

66.654 - 66.663

(2.6242 - 2.6245)

66.663 - 66.672

(2.6245 - 2.6249)

66.672 - 66.681

(2.6249 - 2.6252)

Crankshaft journal

outer diameter

Grade

(punched)

62.967 - 62.975

(2.4790 - 2.4793)

●

Bearing grade No.

●

Bearing thickness

●

Oil clearance

●

Identification color

STD 0

1.816 - 1.820

(0.0715 - 0.0717)

0.039 - 0.066

(0.0015 - 0.0026)

Black

STD 1

1.820 - 1.824

(0.0717 - 0.0718)

0.039 - 0.066

(0.0015 - 0.0026)

red

STD 2

1.824 - 1.828

(0.0718 - 0.0720)

0.039 - 0.066

(0.0015 - 0.0026)

Green

62.959 - 62.967

(2.4787 - 2.6790)

●

Bearing grade No.

●

Bearing thickness

●

Oil clearance

●

Identification color

STD 1

1.820 - 1.824

(0.0717 - 0.0718)

0.039 - 0.066

(0.0015 - 0.0026)

red

STD 2

1.824 - 1.828

(0.0718 - 0.0720)

0.039 - 0.066

(0.0015 - 0.0026)

Green

STD 3

1.828 - 1.832

(0.0720 - 0.0721)

0.039 - 0.066

(0.0015 - 0.0026)

Yellow

62.951 - 62.959

(2.4784 - 2.4787)

●

Bearing grade No.

●

Bearing thickness

●

Oil clearance

●

Identification color

STD 2

1.824 - 1.828

(0.0718 - 0.0720)

0.039 - 0.066

(0.0015 - 0.0026)

Green

STD 3

1.828 - 1.832

(0.0720 - 0.0721)

0.039 - 0.066

(0.0015 - 0.0026)

Yellow

STD 4

1.832 - 1.836

(0.0721 - 0.0723)

0.039 - 0.066

(0.0015 - 0.0026)

Blue

Size

Thickness

US 0.25(0.0098)

1.949 - 1.953 (0.0767 - 0.0769)

Standard dimension R

: 1.5 - 1.7 mm (0.0591 - 0.0669 in)

JEM216G

Stan-
dard

: 0.10 - 0.25 mm (0.0039 - 0.0098 in)

Limit

: 0.30 mm (0.0118 in)

JEM202G

EM-214

[YD]

CYLINDER BLOCK

CONNECTING ROD SIDE CLEARANCE

●

Using feeler gauge, measure side clearance between connect-
ing rod and crankshaft arm.

●

If measured value exceeds the limit, replace connecting rod and
repeat measurement.
If measured value still exceeds the limit, replace crankshaft.

PISTON TO PISTON PIN CLEARANCE
Piston Pin Hole Inner Diameter

Using inside micrometer, measure piston pin hole inner diameter.

Piston Pin Outer Diameter

Using micrometer, measure piston pin outer diameter.

Calculation of Piston to Piston Pin Clearance

(Piston pin clearance) = (Piston pin hole inner diameter)

−

(Piston pin outer diameter)

●

If clearance is exceeds specification, replace either or both piston/piston pin assembly.

PISTON RING SIDE CLEARANCE

●

Using feeler gauge, measure clearance between piston ring and
piston ring groove.

Unit: mm (in)

Standard

: 0.200 - 0.350(0.0079 - 0.0138 in)

Limit

: 0.4 mm (0.0157 in)

JEM203G

Standard

: 28.003 - 28.009 mm (1.1025 - 1.1027 in)

PBIC0116E

Standard

: 27.995 - 28.000 mm (1.1022 - 1.1024 in)

PBIC0117E

Standard

: 0.003 - 0.014 mm (0.0001 - 0.0006 in)

Item

Standard

Limit

Top ring

0.050- 0.090 (0.0020 - 0.0035)

0.2 (0.008)

2nd ring

0.050 - 0.090 (0.0020 - 0.0035)

0.1 (0.004)

Oil ring

0.030 - 0.070 (0.0012 - 0.0028)

—

SEM024AA

CYLINDER BLOCK

EM-215

[YD]

●

Align top ring and external surface of piston. Measure lower side
clearance of top ring with top ring pressed onto upper side of
ring groove.

●

If side clearance exceeds the limit, replace piston ring.

●

Check clearance again. If side clearance still exceeds the limit,
replace piston.

PISTON RING END GAP

●

Check that cylinder bore diameter is within specifications.
Refer to

EM-217, "PISTON TO CYLINDER BORE CLEAR-

ANCE"

●

Using piston, press piston ring to cylinder mid point, and mea-
sure end gap.

Unit: mm (in)

CONNECTING ROD BEND AND TORSION

Use connecting rod aligner to check bend and torsion.

FEM100

Item

Standard

Limit

Top ring

0.20 - 0.30 (0.0079 - 0.0118)

1.0 (0.039)

2nd ring

0.31 - 0.51 (0.0122 - 0.0201)

Oil ring

0.30 - 0.55 (0.0118 - 0.0217)

FEM101

Bend limit

: 0.12 mm (0.0047 in)/100 mm (3.94 in)

Torsion limit

: 0.12 mm (0.0047 in)/100 mm (3.94 in)

SEM038F

SEM003F

EM-216

[YD]

CYLINDER BLOCK

CONNECTING ROD BIG END INNER DIAMETER

●

Install connecting rod caps without connecting rod bearings and
tighten connecting rod nuts to the specified torque. Using inside
micrometer, measure connecting rod big end inner diameter.

CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Connecting Rod Small End Inner Diameter

Use inside micrometer to measure small end inner diameter.

Piston Pin Outer Diameter

Use micrometer to measure piston pin outer diameter.

Calculation of Connecting Rod Bushing Clearance

(Connecting rod small end bushing clearance) = (Connecting rod small end inner diameter)

−

(Piston pin outer

diameter)

●

If out of specifications, replace connecting rod and/or piston and piston pin assembly. Refer to

EM-211,

"HOW TO SELECT CONNECTING ROD BEARING"

Standard

: 55.000 - 55.013 mm (2.1654 - 2.1659 in)

PBIC0119E

Standard

: 28.026 - 28.038 mm (1.1034 - 1.1039 in)

PBIC0120E

Standard

: 27.995 - 28.000 mm (1.1022 - 1.1024 in)

PBIC0117E

Standard

: 0.026 - 0.044 mm (0.0010 - 0.0017 in)

Limit

: 0.057 mm (0.0022 in)

CYLINDER BLOCK

EM-217

[YD]

CYLINDER BLOCK TOP SURFACE DISTORTION

●

Using scraper, remove gasket installed onto cylinder block sur-
face. Remove contamination such as oil, scale, and carbon.

CAUTION:

Keep broken pieces of gasket clear of oil and coolant pas-
sages.

●

Use straightedge and feeler gauge to check block upper surface
for distortion.

MAIN BEARING HOUSING INNER DIAMETER

●

Without installing main bearings, install main bearing caps, and
tighten bolts to the specified torque.

●

Measure the inner diameter of main bearing housing with a bore
gauge.

●

If the measurement is out of the specified range, replace cylin-
der block and main bearing caps.

PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter

●

Using bore gauge, measure cylinder inner diameters at 6 posi-
tions; top, middle, and bottom (C - A) in 2 directions (X, Y).

●

If clearance exceeds the limit, or any flaws or seizures are found
on inner surface of cylinder, horn or bore the applicable cylinder
or redore all cylinder.

Limit

: 0.04 mm (0.0016 in)

SEM501G

Standard

: 66.654 - 66.681 mm (2.6242 - 2.6252 in)

JEM214G

Cylinder inner diameter:

Standard

: 86.000 - 86.030 mm

(3.3858 - 3.5870 in)

Wear limit

: 0.07 mm (0.0028 in)

Out-of-round limit (X - Y)

: 0.015 mm (0.0006 in)

Taper limit (C - A)

: 0.010 mm (0.0004 in)

PBIC0763E

FEM110

EM-218

[YD]

CYLINDER BLOCK

Piston Outer Diameter

Use micrometer to measure piston skirt outer diameter.

Calculation of Piston to Piston Bore Clearance

●

Calculate using piston skirt outer diameter and cylinder inner diameter (direction X, position B).
(Clearance) = (Cylinder inner diameter)

−

(Piston skirt outer diameter)

●

If out of specification, replace piston and piston pin assembly. Refer to

EM-210, "HOW TO SELECT PIS-

TON"

Reboring Cylinder

Determine cylinder bore size by adding piston-to-cylinder bore clearance to piston diameter.

Install main bearing caps and tighten bolts to specified torque. This will prevent distortion of cylinder
bores.

Cut cylinder bore.

●

When any cylinder needs boring, all other cylinders must also be bored.

●

Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so at a time.

Hone cylinders to obtain specified piston-to-bore clearance.

Measure finished cylinder bore for out- of-round and taper.

●

Measurement should be done after cylinder bore cools down.

CRANKSHAFT JOURNAL OUTER DIAMETER

Use micrometer to measure journal outer diameter.

CRANKSHAFT PIN OUTER DIAMETER

Use micrometer to measure pin outer diameter.

Piston skirt diameter:

Measurement position

: 11.0 mm (0.43 in)

Distance from the bottom

Standard

: 85.928 - 85.962 mm

(3.3830 - 3.3843 in)

0.25 (0.0098) O/S

: 86.188 - 86.202

(3.3932 - 3.3938)

0.50 (0.0197) O/S

: 86.438 - 86.452

(3.4031 - 3.4036)

PBIC0125E

Specifications at room temperature [20

C (68

F)]:

0.058 - 0.082 mm (0.0023 - 0.0032 in)

Rebore size calculation:

D = A + B – C

Where,

D:Rebored diameter

A: Piston diameter as measured

B: Piston-to-bore clearance

C: Honing allowance 0.02 mm (0.0008 in)

Standard

: 62.951 - 62.975 mm (2.4784 - 2.4793 in)

FEM114

CYLINDER BLOCK

EM-219

[YD]

CRANKSHAFT OUT-OF-ROUND AND TAPER

●

Using micrometer, measure each journal and pin at 4 points
shown in the figure.

●

Out-of-round value is indicated by difference in dimensions
between directions X and Y at points A and B.

●

Taper value is indicated by difference in dimensions between
points A and B in directions X and Y.

CRANKSHAFT RUNOUT

●

Place V-block onto surface plate to support journals at both ends
of crankshaft.

●

Position dial indicator vertically onto No. 3 journal.

●

Rotate crankshaft to read needle movement on dial indicator.
(Total indicator reading)

CONNECTING ROD BEARING OIL CLEARANCE
Method by Measurement

●

Install connecting rod bearings to connecting rods and caps, and
tighten connecting nuts to the specified torque. Use inside
micrometer to measure connecting rod bearing inner diameter.
(Bearing clearance) = (Connecting rod bearing inner diameter)

−

(Crankshaft pin outer diameter)

●

If out of specifications, check connecting rod big end inner diam-
eter and crankshaft pin outer diameter, and select appropriate
connecting rod bearing to adjust clearance to specifications.
Refer to

EM-211, "HOW TO SELECT CONNECTING ROD

BEARING"

Method Using Plastigage

●

Remove contamination such as oil, dust completely from crank-
shaft pins and each bearing surface.

●

Cut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.

●

Install connecting rod bearings to caps, and tighten connecting
rod nuts to the specified torque.

CAUTION:

Never rotate crankshaft.

●

Remove connecting rod caps and bearings, and measure plasti-
gage width using scale on plastigage bag.

Standard

: 51.954 - 51.974 mm (2.0454 - 2.0462 in)

Out-of-round:

Standard

: 0.003 mm (0.0001 in)

Limit

: 0.005 mm (0.0002 in)

Taper:

Standard

: 0.003 mm (0.0001 in)

Limit

: 0.005 mm (0.0002 in)

SEM316A

Standard

: 0.05 mm (0.0020 in)

Limit

: 0.10 mm (0.0039 in)

FEM116

Standard

: 0.031 - 0.061 mm (0.0012 - 0.0024 in)

PBIC0119E

EM142

EM-220

[YD]

CYLINDER BLOCK

CAUTION:

If out of specification, take same action mentioned in “Method by measurement”.

MAIN BEARING OIL CLEARANCE
Method by Measurement

●

Install main bearings to the cylinder block and bearing cap, and tighten the bolts to the specified torque.
Then, measure the inner diameter of the main bearings.
(Bearing clearance) = (Bearing inner diameter)

−

(Crankshaft journal outer diameter)

●

If out of specification, check main bearing housing inner diameter and crankshaft journal outer diameter,
and select appropriate main bearing to adjust clearance to specifications. Refer to

EM-212, "HOW TO

SELECT MAIN BEARING"

Method Using Plastigage

●

Remove contamination such as oil and dust completely from
crankshaft journals and each bearing surface.

●

Cut plastigage slightly shorter than bearing width. place it in
crankshaft turning direction, avoiding oil holes.

●

Install main bearings and bearing cap and tighten to the speci-
fied torque.

CAUTION:

Never rotate crankshaft.

●

Remove main bearings and bearings, and measure plastigage
width using scale on plastigage bag.

CAUTION:

If out of specification, take same action mentioned in “Method by measurement”.

●

Install main bearings to the cylinder block and bearing cap, and tighten the bolts to the specified torque.
Then, measure the inner diameter of the main bearings.

MAIN BEARING CRUSH HEIGHT

●

When the bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of bear-
ing must protrude.

●

If out of specification, replace main bearings.

MAIN BEARING CAP BOLT DEFORMATION

●

Measure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.

●

When the necked point is identified at a point other than where
specified, measure at the point as d2.

●

Calculate the difference between d1 and d2.

Standard

: 0.039 - 0.066 mm (0.0015 - 0.0026 in)

PBIC0131E

Standard

: Crush height must exist.

SEM502G

Limit

: 0.13 mm (0.0051 in)

JEM219G

CYLINDER BLOCK

EM-221

[YD]

CONNECTING ROD BOLT DEFORMATION

●

Install nuts to connecting rod bolts. Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread on
the bolt.

●

If the nut does not screw in smoothly, measure the outer diame-
ter of the bolt thread at the point specified in the figure.

●

If a necked point is identified, measure at that point.

●

If the measurement exceeds the limit, replace connecting rod
bolts and nuts.

OIL JET

●

Check nozzle for deformation and damage.

●

Blow compressed air from nozzle, and check for clogs.

●

If it out of the standard, replace oil jet.

OIL JET RELIEF VALVE

●

Using a clean plastic stick, press check valve in oil jet relief
valve. Make sure that valve moves smoothly with proper reac-
tion force.

●

If it is out of the standard, replace oil jet relief valve.

MOVEMENT AMOUNT OF FLYWHEEL

NOTE:

●

Inspection for double mass flywheel only.

●

Do not disassembly double mass flywheel.

Flywheel Runout

●

Measure deflection of flywheel contact surface to the clutch with a dial gauge.
Measure deflection at 210 mm (8.27 in) dia.

●

When measured value exceeds the limit, replace flywheel with a
new one.

Standard

: 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.

Limit

: 8.75 mm (0. 3445 in) dia.

JEM220G

Standard

: Deformation and damage.

JEM221G

Standard

: Valve moves smoothly with proper reaction force.

JEM222G

YD22DDT engine

Limit

: 0.15mm (0.0059in)

YD22DDTi engine

Standard

: 0.45mm (0.0177 in) or less

Limit

: 1.3mm (0.051 in)

PBIC0683E

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-223

[YD]

SERVICE DATA AND SPECIFICATIONS (SDS)

PFP:00030

Standard and Limit

EBS00QG0

GENERAL SPECIFICATIONS

INTAKE MANIFOLD AND EXHAUST MANIFOLD

Unit: mm (in)

DRIVE BELTS

Belt Deflection:

Unit: mm (in)

*: When engine is cold.

Cylinder arrangement

In-line 4

Displacement

Unit: cm

(cu in)

2,184 (133.27)

Bore and stroke

Unit: mm (in)

86 x 94 (3.39 x 3.70)

Valve arrangement

DOHC

Firing order

1-3-4-2

Number of piston rings

Compression

Oil

Number of main bearings

Compression ratio

16.7

Compression pressure

Unit: kPa (bar, kg/cm

, psi)/200 rpm

Standard

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

Minimum

2,452 (24.5, 25.0, 356)

Differential limit between cylinders

490 (4.9, 5.0, 71)

Valve timing

Unit: degree

224

212

-2

EM120

Item

Limit

Surface distortion

Intake manifold

0.1 (0.004)

Exhaust manifold

0.3 (0.012)

Applied belt

Belt deflection with 98 N (10 kg, 22 lb) force applied*

New

Adjusted

Limit for re-adjusting

Air conditioner compressor
belt

4 - 5

(0.16 - 0.20)

6 - 7

(0.24 - 0.28)

8.5 (0.335)

Alternator & water pump
belt

9.0 - 10.5

(0.354 - 0.413)

11.0 - 12.5

(0.433 - 0.492)

16.5 (0.650)

EM-224

[YD]

SERVICE DATA AND SPECIFICATIONS (SDS)

CYLINDER HEAD

Unit: mm (in)

VALVE
Valve

Unit: mm (in)

Valve Clearance

Unit: mm (in)

*1: Approximately 20

C (68

*2: Approximately 80

C (176

Item

Standard

Limit

Head surface distortion

Less than 0.03 (0.0012)

0.04 (0.0016)

JEM204G

Valve head diameter “D”

Intake

28.0 - 28.3 (1.102 - 1.114)

Exhaust

26.0 - 26.3 (1.024 - 1.035)

Valve length “L”

Intake

106.72 (4.2016)

Exhaust

106.36 (4.1874)

Valve stem diameter “d”

Intake

5.965 - 5.980 (0.2348 - 0.2354)

Exhaust

5.945 - 5.960 (0.2341 - 0.2346)

Valve seat angle “

”

Intake

′

- 45

′

Exhaust

Valve margin “T”

Intake

1.38 (0.0543)

Exhaust

1.48 (0.0583)

Valve margin “T” limit

More than 1.0 (0.039)

Valve stem end surface grinding limit

Less than 0.2 (0.008)

SEM188

Item

Cold*1

Hot*2 (reference data)

Intake

0.24 - 0.32 (0.0094 - 0.0126)

0.274 - 0.386 (0.011 - 0.015)

Exhaust

0.26 - 0.34 (0.0102 - 0.0134)

0.308 - 0.432 (0.012 - 0.017)

Almera Tino V10 (2003 year). Manual - part 210