Engine Mechanical

Engine Mechanical Engine
Engine Mechanical
Specifications
Torque
Description Value
Bolt - Air Cleaner Bracket to Body 5-7 Nm
Bolt - Battery Tray to Body 40-50 Nm
Bolt - Engine Mounting to Cylinder Block 40-50 Nm
Bolt - Flywheel to Crankshaft (32–38)Nm + 60°
Bolt - Crankshaft Damper to Crankshaft 60 Nm + 120°
Bolt - Timing Chain Upper Cover Plate to Cylinder Head 8-12 Nm
(M6 x 35)
Bolt - Timing Chain Lower Cover Plate to Cylinder Block 8-12 Nm
and Lower Crankcase
Bolt - Chain Guide Rail and Tensioner Guide Rail 22-28 Nm
Bolt - Upper Guide Rail to Cylinder Head Front Camshaft 8–12 Nm
Bearing Cap
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Bolt - Timing Chain Tensioner to Cylinder Head 57-63 Nm
Bolt - Exhaust Camshaft Sprocket to Camshaft 25 Nm + 45°
Bolt - Intake Phase Modulator to Camshaft 70-80 Nm
Bolt - Oil Pump Sprocket to Oil Pump 22-28 Nm
Bolt - Camshaft Bearing Cap to Cylinder Head 8-12 Nm
Bolt - Ignition Coil 8–12 Nm
Bolt - Cylinder Head to Cylinder Block 30 Nm + 90°+ 90°+ 45°
Bolt - Cylinder Head Chain Case to Cylinder Block 10-12 Nm
Bolt - Oil Control Valve to Cylinder Head 5-7 Nm
Bolt - Thermostat Cover to Cylinder Head 8-12 Nm
Bolt - Alternator to Cylinder Head 40-50 Nm
- Spark Plug 20-30 Nm
Bolt - Timing Chain Upper Cover Plate to Cylinder Head 8-12 Nm
(M6 x 20)
Bolt - Lower Crankcase to Cylinder Block 22-30 Nm
Bolt - Main Bearing Cap to Cylinder Block (20 ± 2) Nm + 90°+(45 ± 2)°
Bolt - Connecting Rod (18 ± 2) Nm + (90 ± 5)°
Bolt - Crankshaft Rear Oil Seal 8-12 Nm
Bolt - Oil Pump to Lower Crankcase 8-12 Nm
Bolt - Oil Baffle to Lower Crankcase 8-12 Nm
- Oil Filter 16–18 Nm
Plug - Lower Crankcase Drain 35-40 Nm
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Engine Engine Mechanical
Parameter
1.5VCT - Overall
Type 1.5-liter gasoline engine, 16-valve, double overhead camshaft,
variable intake cam timing
Cylinder Layout 4-cylinder, in-line, transverse, the first cylinder in the front of
the engine
Cylinder Bore Diameter 75.00 mm
Stroke 84.80 mm
Displacement 1,498 cm3
Firing Order 1-3-4-2
Compression Ratio 10.5:1
Rotating Direction Rotating clockwise when viewed from the front of the engine
Rated Power 80 kW @ 6,000 rev/min
Maximum Torque 135 Nm @ 4,500 rev/min
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Idle Speed 750±50 rev/min
Maximum Engine Speed 7,000 rev/min
Weight (without oil, PAS, A/C and clutch assembly) 116 kg (MT), 111 kg (AT)
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1.5VCT - Crankshaft
Crankshaft
Crankshaft End Play 0.205±0.1 mm
Service Value Limit 0.34 mm
Main Journal Diameter:
Class A 53.690-53.700 mm
Class B 53.680-53.690 mm
Main Journal Tolerance:
Class 0 49.993-50.000 mm
Class 1 49.992-49.984 mm
Pin Journal Diameter 48.000-47.984 mm
Maximum Out-of-round 0.008 mm

Main Bearing:
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Quantity 5 on top and 5 at bottom
Type Steel shell layer, antifriction alloy, the upper half of bearing has
oil passages.
Half-plate washers are on both of the left and right thrust sides
Thrust Plate
of the third main bearing and adhere to the thrust surfaces.
Thickness of Thrust Washer 2.810-2.855 mm
Bearing Backlash 0.020-0.054 mm
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1.5VCT - Cylinder Block and Piston

Cylinder Block:
Material Cast iron, HT250
Cylinder Liner Type Plateau honing checker liner
Cylinder Liner Diameter 74.985-75.000 mm

Cylinder Block Correction Size:
Bore Maximum Diameter of Skirt Gap between Piston and

Portion of Piston Cylinder Bore
Normal Size 74.985-75.000 74.941-74.959 0.026-0.059
A (+0.5) 75.485-75.500 75.441-75.459 0.026-0.059
B (+1.0) 75.985-76.000 75.941-75.959 0.026-0.059
C (+1.5) 76.485-76.500 76.441-76.459 0.026-0.059
Connecting Rod:
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Type Fractured connecting rod, Material C70S6
Distance between Centres 143.7±0.05 mm
Piston Pin Type Semi-floating
Fitted into Connecting Rod Interference
Length 51.7-52.0 mm
Connecting Rod Bearing:
Gap 0.020-0.071 mm
Axial Play 0.100-0.246 mm
Piston:
Type Aluminum alloy, surface graphitized, deviating toward the
piston pin during thermal expansion
Piston Diameter:
74.941-74.959 mm
Piston Pin Opening Tolerance
0.009-0.020 mm
Maximum Ovality
0.002 mm
Piston Ring:
Type: 2 compression rings, 1 oil ring
Top Compression Ring Outer circle with eccentric barrel face, surface nitrided
2nd Compression Ring Nose shape, and surface bonderized

Oil Ring Spring nitrided, the side rail nitridized and then bonderized
Tolerance from Piston Ring to Ring Groove:
Top Compression Ring 0.040-0.080 mm
2nd Compression Ring 0.030-0.062 mm
Oil Ring 0.015-0.045 mm
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Piston Ring End Gap (Measure at 20 mm from the cylinder
liner opening):
0.25-0.40 mm
Top Compression Ring
0.37-0.57 mm
2nd Compression Ring
0.10-0.60 mm
Oil Ring
Width of Piston Ring Groove:
Top Compression Ring 0.970-0.990 mm
2nd Compression Ring 1.170-1.190 mm

Oil Ring 1.880-1.980 mm
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1.5VCT Cylinder Head and Valve

Cylinder Head:
Material Aluminum alloy
Cylinder Head Bend - Maximum 0.05 mm
Cylinder Head Height:
New 118.95-119.05 mm
Finish Limit 0.20 mm
Camshaft:
Double overhead camshaft which directly acts on the
Type
mechanical tappet
Bearing 5 for each camshaft, arranged in line
Drive Chain drive at crankshaft gear
Camshaft Thrust Gap: 0.06-0.19 mm
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Bearing Backlash: Front 0.025-0.066 mm, rear 0.024-0.066 mm
Mechanical Tappet:
Type Mechanical tappet, directly driven by the camshaft
Outer Diameter of Mechanical Tappet f29.964 mm-f29.980 mm
Valve Timing:
Intake Valve:
Open 22°ATDC
Close 68°ABDC
Maximum Lift 7.7 mm
Exhaust Valve:
Open 45°BBDC
Close 11°ATDC
Maximum Lift 8.2 mm
Valve:
Valve Stem Diameter:
Intake Valve f5.952-f5.967 mm
Exhaust Valve f5.947-f5.962 mm
Gap between Valve Stem and Valve Guide:
Intake Valve 0.033-0.073 mm
Exhaust Valve 0.038-0.078 mm
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Valve Stem Mating Height:
New Intake Valve 50.021-50.881
New Exhaust Valve 49.925-50.785

Valve Head Diameter:
Intake Valve f29.2-f29.4 mm
Exhaust Valve f24.0-f24.2 mm
Valve Seat Width

1.0 mm-1.4 mm
Intake Valve
1.4 mm-1.8 mm
Exhaust Valve
Intake 150°, 90°, 60°
Angle of Valve Seat Surface - Intake Valve and Exhaust Valve
Exhaust 150°, 90°, 60°
Angle of Valve Surface - Intake Valve and Exhaust Valve 45°
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Intake Valve: 0.11-0.19 mm
Valve Gap
Exhaust Valve: 0.20-0.28 mm
Valve Spring:
Free Length 50.0 mm
Refit Length 37.0 mm
Assembly Load 250±12.5 Nm
Intake Valve Open Load 442±18 Nm
Exhaust Valve Open Load 464±18 Nm
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Lubrication
Lubrication:
Type Cast-aluminum lower crankcase
Oil Pump Type: Rotor pump driven by chain
Engagement Gap of Inner and Outer Rotors 0.03-0.11 mm
Gap between Rotor and Pump Cover End Surface 0.05-0.086 mm

Pressure Limiting Valve Spring Free Length 67.95±1 mm
Oil Filter Rotary type full flow oil filter
Cut-off Pressure of 3,500 rev/min Pressure Limiting Valve 5.4-6.58 bar
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Usage Times of Bolt
Part No. Name Usage Times
BLT200010 Bolt - Main Bearing Cap Once
90004180 Screw - Crankshaft Sensor Signal Plate Once
BLT200011 Bolt - Connecting Rod Once
90003592 Bolt - Oil Pump to Oil Pan Once
90003620 Stud Bolt - Intake Manifold to Cylinder Once

Head
BLT200019 Once
Cylinder Head Bolt
99000007 Once
Bolt - Cylinder Head to Cylinder Block
BLT200025 Once
Bolt - Camshaft Sprocket
BLT200012 Once
Bolt - Crankshaft Damper
90004291 Once
Bolt - Front Cover to Cylinder Head
90000433 Once
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Bolt - Lower Front Cover to Cylinder
BLT200013 Once
Block
BLT200013 Once
Bolt - Automatic Gear Flywheel to
BLT200015 Crankshaft Once
90000829 Bolt - Flywheel Once
Bolt - Tensioner
Hexagon Flange Bolt - Exhaust Manifold
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Description and Operation

System Component Layout
NSE Engine Component Layout
1. 1.5VCT Engine
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Cylinder Block Exploded View
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1. Cylinder Block 9. Crankshaft Sensor Signal Plate

2. Bolt - Connecting Rod 10. Crankshaft Rear Oil Seal
3. Crankshaft Assembly 11. Screw - Crankshaft Sensor Signal Plate
4. Main Bearing (Upper) 12. Bolt - Crankshaft Rear Oil Seal
5. Main Bearing (Lower) 13. Location Pin - Crankshaft Sensor Signal Plate
6. Connecting Rod Big End Bearing 14. Location Pin - Between Crankshaft and Flywheel
7. Main Bearing Thrust Plate 15. Location Pin - Cylinder Block to Transmission Case
8. Cylinder Block Rear End Surface Cover Plate 16. Location Pin - Front Cover to Cylinder Block
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17. O-ring - Lower Crank Case to Cylinder Block (Oil 25. 2nd Ring
Passage) 26. 3rd Ring
18. Plug - Oil Passage 27. Piston
19. Plug - Oil Pressure Switch 28. Connecting Rod
20. Washer - Cylinder Block Oil Passage Plug 29. Piston Pin
21. Plug - Timing Hole 30. Main Bearing Cap
22. Location Pin - Main Bearing Cap 31. Main Bearing Cap
23. Bolt - Main Bearing Cap
24. Top Ring
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Camshaft Cover Exploded View
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1. Ignition Coil 4. Nut - Ignition Coil

2. Ignition Coil Bracket 5. High Tension Cord
3. Bolt - High Tension Cord 6. Spark Plug
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7. Stud Bolt - Camshaft Cover 12. C-Tube Clamp - Full Load Breather Tube
8. Bolt - Camshaft Cover 13. Clamp
9. Seal - Oil Control Valve Body 14. Camshaft Cover
10. Oil Filler Cap 15. Seal Ring - Camshaft Cover (Inner)
11. Full Load Breather Tube Assembly 16. Seal Ring - Camshaft Cover (Outer)
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Cylinder Head Exploded View
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1. Cylinder Head 4. Phase Sensor Signal Plate - Camshaft

2. Intake Camshaft 5. Bolt - Camshaft Signal Plate to Camshaft
3. Exhaust Camshaft 6. Camshaft Front Bearing Cap Assembly
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7. Location Pin - Camshaft Front Bearing Cap to Cylinder 19. Check Valve
Head 20. Intake Valve
8. Bolt - Camshaft Bearing Cap to Cylinder Head 21. Exhaust Valve
9. Bolt - Front Camshaft Bearing Cap 22. Exhaust Valve Seat
10. Oil Passage Plug 23. Intake Valve Seat
11. Oil Passage Plug 24. Valve Stem Seal
12. Oil Control Valve 25. Valve Spring
13. Camshaft Rear Bearing Cap 26. Valve Spring Seat
14. Bolt - Oil Control Valve 27. Tappet
15. Cylinder Head Bolt 28. Valve Keeper
16. Bolt - Cylinder Head to Cylinder Block 29. Oil Passage Plug
17. Location Pin - Cylinder Head to Cylinder Block
18. Cylinder Head Shim
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Oil Pump and Oil Filter Exploded View
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1. Oil Pump 9. Pin - Oil Pump Chain Tensioner
2. Oil Filter 10. Oil Pump Chain
3. Oil Filter Mounting Stud 11. Oil Pump Sprocket
4. Location Pin - Oil Pump to Lower Crank Case 12. Heater Return Pipe Assembly
5. Oil Cooler Hose 13. Bolt - Heater Return Pipe to Lower Crank Case
6. Clamp - Oil Cooler Hose 14. Oil Pump Chain Tensioner
7. Bolt - Oil Pump Sprocket 15. Crankshaft Sprocket - Oil Pump Drive
8. Bolt - Oil Pump to Lower Crank Case
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Lower Crank Case Exploded View
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1. Lower Crank Case 8. Oil Baffle
2. Location Pin - Lower Crank Case 9. Bolt - Oil Baffle
3. Pin Bush - A/C Compressor to Lower Crank Case 10. Bolt - Suction Tube to Lower Crank Case Assembly
4. Drain Plug 11. Oil Dipstick
5. Washer - Drain Plug 12. Bolt - Lower Crank Case to Cylinder Block
6. Suction Tube Assembly 13. Plug
7. O-ring - Suction Tube to Oil Pump
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Timing Chain System Exploded View
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1. Upper Front Cover 12. Bolt - Upper Front Cover to Cylinder Head
2. Lower Front Cover 13. Bolt - Crankshaft Damper
3. Crankshaft Front Oil Seal 14. Bolt - Intake Phase Modulator
4. Timing Chain 15. Tensioner Rail
5. Crankshaft Sprocket - Timing Drive 16. Upper Guide Rail
6. Exhaust Camshaft Sprocket 17. Chain Guide Rail
7. Intake Phase Modulator 18. Bolt - Chain Tensioner Pulley to Cylinder Block
8. Bolt - Lower Front Cover to Cylinder Block 19. Timing Hydraulic Tensioner
9. Bolt - Lower Front Cover to Cylinder Block 20. Oil Control Bushing
10. Bolt - Sprocket Upper Guide Rail to Cylinder Head Front 21. Bolt - Camshaft Sprocket
Bearing Cap 22. Crankshaft Damper
11. Bolt - Upper Front Cover to Cylinder Head
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Exhaust Manifold Exploded View
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1. Exhaust Manifold 3. Bolt
2. Exhaust Manifold Gasket 4. Nut
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Intake Manifold Exploded View
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1. Intake Manifold 9. Canister Solenoid Valve Rubber Boot
2. Bolt 10. Canister Solenoid Valve
3. Nut 11. Clamp
4. Intake Manifold Gasket - Cylinder Head Side 12. Clamp
5. Intake Manifold Gasket - Throttle Valve Side 13. Partial Load Breather Tube Assembly
6. Tube Clamp - Canister Solenoid Valve Connector Tube 14. Bolt - Throttle Body
7. Connector Tube - Canister Solenoid Valve to Intake 15. Throttle Body
Manifold
8. Tube Clamp - Canister Solenoid Valve Connector Tube
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Accessory Belt System
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1. Accessory Belt 4. Pulley - PAS Pump

2. Accessory Belt Tensioner 5. Bolt - PAS Pump Pulley
3. PAS Pump Idler 6. Bolt - Tensioner
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7. Bracket Assembly - PAS Pump 9. Bolt - PAS Pump Bracket to Cylinder Block
8. Bolt - PAS Pump to Support Plate
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Engine Sensor
1. Water Temperature Sensor (Oil Temperature Sensor) 9. Cam Phase Sensor

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2. Washer - Water Temperature Sensor (Washer - Oil 10. Bolt - Phase Sensor
Temperature Sensor) 11. Front Oxygen Sensor
3. TMAP 12. Crankshaft Sensor Assembly
4. Bolt - TMAP 13. O-ring - Crankshaft Sensor
5. Knock Sensor 14. Bolt - Crankshaft Sensor
6. Bolt - Knock Sensor 15. Oil Pressure Switch Strainer
7. Oil Pressure Switch 16. Rear Oxygen Sensor
8. Washer - Oil Pressure Switch
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Water Pump and Thermostat
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1. Water Pump 3. Water Pipe
2. Thermostat Assembly
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Fuel Rail Assembly
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1. Fuel Rail Assembly 4. Clamp - Fuel Injector

2. Fuel Rail 5. Bolt - Fuel Rail to Intake Manifold
3. Fuel Injector 6. O-ring - Fuel Injector
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Description end. When the engine is not running, both parts of the phase
General modulator are locked together by one pin under elastic load;
When the engine is running, they are released hydraulically to
The NSE engine has an in-line, 4-cylinder, 16-valve and double
ensure smooth starting.
overhead camshaft structure, and timing chain drive and
electronically controlled multiport fuel injection system. An oil control valve is fitted on the front camshaft bearing
cap and secured with an O-ring seal and a bolt. The control
It mainly consists of a cylinder block, a cylinder head, a
valve is a 4-way proportioning valve, including an inlet, a return
crankshaft, connecting rods and camshafts, etc. The cylinder
port and two oil passages connected to the phase modulator
head, which is made of cast-aluminum material, is connected
operating chamber.
to the cast-iron cylinder block with 10 high-strength bolts
through the multi-layer cylinder gasket, and another 3 Cylinder Block Components
high-strength bolts are directly connected to the cast-iron The conventional cast-iron material HT250 is used for the
cylinder block, thus achieving a high-strength and reliable cylinder block, which has high overall strength and does not
structure. tend to deform. Liner is formed by honing the cylinder bore.
Cylinder Head Components To ensure the heat dissipation efficiency of the cylinder block,
a Y-water passage is provided between two adjacent cylinders.
The structure of four valves for each cylinder is used for the
cylinder head. The spark plug is located in the centre of the The semi-floating type piston pin is fitted to the thermal
combustion chamber. Due to the use of the overhead valve expansion piston made of aluminum alloy. The piston pin
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mechanism, a strong swirl will be formed in the combustion will deviate toward the thrust side when the engine is cold,
chamber and mixture will be distributed evenly, which is helpful to reduce "piston slap". And interference fit is used for the
for the spread of flame and improvement of combustion, thus connecting rod small end. Two compression rings and one oil
increasing the fuel economy, power performance and emission ring are fitted to each piston.
performance of the engine.
The connecting rod made of forged steel has an "H" section
Mechanical tappets are mounted on the top of each valve and structure. The connecting rod big end moves on the bearing
directly driven by the camshaft. The bosses at the bottom of of the crankshaft journal. Forging and cracking technology is
the mechanical tappet are grouped by size, and the valve gap is applied to the connecting rod.
ensured by selecting proper mechanical tappets grouped. The
The crankshaft has 4 balance blocks which are supported by
valve stem oil seal is press-fitted to the cylinder head oil seal
five bearings. It controls the end float by the thrust washer
retainer and it is also used as the valve spring seat to support
on the top of the centre main bearing. The radial gap of the
the valve spring.
bearing can be selected and is controlled by the bearings of
Exhaust valve is carbon deposit removing type, and the valve two different levels. The oil groove provided in the upper half
stem with processed sides can clean carbon deposits from of the main bearing supplies oil for the connecting rod big end
the end of the valve guide and combustion chamber, so as to bearing through the oil hole in the crankshaft.
prevent the valves seizing up. Lower Crank Case Components
For the metal cylinder gasket with the multi-layer structure, The lower crank case assembly consists of the lower crank
the pressing ring structure is used for the cylinder bore part case, oil pump assembly, oil strainer and oil filter.
to strengthen the sealing, and the partial rubber coating
The shape of the aluminum lower crank case is designed to be
technology is applied to ensure sealing performance.
suitable for accumulating the oil around the oil strainer. The oil
There are four oil passages at the camshaft front bearing pump and oil strainer are integrated and then assembled to the
cap, one inlet passage, one return passage and two operating bottom of the lower crank case. The oil passes the oil strainer
passages. Oil flows into the oil control solenoid valve through with a strainer, and then the oil filter after being pressurized
the passages. Camshaft signal plate is fitted on the end of the by the oil pump.
intake camshaft to provide signal for the camshaft position
The oil, clean and free of impurities, is distributed to the main
sensor. The timing pin hole on the camshaft is used to control
bearing and cylinder head through the main oil passage of the
camshaft timing phase when assembling.
cylinder block to lubricate the parts such as the crankshaft,
The phase modulator is fitted on the drive side of the intake connecting rod, camshaft and etc. The mating surfaces of the
camshaft and secured by bolts. The main parts of the phase lower crank case and cylinder block are sealed with sealant and
modulator are made by powder metallurgy. The outer casing secured with bolts. The drain bolt is located on the left side
(stator) driven by the timing chain is hydraulically connected of lower crank case (in the direction of the engine front end
to the inner rotor through five vanes fixed on the camshaft surface).
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Engine Accessory system again, and then to the cylinder for combustion, thus
reducing air pollution.
The accessory is a single 5-ribbed belt drive system driven by
the crankshaft pulley: drive the water pump, power assisted The oil vapour in the crank case can be separated by the oil
steering (PAS) pump, alternator and A/C compressor, and the separator in the camshaft cover, and the oil returns to the
belt is tensed by the damper tensioner. crank case.
Crank Case Ventilation
The ventilation system, using the vacuum of the intake system,
leads the exhaust gas blown into the crank case to the intake
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Operation
Lubrication Circuit
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1. Cylinder Head Oil Passage 5. Oil Filter
2. Cylinder Block Main Oil Passage 6. Oil Pump
3. Crankshaft Crossover Oil Passage 7. Main Oil Passage
4. Oil Inlet Tube 8. Timing Chain Tensioner
The lubrication system is a full flow type filtering and forced oil Then, oil enters the main oil passage and directly lubricates the
supplying system. Oil is drawn up from the oil pan by the oil main bearing through the crossover circuit. The oil can be sent
pump through the oil strainer which has a strainer to prevent to the connecting rod big end bearing from the main bearing
foreign matter from entering the oil pump. by the crossover circuit of the crankshaft.
The oil pump with an pressure limiting valve is driven by the Two side oil passages in the cylinder head are connected to
crankshaft through the chain. When the oil pressure reaches the main oil passage of the cylinder block. The oil enters
a certain level, the pressure limiting valve will open and the 2 lateral oil paths of standard length after entering the side
excess oil will return to the intake side of the oil pump. So oil passage, and it is supplied to each mechanical tappet and
the oil pressure can be maintained within a certain operating camshaft journal. The oil pressure switch and oil temperature
pressure range, ensuring the normal operation of the engine. sensor are fitted on the rear end of the lateral oil path to
The oil coming out of the oil pump outlet enters the full flow monitor oil pressure and oil temperature respectively.
type oil filter.
The oil splashed by the crankshaft lubricates the cylinder wall.
The full flow type oil filter is directly fitted to the oil pan, and a The oil collected from under the piston crown lubricates the
bypass valve is fitted on the oil filter. When the filter element connecting rod small end, and it enters the piston pin from the
is blocked, the valve opens to keep the oil flowing smoothly. connecting rod small end through the oil path.
But the oil filter needs to be replaced as soon as possible.
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Service Procedures
Power Assembly Removal and Refit - MT
Removal
1. Hold the vehicle on the lift.
2. Disconnect the battery negative terminal.
3. Remove the battery.
Battery Box Removal

4. Remove the bolts securing the battery tray and remove
the battery support.
7. Drain the cooling system.

Drain Coolant
8. Drain the power assisted steering fluid.
9. Remove the expansion tank.
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Expansion Tank Removal
10. Remove the bonnet lock body.
Bonnet Lock Body Removal
11. Remove the modular front end panel.
Modular Front End Panel Removal
12. Remove the radiator.
Radiator Removal
13. Discharge the fuel pressure.
Fuel System - Discharge Pressure
14. Detach the oil supply and the return tube of the fuel rail.
5. Remove the air cleaner assembly.

Air Cleaner Assembly Removal
6. Remove the bolts securing the air cleaner bracket and
remove the bracket.
15. Detach the A/C compressor connector and the line.
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23. Drain the transmission fluid.
Manual Transmission Fluid - Drain
24. Remove the drive shaft assembly.
Drive Shaft RH Removal
Drive Shaft LH Removal
25. Loosen the 2 nuts securing the slave cylinder to the
manual transmission slave cylinder bracket, loosen and
temporarily set the slave cylinder aside.
Caution: DO NOT hang the slave cylinder for a long time.
26. Fit the engine lifting lug special tool TEN00012.
16. Detach the lines and the hoses from the power assisted
steering pump.
17. Disconnect the generator wire connector.
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27. Use the lift and connect the adjustable lift
bracketT10007 to the engine.
28. Use a lift to raise the weight of the engine instead of
applying the load to the mounting bracket.
18. Detach the engineECM connector.
29. Remove the lower tie rod.
19. Remove the bolts that connect the exhaust manifold
and the front exhaust pipe.
30. Remove the power assembly mounting.
20. Disconnect the back-up light switch connector. Power Assembly Mounting Removal
21. Notice the mounting position and loosen the two cable 31. Remove the transmission case mounting.
ball joints from the manual transmission gear shift
rocker arm.
22. Loosen the snap fit, and loosen the exterior select and
gear shift cable from the cable bracket.
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Radiator Refit
21. Fit the expansion tank.
Expansion Tank Refit
22. Fit the bonnet lock body.
Bonnet Lock Body Refit
23. Fit the modular front end panel.
Modular Front End Panel Refit
24. Fit the bolts securing the air cleaner bracket and tighten
them to 5-7 Nm
25. Air cleaner assembly.
32. Raise the lift and remove the power assembly from Air Cleaner Assembly Refit
the vehicle. 26. Fit the bolts securing the battery tray and tighten them
Refit to 40-50 Nm.
1. Lower the power assembly into the engine bay with 27. Fit the battery.
help. Battery Refit
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2. Place the unit in the mounting position. 28. Refill the cooling system.
3. Fit the transmission case mounting.
Cooling System - Refill
4. Fit the power assembly mounting.
Power Assembly Mounting Refit
5. Fit the lower tie rod.
6. Lower the lift, disconnect the connector and remove
the adjustable lift bracket T10007.
7. Remove the engine lifting lug special tool TEN00012
8. Position the slave cylinder and tighten the 2 slave
cylinder set nuts to 19-25 Nm.
9. Position the gear shift lever cable on the cable bracket
and secure it with snap fits.
10. Connect the gear shift cable ball joint to the gear shift
rocker arm.
11. Check the transmission gear shift operation.
12. Connect the back-up light switch connector and secure
the wiring harness clamp.
13. Fit the drive shaft assembly.
Drive Shaft Assembly RH Refit
Drive Shaft Assembly LH Refit
14. Fit the bolts connecting the exhaust manifold and front
exhaust pipe.
15. Fit the engineECM connector.
16. Fit the generator wire connector.
17. Connect the line and hose to the power assisted
steering pump.
18. Fit the A/C compressor connector and line.
19. Fit the supply pipe line and return pipe line of the fuel
rail.
20. Fit the radiator.
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Power Assembly Removal and Refit - AT 7. Drain the cooling system.
Removal Drain Cooling System
1. Hold the vehicle on the lift. 8. Drain the power assisted steering fluid.
2. Disconnect the battery negative terminal. 9. Remove the expansion tank.
3. Remove the battery.
Expansion Tank Removal
Battery Box Removal
10. Remove the bonnet lock body.
4. Remove the bolts securing the battery tray and remove
Bonnet Lock Body Removal
the battery support.
11. Remove the modular front end panel.
Modular Front End Panel Removal
Radiator Removal
13. Discharge the fuel pressure.
Fuel System - Pressure Discharge
14. Disengage the supply pipe line and return pipe line of
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the fuel rail.
15. Disengage the A/C compressor connector and line.
5. Remove the air cleaner assembly.

Air Cleaner Assembly Removal
6. Remove the bolts securing the air cleaner bracket, and
remove the bracket.
16. Disengage the line and hose from the power assisted
steering pump.
17. Disconnect the generator wire connector.
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18. Disengage the engine ECM. 30. Connect the adjustable lift bracketT10007 to the
19. Remove the bolts connecting the exhaust manifold and engine with the lift.
front exhaust pipe. 31. Use a lift to raise the weight of the engine instead of
applying the load to the mounting bracket.
32. Remove the lower tie rod.
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20. Drain the automatic transmission fluid.
Automatic Transmission Fluid - Drain
33. Remove the power assembly mounting.
21. Remove the drive shaft assembly.
Power Assembly Mounting Removal
Drive Shaft RH
34. Remove the transmission case mounting.
Drive Shaft LH
22. Remove the oil cooler inlet tube and return tube.
Automatic Transmission Case Oil Cooling Pipe
Removal
23. Loosen the cable on the cable bracket, and disconnect
the cable from the neutral start switch.
24. Disconnect the input speed sensor connector.
25. Disconnect the output speed sensor connector.
Caution: DO NOT hang the slave cylinder for a long time.
26. Disconnect the neutral start switch connector.
27. Disconnect the valve body wire connector.
28. Loosen 3 snap fits securing the automatic transmission 35. Raise the lift and remove the power assembly from
wire to the automatic transmission. the vehicle.
29. Fit the engine lifting lug special tool TEN00013. Refit
1. Lower the power assembly into the engine bay with
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help. 28. Air cleaner assembly.
2. Place the power assembly in the mounting position. Air Cleaner Assembly
3. Fit the transmission case mounting. 29. Fit the bolts securing the battery tray and tighten them
4. Fit the power assembly mounting. to 40-50 Nm.
Power Assembly Mounting Refit 30. Fit the battery.
5. Fit the lower tie rod. Battery Refit
6. Lower the lift, disconnect the connector and remove 31. Fit the cooling system.
the adjustable lift bracket T10007.
Cooling System Refill
7. Remove the engine lifting lug special tool TEN00012.
8. Attach 3 snap fits securing the automatic transmission
wire to the automatic transmission.
9. Fit the valve body wire connector.
10. Fit the neutral start switch connector.
11. Fit the output speed sensor connector.
12. Fit the input speed sensor connector.
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13. Fit the cable on the cable bracket and connect the cable
to the neutral start switch.
14. Fit the oil cooler inlet tube and return tube.
Refit of Automatic Transmission Case Oil
Cooling Pipe
15. Fit the drive shaft assembly.
Drive Shaft Assembly RH Refit
Drive Shaft Assembly LH Refit
16. Automatic transmission fluid.
Automatic Transmission Fluid - Refill
exhaust pipe.
18. Fit the engineECM connector.
19. Fit the generator wire connector.
20. Connect the line and hose to the power assisted
steering pump.
21. Fit the A/C compressor connector and line.
22. Fit the supply pipe line and return pipe line of the fuel
rail.
Radiator Refit
24. Fit the expansion tank.
Expansion Tank Refit
25. Fit the bonnet lock body.
Bonnet Lock Body Refit
26. Fit the modular front end panel.
Modular Front End Panel Refit
27. Fit the bolts securing the air cleaner bracket and tighten
them to 5-7 Nm.
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Power Assembly Mounting

Removal
2. Support the engine with a jack.
Caution: To prevent damage to components, place a
wood board or hard rubber at the bottom of the jack.
3. Remove the bracket connecting the vehicle and engine
mounting RH.
Refit
1. Clean the engine mounting and mounting surfaces of
the engine mounting and cylinder block.
2. Fit the engine mounting to the engine with engine
mounting bolts, and the tightening torque for fitting is
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40-50 Nm
4. Remove the wire bracket and other items fitted on the

engine mounting.
3. Connect the battery ground.
5. Unscrew the 3 bolts securing the engine mounting RH

to the cylinder block.
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Flywheel MT
Removal
1. Remove the clutch assembly.
Clutch Assembly Removal
2. Remove the plug from the timing hole of the cylinder
block.
3. Turn the flywheel until the flywheel pin hole is aligned
with the pin hole of the cylinder block.
4. Insert the flywheel timing pin special toolTEN00002
into the flywheel pin hole through the timing hole of
the cylinder block to lock the flywheel.
7. Remove the flywheel timing pin special tool

TEN00002.
Refit
1. Saw two gullets on the bolt used in the flywheel with
an angle of 45 degrees between the gullet and bolt
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shank, and then clean the bolt holes on the crankshaft
in order with the bolt.
2. Clean the mating surfaces of the flywheel and
crankshaft.
3. Fit the flywheel to the crankshaft.
4. Fit new bolts coated with sealant and tighten them
firmly by hand.
5. Unscrew and dispose of the 6 bolts securing the
flywheel to the crankshaft.
into the timing hole of the cylinder block to lock up
the flywheel.
6. In diagonal order, tighten the bolts to (32–38)Nm +
60°
6. Remove the flywheel from the crankshaft.

TEN00002.
8. Fit the plug.
9. Fit the clutch assembly.
Clutch Assembly Refit
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Torque Converter Drive Plate AT

Removal
1. Remove the automatic transmission.
Automatic Transmission Removal
2. Remove the plug from the timing hole of the cylinder
block.
3. Turn the drive plate to align the drive plate pin hole
with the pin hole of the cylinder block.
into the drive plate pin hole through the cylinder block
timing hole to lock the drive plate.

TEN00002.
Refit
1. Saw two gullets on the bolt used in the drive plate with
an angle of 45 degrees between the gullet and bolt
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shank, and then clean the bolt holes on the crankshaft
in order with the bolt.
2. Clean the mating surfaces of the drive plate and
crankshaft.
3. Fit the drive plate to the crankshaft.
4. Fit new bolts coated with sealant and DO NOT tighten
them firmly.
5. Unscrew and dispose of 6 bolts securing the flywheel
to the crankshaft and the 6 bolts securing the drive
into the timing hole of the cylinder block to lock up
plate to the crankshaft.
the drive plate.
6. In diagonal order, tighten the bolts to (32–38)Nm +
60°
6. Remove the drive plate from the crankshaft.
7. Remove the drive plate timing pin special tool

TEN00002.
8. Fit the plug.
9. Fit the automatic transmission.
Automatic Transmission Refit
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Crankshaft Pulley toolTEN00008 hold the crankshaft pulley.
Removal
1. Disconnect the battery ground.
2. Raise the front part of the vehicle.
Warning: DO NOT work under the vehicle supported only
with a jack. It is essential to support the vehicle on safety
stands.
3. Remove the front right wheel.
4. Remove the ignition coil.
Ignition Coil Removal
5. Remove the camshaft cover.
Camshaft Cover Removal
6. Remove the plug fitted into the timing pin hole on the 12. Loosen and remove the bolt from the pulley to the
cylinder block. crankshaft, and dispose of it.
with the cylinder block pin hole.
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13. Remove the crankshaft pulley.
8. Insert the timing pin special toolTEN00002 into the Caution: Avoid damaging the crankshaft front oil seal lip
cylinder block timing pin hole and the flywheel pin hole, when removing the pulley.
to lock up the flywheel.
9. Use the camshaft lock special toolTEN00004 to lock
the camshaft phase.
Refit
1. Clean the mating surfaces of the crankshaft pulley and
the crankshaft front oil seal.
10. Remove the accessory drive belt.
Caution: If it is necessary to replace the crankshaft front
Accessory Drive Belt Removal oil seal, try to keep the centre axis of the pulley align with
11. Using the crankshaft pulley holding special the centre axis of the crankshaft without deflection to
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avoid damaging the seal lip during pushing the crankshaft Timing Chain Upper Cover Plate
pulley with hand. Removal
2. Fit the crankshaft pulley, using the crankshaft pulley 1. Remove the camshaft cover.
holding special toolTEN00008 hold the crankshaft Camshaft Cover Removal
pulley, then tighten the bolts and the torque is 60 Nm
2. Loosen the 8 bolts securing the timing chain upper
+ 120°.
cover plate.
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3. Fit the accessory drive belt.
3. Remove the bolts securing the timing chain upper cover
Accessory Drive Belt Refit plate, and there are 8 set bolts in total.
4. Remove the camshaft phase lock special tool
Caution: When removing the timing chain upper cover
TEN00004.
plate, ensure that the cover plate does not deform.
TEN00002. 4. Remove the timing chain upper cover plate.
6. Fit the plug.

7. Fit the camshaft cover.
Camshaft Cover Refit
8. Fit the ignition coil.
Ignition Coil Refit
9. Fit the front right wheel.
10. Lower the vehicle.
Refit
1. Check the timing chain upper cover plate.
Caution: Ensure that there is no damage on the timing
chain upper cover plate, otherwise, it may cause oil leak.
2. Apply adhesive to the mating surfaces of the timing
chain upper cover plate and the cylinder head along the
seal area (1.5-2.0 mm wide).
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Timing Chain Lower Cover Plate
Removal
Warning: Always replace both crankshaft front oil seal and
timing chain lower cover plate together.
Accessory Drive Belt Removal
Crankshaft Pulley Removal
4. Using the pulley replacer special toolTEN00009 to
remove the water pump pulley.
3. Fit the bolts securing the timing chain upper cover

plate, and tighten them to 8-12 Nm, and there are
8 set bolts in total.
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5. Remove the bolts securing the timing chain lower cover

plate.
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6. Remove the timing chain lower cover plate, and then

dispose of the crankshaft front oil seal and the timing
chain lower cover plate.
Caution: Be sure to keep the flatness of the timing chain
lower cover plate when removing it, otherwise, it will
cause oil leak.
4. Apply adhesive with a width of about 2.5 mm as shown

in the illustration above by using the appropriate tool,
be sure to keep the adhesive continuous.
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Refit
1. Remove the adhesive on the contact surfaces of the
cylinder body and the timing chain lower cover plate,
and ensure that there is no adhesive remaining on the
cylinder block.
2. Clean the crankshaft pulley journal.
3. Fit the timing chain lower cover plate pin (if not
removed, then refit is unnecessary).
5. Fit the timing chain lower cover plate assembly bolts,

tighten them in the order of 1 to 16 as shown in the
illustration below to the torque 8-12 Nm, and finish
the fitting in 3 - 5 minutes.
6. Fit the crankshaft pulley.

Crankshaft Pulley Refit
7. Using the pulley replacer special tool TEN00009, fit the
water pump pulley.
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Timing Chain
Removal
1. Raise the front part of the vehicle.
stands.
2. Loosen the drain bolt to drain the oil.
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3. Remove the front right wheel.
4. Remove the ignition coil.
Ignition Coil Removal
8. Fit the accessory drive belt. Camshaft Cover Removal

6. Remove the plug fitted into the timing pin hole on the
Accessory Drive Belt Refit
cylinder block.
8. Insert the timing pin lock special toolTEN00002 into
the cylinder block timing pin hole and the flywheel pin
hole, to lock up the flywheel.

the camshaft phase.
11. Loosen and remove the bolt from the crankshaft pulley
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to the crankshaft, and dispose of it.

13. Using the pulley replacer special tool TEN00009,
18. Using the oil pump sprocket holding special tool

TEN00006, remove the oil pump sprocket bolts.
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19. Detach the oil pump chain tensioner to the right, and
remove the oil pump sprocket together with the oil
pump chain and the crankshaft sprocket driving the oil
pump.
14. Remove the timing chain upper cover plate.
Timing Chain Upper Cover Plate Removal
15. Remove the timing chain lower cover plate.
Timing Chain Lower Cover Plate Removal
16. Remove the timing chain tensioner, and dispose of the
seal washer.
17. Remove the upper rail.
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20. Remove the oil pump chain tensioner. 25. Remove the guide rail pivot pins and remove the
21. Remove the intake phase modulator bolts, and dispose tensioner rail and the chain guide rail from the upper
of them. end of the chain case.
22. Using the camshaft sprocket holding special
toolTEN00005 remove the exhaust camshaft sprocket
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bolts, and dispose of them.
Refit
cylinder block.
23. Remove the intake phase modulator and the exhaust 2. Turn the flywheel until the flywheel pin hole is aligned
camshaft sprocket. with the cylinder block pin hole.
3. Insert the flywheel lock special toolTEN00002 into
the cylinder block timing pin hole and the flywheel pin
24. Remove the crankshaft sprocket - timing drive and the

timing chain.

the camshaft phase.
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5. Check each part for any damage, oil, rust and dirt 10. Fit the upper guide rail on the camshaft front bearing
before assembly. If there is any damage, DO NOT use cap, secure it with two bolts, and tighten them to the
it. If there is any oil, be sure to wipe it off. torque 8–12 Nm.
6. Set the chain guide rail in from the upper right side of
the guide rail box, screw each pivot pin, finally tighten
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the pivot pins in order to the torque 22-28 Nm.
7. Set the tensioner guide rail in from the upper left side
of the guide rail box, screw the pivot pins, finally tighten
the pivot pins to the torque 22-28 Nm.
11. After replacing the timing hydraulic tensioner washer

with a new one, screw the timing hydraulic tensioner
onto the cylinder head, and tighten it to the torque
57-63 Nm.
8. Set a crankshaft sprocket - timing drive into the front of

the crankshaft. Place the timing chain in from the top
of the cylinder head guide rail box, set the lower part
of the chain onto the crankshaft sprocket, and hang the
chain on the upper rail mounting boss. Fit the intake
phase modulator to the intake camshaft and pretighten
the bolts.
9. After fitting the camshaft sprocket to the exhaust
camshaft with the camshaft sprocket holding special
toolTEN00005 and pretightening the bolts, fit the
chain onto the two sprockets.
12. Tighten the intake phase modulator and the exhaust
camshaft sprocket onto the camshaft, fasten the exhaust
camshaft sprocket bolt to the torque 25 Nm + 45°,
and the intake phase modulator bolts to 70-80 Nm.
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Timing Chain Upper Cover Plate Refit
23. Fit the water pump pulley.
13. Fit the oil pump chain tensioner.

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26. Remove the camshaft phase lock tools.
TEN00002.
28. Fit the plug.
14. Set the oil pump chain onto the crankshaft sprocket - Camshaft Cover Refit
oil pump drive, and then slide the crankshaft sprocket - 30. Fit the ignition coil.
oil pump drive into the front of the crankshaft.
Ignition Coil Refit
Caution: At the foot of the crankshaft sprocket-oil pump
31. Fit the wheel.
teeth side is a dent mark that is used to distinguish it with
the crankshaft sprocket-timing chain.
33. Inspect the oil level, and add oil if necessary.
15. Set the oil pump sprocket into the oil pump chain.
Tip: The side with product logo faces outward.
16. Rotate the oil pump sprocket, to align the D-hole in its
centre with the D-shaft of the oil pump.
17. Pull the lower part of the oil pump chain tensioner to
the right, set the oil pump sprocket onto the oil pump
shaft, and firmly push the crankshaft sprocket into the
end.
18. Release the oil pump chain tensioner.
19. Check whether the oil pump chain is correctly pressed
on the guide surface of the tensioner.
20. Using the special tool TEN00006, set the oil pump
sprocket, screw the oil pump sprocket bolts, finally
tighten them to the torque 22-28 Nm.
21. Fit the timing chain lower cover plate.
Timing Chain Lower Cover Plate Refit
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Camshaft Cover
Removal
1. Remove the oil dipstick.
7. Remove the camshaft cover, be careful to protect the

check valve diaphragms and keep them clean.
Refit
2. Loosen and remove the wire harness bracket bolt and 1. Inspect the top surface of the cylinder head to protect
the high tension cord bolt, confirm the location of each it from any damage, and clean the top surface of the
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bolt, and set them aside. cylinder head, removing any oil.
2. Apply silicone to the seam of the timing chain upper
cover plate and the cylinder head with a diameter of
4 mm.
3. Remove the high tension cord and the cord bracket.

High Tension Cord Removal
4. Detach the full load and the partial load breather tube
clamps. 3. Place the camshaft cover on the cylinder head.
4. Fit the bolts, and tighten them in the order as shown in
the illustration below to 8-12 Nm.
5. Remove the full load and the partial load breather tubes.
6. Loosen and remove the 19 bolts securing the camshaft
cover, and confirm each location. 5. Fit the high tension cord and the high tension cord
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bracket, and tighten the set bolt to 8–12 Nm. Camshaft - Intake or Exhaust
High Tension Cord Refit
Removal
6. Fit the oil dipstick. 1. Disconnect the battery ground.

cylinder block.
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into the cylinder block timing pin hole and the flywheel
pin hole, to lock up the flywheel.
8. Using the pulley replacer special tool TEN00009,
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Caution: Remove the intake camshaft and the signal plate

as an assembly, DO NOT remove the signal plate.
Refit
1. Clean the camshafts.
2. Clean the cylinder head upper surface, mechanical
tappet top surfaces and the camshaft bearing caps.
3. Apply oil to the camshaft journals, the bearing seats
and the tops of the tappets evenly.
4. Place the camshafts into the bearing seats, fit the
camshaft bearing caps, screw the camshaft bolts
(without tightening), rotate the camshafts, measure the
valve gaps (service model intake side: 0.11 - 0.19 mm,
9. Remove the timing chain upper cover plate. exhaust side: 0.20 - 0.28 mm) and calculate according
Timing Chain Upper Cover Plate Removal to the valve gaps to obtain the most suitable mechanical
tappets.
Caution: Assemble the intake camshaft and the signal
plate as an assembly, DO NOT remove the signal plate.
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11. Remove the timing chain.
Timing Chain Removal
12. Loosen the 19 bolts on the camshaft bearing caps in the
order shown in the illustration, until the valve spring
pressure is no longer applied to the camshafts.
13. Remove the camshaft bearing caps.

14. Remove 2 camshafts.
5. Replace the mechanical tappets with appropriate

ones, place the camshafts into the bearing seats, fit
the camshaft bearing caps, screw the camshaft bolts
(without tightening), use the camshaft timing special
toolTEN00004 to secure the intake and exhaust
camshafts, and tighten the camshaft bearing caps in
the order shown in the illustration and the tightening
torque is 8-12 Nm.
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Mechanical Tappet
Removal
3. Remove the camshaft - intake or exhaust.
Camshaft - Intake or Exhaust Removal
4. Use a tenacious magnet to remove the mechanical
tappets carefully and put them aside.
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Refit
1. Clean the tappet bores.
6. Fit the timing chain.
2. Lubricate the standard tappets (H group) and fit them
Timing Chain Refit to the tappet bores. Fit the camshafts and select the
7. Fit the timing chain upper cover plate. tappet group according to the valve gaps.
3. Fit the selected tappet group.
Timing Chain Upper Cover Plate Refit
8. Fit the timing chain lower cover plate. The valve mechanical tappet series chart is as follows:
Timing Chain Lower Cover Plate Refit Size# Part Number Tappet Thickness
9. Fit the water pump pulley. A 10050424 3.015
B 10050425 3.045
Crankshaft Pulley Refit C 10050426 3.075
D 10050427 3.105
E 10050428 3.135
F 10050429 3.165
TEN00002.
13. Fit the plug. G 10050430 3.195
14. Remove the timing special tool TEN00004. H 10050431 3.225
15. Fit the camshaft cover. I 10050432 3.255
Camshaft Cover Refit J 10050433 3.285

16. Connect the battery ground. K 10050434 3.315
L 10050435 3.345
M 10050436 3.375
N 10050437 3.405
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O 10050438 3.435 Valve Removal and Refit

Removal
P 10050439 3.465
Q 10050440 3.495
R 10050441 3.525
S 10050442 3.555
T 10050443 3.585 cylinder block.
4. Fit the camshaft - intake or exhaust. 4. Turn the flywheel until the flywheel pin hole is aligned
Camshaft - Intake or Exhaust Refit
into the cylinder block timing pin hole and the flywheel
Camshaft Cover Refit pin hole, to lock up the flywheel.
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8. Remove the water pump pulley.

12. Remove the camshaft - intake or exhaust.
Camshaft - Intake or Exhaust Removal
13. Using a tenacious magnet, take care to remove the 16
mechanical tappets and put them aside.
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14. Remove the cylinder head bolts in the order shown in 19. Use the special toolT10006 to remove the valve oil
the illustration, and remove the cylinder head. seal.
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15. Use the special toolT10005 to compress the valve Refit
spring. 1. Remove the carbon deposits and other impurities from
the valve guide, the valve, the valve retainer and the
combustion surface.
2. Check the existing valve stem diameter. Using a new
valve, check the valve guide gap.
3. Inspect the conditions of the valve seat and the valve, if
they are to be reused.
4. Check the mating height of the valve stem.
5. Check the condition of the valve spring.
6. Make sure that the mechanical tappet, the valve, the
valve spring, the spring cover and the keeper are all
clean.
7. Lubricate the valve and the valve stem oil seal.
16. Remove the valve keeper and release the valve spring. 8. Use the special toolTEN00014 to fit the valve stem
17. Remove the special tool T10005. oil seal to the valve guide.
18. Remove the valve spring, the valve spring seat and the
valve.
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9. Fit the valve, the spring and the spring cover, use the 12. Tighten the cylinder head bolts in the order shown
special toolT10005 to compress the valve spring, and in the illustration, the tightening torque is 30 Nm +
fit the keeper. 90°+ 90°+ 45°, tighten the chain case bolts and the
tightening torque is 10-12 Nm.
13. Lubricate the tappet and the tappet bore, and fit the
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tappet into the tappet bore.
14. Clean the camshafts and the cylinder head upper mating
surface.
15. Lubricate the camshaft journals and the bearing seats.
16. Fit the camshaft - intake or exhaust.
Camshaft - Intake or Exhaust Refit
17. Fit the timing chain.
Timing Chain Refit
18. Fit the timing chain upper cover plate.
10. Release the valve spring and remove the special tool Timing Chain Upper Cover Plate Refit
T10005.
11. Place the cylinder head on the cylinder block equipped
with gasket, and take care to put into 10 cylinder head Timing Chain Lower Cover Plate Refit
bolts and 3 chain case bolts. 20. Fit the water pump pulley.

23. Remove the flywheel timing pin.
24. Fit the plug.
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Cylinder Head Assembly
Removal
2. Remove the generator.
Generator Removal
3. Remove the exhaust manifold and dispose of the
exhaust manifold gasket.
Exhaust Manifold Removal
4. Remove the bolts securing the thermostat assembly to
the cylinder head, and remove the thermostat assembly.
11. Remove the oil control valve.

Oil Control Valve Removal
12. Remove the upper guide rail.
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5. Remove any dirt at the gaps of the spark plugs.
6. Remove the spark plugs.
Spark Plug Removal
7. Remove the oil dipstick.
13. Remove the chain and put it aside.
14. Remove the intake and exhaust camshafts.
Intake and Exhaust Camshafts Removal
15. Remove the mechanical tappets.
Mechanical Tappet Removal
16. Remove the cylinder head assembly, and then dispose
of the cylinder head gasket.

10. Remove the timing chain tensioner.
17. Remove the intake and exhaust valves.

Intake and Exhaust Valves Removal
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Refit sprocket to the corresponding camshaft. Fit the bolts,

1. Clean the seal areas of the cylinder head and the timing but DO NOT tighten them. Then engage the chain and
chain upper cover plate. Clean the mating surfaces of the sprocket teeth.
the camshaft cover and the intake and exhaust manifolds
with defoaming agent and plastic scraper (Note: DO
NOT clean the sealing surfaces with a metal scraper).
2. Dry the oil passages and the coolant passages.
3. Use a new cylinder gasket.
11. Tighten the phase modulator and the exhaust sprocket

bolts (the phase modulator bolt: 70-80 Nm, the
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sprocket bolt: 25 Nm + 45°).
12. Fit the sprocket upper guide rail on the camshaft front
bearing cap, fit 2 bolts, tighten them and the torque is
8–12 Nm.
4. Fit the intake and exhaust valves.
Intake and Exhaust Valves Refit
5. Place the cylinder head onto the cylinder block, and
then pretighten it with bolts (Note: no lubricant should
be applied to the cylinder head bolts).
6. Using a special socket, tighten the 10 cylinder head
bolts in the order as shown (Torque: 30 Nm + 90°+
90°+ 45°), then tighten the 3 bolts next to the chain
case (Torque: 10-12 Nm).
13. Fit the timing chain tensioner, and the torque is 57-63
Nm.
7. Fit the mechanical tappets.

Mechanical Tappet Refit
8. Fit the intake and exhaust camshafts.
Intake and Exhaust Camshafts Refit
9. Push the oil control bushing into the hole in the intake
side camshaft end. 14. Fit the oil control valve bolt, and the torque is 5-7 Nm.
10. Fit the intake phase modulator and exhaust camshaft Oil Control Valve Refit
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Cylinder Head Inspection
Removal
2. Remove the generator.
Generator Removal
3. Remove the exhaust manifold and dispose of the
exhaust manifold gasket.
Exhaust Manifold Removal
4. Unscrew the bolts securing the thermostat assembly to
the cylinder head, and remove the thermostat assembly.
5. Remove any dirt in the spark plug gaps.
15. Fit the timing chain upper cover plate, and the torque 6. Remove the spark plugs.
is 8-12 Nm. Spark Plug Removal
Timing Chain Upper Cover Plate Refit 7. Remove the oil dipstick.
16. Fit the camshaft cover assembly, and the torque is 8-12
Nm.
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17. Insert the dipstick into the dipstick hole.
18. Fit the thermostat housing, and tighten it to 8-12 Nm.

10. Remove the timing chain tensioner.
19. Fit the intake manifold.

Intake Manifold Refit
20. Fit the exhaust manifold and a new exhaust manifold
gasket.
Exhaust Manifold Refit
21. Fit the generator, and the torque is: 40-50 Nm.
Generator Refit
22. Fit the spark plugs, and the torque is 20-30 Nm.
Spark Plug Refit
11. Remove the oil control valve.
Oil Control Valve Removal
12. Loosen the bolts securing the sprocket upper guide rail,
and remove the sprocket upper guide rail.
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13. Remove the chain and put it aside. 19. Loosen the bolts securing the camshaft bearing caps,
14. Remove the cylinder head assembly and dispose of the identify the position of each camshaft bearing cap and
cylinder head gasket. remove the camshaft bearing caps.
Cylinder Head Assembly Removal
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15. Using a dial test indicator, check the end play of the
camshaft.
20. Identify the position of each camshaft and remove the

camshafts.
21. Remove the 16 mechanical tappets from the cylinder
head, and arrange them in order to avoid misuse.
16. If the end play exceeds the tolerance, replace the
camshaft with a new one and check it again. If the end
play still exceeds the tolerance, replace the cylinder
head assembly.
Camshaft End Play: 0.06 0.19 mm
17. Loosen the cylinder head bolts gradually, remove the

cylinder head assembly and put it a the wooden block.
Be careful to protect the flame face and avoid scratches.
18. Remove and dispose of the cylinder head gasket.
22. Measure the outer diameter of each mechanical tappet

(Outer diameter of mechanical tappet: 29.980 –
29.964).
23. Clean the camshafts, camshaft bearing caps and cylinder
head bearing seats.
24. Check the camshafts and replace them if there are
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scratches, dents or excessive wear.
25. Secure the camshafts onto the cylinder head, and place
a plastic gauge on each journal. Then fit the camshaft
bearing caps, and DO NOT turn the camshafts.
26. Loosen the camshaft bearing cap bolts slowly and
remove the camshaft bearing caps.
31. Use the special toolT10006 to remove the valve oil

seal.
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27. Measure the widest part of the plastic gauge on each
journal. If the gap exceeds the tolerance, replace the
camshaft with a new one and check it again. If the gap
still exceeds the tolerance, replace the cylinder head
assembly with a new one.
Bearing Backlash Service play
First Journal 0.025 0.066 mm 0.1 mm
Last 4 Journals 0.024 0.066 mm 0.1 mm 32. Clean each joint surface of the cylinder head.
28. Support the exhaust manifold side of the cylinder head 33. Check the cylinder head for damage, especially the
with a wooden block, and remove the intake valves in flame face of the cylinder head.
this position. 34. Check if there are scratches on the flame face of
29. Use the special toolT10005 to compress the valve the cylinder head. The check should be performed
spring, remove 2 keepers from the valve, release the crosswise as shown, or from one corner to the other.
valve spring and then remove the tool.
35. Check the height of the cylinder head. The cylinder

30. Remove the remaining valve spring seat, valve spring head can be resurfaced and the maximum amount is
and valve. Place them aside in the original fitting order. 0.20 mm.
V 2.0 89
Height of Cylinder Head Valve Seat:

New 118.95 119.05 mm Angle 45°
Resurfacing Value Limit 0.20 mm Width A:
36. Clean the carbon deposits off the surfaces of valves, Intake 1.2 mm
valve guides, valve seats and combustion chambers. Exhaust 1.6 mm
Valve Surface Angle B:
Intake 45°
Exhaust 45°
40. Press the valve to the seat with even abrasive

compound.
41. Coat the valve seat with Prussian blue, put the valve in
and press it in place without turning. Remove the valve
and check if the Prussian blue is even and the seat is in
the centre. The shown blue position of the seat must
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be in the centre of the valve surface.
42. Coat the valve seat and check again.
37. Check the diameters of the existing valve stems, and
43. Check the mating height of the valve stem.
use a new valve to check the gaps of the valve guides.
New Intake Valve 50.021 50.881 mm
Valve Stem Diameter:
New Exhaust Valve 49.925 - 50.785 mm
Intake Valve 5.952 5.967 mm
Service Limit 0.26 mm
Exhaust Valve 5.947 5.962 mm
44. If the limit is still exceeded, the cylinder head assembly
Gap between valve stem and
must be replaced.
valve guide:
0.033 0.073 mm 45. Check the condition of the valve spring:
Intake Valve
0.038 0.078 mm Free Length 50 mm
Exhaust Valve
Refit Length 37.0 mm
If necessary, replace the valve with a new one. If it is necessary
Load - Valve Closes 250 ± 12 Nm
to replace the valve guide, replace the cylinder head assembly.
38. If the cylinder head is to be reused, check the condition Load - Intake Valve Opens 442 ± 18 Nm
of the valve seats and valves. Load - Exhaust Valve Opens 464 ± 18 Nm
Refit
1. Clean the sealing areas of the cylinder head and timing
chain upper cover plate. Clean the mating surfaces of
the camshaft cover and the intake and exhaust manifolds
with defoaming agent and plastic scraper (Note: DO
NOT clean the sealing surface with a metal scraper).
2. Dry the oil passages and coolant passages with air.
3. Using TEN00014, fit new valve stem oil seals.
39. Machine the valve surface angle and valve seats to meet
the following standards:
V 2.0 90
4. Lubricate the valve stem and valve assemblies, and use 7. Using a special socket, tighten the 10 cylinder head
the toolT10005 to compress the valve spring. Fit the bolts in the order as shown (Torque: 30 Nm + 90°+
intake and exhaust valves, valve springs, valve spring 90°+ 45°), and then tighten the 3 bolts near the chain
seats and the valve keepers. case (Torque: 10-12 Nm).
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5. Fit a new cylinder gasket.
8. Lubricate the outsides of the mechanical tappets, and

6. Place the cylinder head onto the cylinder block, and fit them to their original positions.
then pretighten it with bolts.
Warning:
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Size # Part Number Tappet Thickness

A 10050424 3.015
B 10050425 3.045
C 10050426 3.075
D 10050427 3.105
E 10050428 3.135
F 10050429 3.165
G 10050430 3.195
H 10050431 3.225
I 10050432 3.255
9. Lubricate the surfaces of camshaft bearings and
place the camshafts on the cylinder head. Then fit J 10050433 3.285
the camshaft bearing caps to correct positions and K 10050434 3.315
pretighten them with bolts.
L 10050435 3.345
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M 10050436 3.375
N 10050437 3.405
O 10050438 3.435
P 10050439 3.465
Q 10050440 3.495
R 10050441 3.525
S 10050442 3.555
T 10050443 3.585
11. Remove the camshafts and fit the mechanical tappet

of correct size to the corresponding position. Fit the
10. Measure the gap of each mechanical tappet by: turn the
camshafts using the previous method and check the
camshaft to locate the base circle above the mechanical
gaps.
tappet, measure and record the gap between the
camshaft and mechanical tappet. Repeat the same 12. Tighten the bolts securing the bearings in the order
operation for every mechanical tappet. Calculate the as shown and the torque is 8-12 Nm. Then turn the
gap and select the proper mechanical tappet to ensure camshaft two turns and measure the rotational torque
correct gap. Intake side gap: 0.11 - 0.19 mm, exhaust (Note: it is necessary to rotate).
side gap: 0.20 - 0.28 mm.
13. Apply clean oil to the mechanical tappets. Turn the

camshafts to make the timing holes face upward, then
The valve mechanical tappet series chart is as follows: use the camshaft timing special toolTEN00004 to
V 2.0 92
secure the camshafts. Adjust the crankshaft position 16. Fit the sprocket upper guide rail to the camshaft front
to 90 degrees before the top dead centre of cylinder bearing cap. Fit 2 bolts, tighten them and the torque is
1 (Note: crankshaft angle). Then insert the flywheel 8–12 Nm.
timing pin special toolTEN00002 into the cylinder
block timing pin hole and flywheel pin hole, to lock up
the flywheel.
17. Fit the timing chain tensioner to the cylinder head,

tighten it, and the torque is 57-63 Nm.
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18. Fit the oil control valve, and the torque is 5-7 Nm.
14. Press the oil control bushing into the hole in the intake Oil Control Valve Refit
side camshaft end. Fit the intake phase modulator
19. Fit the timing chain upper cover plate, and the torque
and exhaust camshaft sprocket to the corresponding
is 8-12 Nm.
camshaft. Fit the bolts, but DO NOT tighten them.
Then engage the chain and sprocket teeth. Timing Chain Upper Cover Plate Refit
20. Fit the camshaft cover assembly, and the torque is 8-12
Nm.
21. Insert the oil dipstick into the dipstick hole.
22. Fit the thermostat housing and tighten it to 8-12 Nm.
23. Fit the intake manifold.
Intake Manifold Refit
24. Fit the exhaust manifold and a new exhaust manifold
gasket.
Exhaust Manifold Refit
25. Fit the generator, and the torque is: 40-50 Nm.
Generator Refit
15. Tighten the intake phase modulator and exhaust
camshaft sprocket bolts (Timing chain bolt: 70-80 Nm, 26. Fit the spark plugs, and the torque is 20-30 Nm.
sprocket bolt: 25 Nm + 45°). Spark Plug Refit
V 2.0 93
27. Connect the battery ground. Cylinder Gasket

Removal
cylinder block.
with the pin hole on the cylinder block.
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into the cylinder block timing pin hole and flywheel pin
8. Using the special pulley replacer tool TEN00009,
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9. Remove the timing chain upper cover plate. 8. Fit the cylinder head assembly.
Timing Chain Upper Cover Plate Removal Cylinder Head Assembly Refit
10. Remove the timing chain lower cover plate. 9. Fit the timing chain.
Timing Chain Lower Cover Plate Removal Timing Chain Refit
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11. Remove the timing chain. 10. Fit the timing chain upper cover plate.
Timing Chain Removal Timing Chain Upper Cover Plate Refit
12. Remove the cylinder head assembly. 11. Fit the timing chain lower cover plate.
Cylinder Head Assembly Removal Timing Chain Lower Cover Plate Refit
13. Remove the cylinder head gasket from the cylinder 12. Fit the water pump pulley.
block and dispose of it.
TEN00002.
16. Fit the plug.
Refit
1. Clean the mating surfaces of the cylinder head and
cylinder block.
2. Check if there is any scratch on the surface of the
cylinder head.
3. Check the height of the cylinder head.
4. Clean the oil and coolant passages.
5. Clean the cylinder head bolts and dry them, and check
the threads for damage.
6. Apply a thin layer of oil on the threads of the cylinder
head bolts.
7. Fit a new and clean cylinder head gasket to the cylinder
block.
V 2.0 95
Lower Crank Case

Removal
2. Lift up the front part of the vehicle.
stands.
3. Drain the engine oil.
4. Remove the oil filter.
Oil Filter Removal
5. Remove the front exhaust pipe assembly.
Caution: When fitting the lower crankcase, try to make
Front Exhaust Pipe Assembly Removal
the lower crankcase close to the flywheel end as near
6. Remove the accessory drive belt. as possible to avoid creating a gap when connecting the
Accessory Drive Belt Removal lower crankcase and the transmission case.
7. Remove the crankshaft rear oil seal cover plate. 5. In the order shown in the illustration, gradually tighten
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the lower crank case bolts to 22-30 Nm.
Crankshaft Rear Oil Seal Removal
9. Release the oil pump chain.
10. Remove all the fastening bolts from the lower crank
case to the cylinder block.

8. Fit the front exhaust pipe assembly.
11. Remove the lower crank case. Front Exhaust Pipe Assembly Refit
Refit 9. Remove the supports and lower the vehicle.
1. Make sure the lower crank case and the cylinder block 10. Fit a new oil filter.
mating surfaces are clean.
Oil Filter Refit
2. Fit the oil pump chain.
11. Add oil to the engine.
3. Fit the crankshaft rear oil seal cover plate.
Crankshaft Rear Oil Seal Refit
4. Please apply the sealant recommended by SAIC Motor
to the lower crank case mating surface and assemble
them.
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Connecting Rod Bearing Inspection of the cylinder bores from the flame face with a tool
Removal such a the plastic stick or wooden stick, and remove
1. Remove the accessory drive belt. the remaining connecting rod bearings.
Accessory Drive Belt Removal Caution: When fitting the piston, DO NOT scratch the
2. Remove the timing chain upper cover plate. cylinder liner with the connecting rod fracture.
Timing Chain Upper Cover Plate Removal 15. Remove the main bearing cap bolts and main bearing
3. Remove the timing chain lower cover plate. caps, and remove the main bearings from the bearing
seats.
16. Remove the crankshaft.
5. Cylinder head assembly.
6. Remove the engine flywheel or the torque converter
drive plate.
Manual Flywheel Removal
Torque Converter Drive Plate Removal
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7. Remove the crankshaft rear oil seal.
Crankshaft Rear Oil Seal Removal
8. Remove the lower crank case assembly.
Lower Crank Case Removal
17. Remove the 2 thrust washers from the fifth main
9. Fit the crankshaft pulley bolt, and gently turn it.
bearing position.
10. On the connecting rod big ends, mark the order of the
18. Remove the main bearings from the cylinder block.
cylinders to which the connecting rods are fitted.
Refit
Caution: Keep the connecting rod big end caps, bearings
and bolts in their original refit order. 1. Clean the mating surfaces of the cylinder block and
bearing seats.
11. Turn the crankshaft pulley bolt to rotate the crankshaft
2. Clean the pin and pin hole.
so that all the connecting rod bolts can be removed
easily. 3. Clean the fitting positions for the bearings and thrust
washers in the cylinder block.
12. Unscrew the connecting rod bolts and remove the
connecting rod lower end caps (connecting rod big end 4. Clean the fitting positions for the bearings on the
caps). bearing seats.
5. Clean the fitting positions for the bearings on the
connecting rods and caps.
6. Clean the crankshaft and check if it is damaged.
7. Align the two connecting rod bearings with the bearing
grooves, and press them into the connecting rod big
end hole respectively. Make sure the end surfaces of
the bearings are flush with the fracture surface of the
connecting rod big end hole as much as possible.
Caution: The connecting rod bearings are not grouped.
13. Remove the connecting rod bearings from the

connecting rod lower end caps (connecting rod big end
caps).
14. Gently push the piston connecting rod assemblies out
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Flywheel Refit
Torque Converter Refit
18. Fit the crankshaft rear oil seal.
19. Fit the cylinder head assembly.
Caution: Record the main bearing mark number on the

front of the crankshaft.
8. Check the diameter of the crankshaft main journal
(Refer to "Parameter").
Parameter
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9. Determine the proper main bearing to fit in accordance
with the selected size and model (Refer to "Parameter").
Parameter
Caution: The bearings with oil grooves and oil holes are
fitted in the main bearing holes of the cylinder block, and
bearings without oil grooves and oil holes are fitted in the
main bearing caps.
10. The matching rule of the main bearing: the upper
bearings are grouped according to the size of the
cylinder block (A stands for blue and B for red).
11. Lower bearings are grouped by the crankshaft size (1
stands for blue and 0 for red).
12. Clean the seal surfaces of the cylinder block and the
bearing seats with a cloth free of rough edges and
appropriate solvent.
Tip: Please use SAIC Motor recommended cleaning
solvent to remove the remaining sealer.
13. Fit the selected crankshaft main bearings to the cylinder
block and bearing seats.
14. Clean both sides of the cylinder block fourth main
bearing and fit new thrust washers to them.
Tip: The oil groove surface of the thrust washer is the
surface contacting with the crankshaft thrust surface,
and never fit it reversely.
15. Fit the crankshaft and then the main bearing caps.
Torque: (20 ± 2) Nm + 90°+(45 ± 2)°.
16. Put the piston connecting rod set in the guide sleeve
and press it into the cylinder. Fit the connecting rod big
end cap. Torque: (18 ± 2) Nm + (90 ± 5)°.
17. Fit the manual flywheel or the torque converter drive
plate.
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Piston Inspection
Removal
1. Remove the cylinder head assembly.
2. Loosen the connecting rod bolts.
3. Check if the piston is deformed or cracked.

4. At a right angle to the piston pin, measure the piston
diameter at the measuring point 11 mm up from under
the skirt portion (Refer to "Parameter").
Parameter
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3. Remove the connecting rod cap. Caution: Pistons and connecting rods are only supplied
as assemblies, and as the connecting rods are grouped
4. Remove the connecting rod bearing.
according to weight, be sure that the piston connecting
5. Push the piston to the top of the cylinder bore.
rod assemblies of the four cylinders are of the same
Caution: Remove the carbon deposits on the top of the weight.
cylinder bore first to avoid scratching the piston rings and
5. Fit the oil ring spring.
the piston.
6. Make the "TOP" mark face the piston top, and fit
6. Make sure the connecting rod does not contact to the the oil ring side rail, 2nd compression ring and top
inner wall of the cylinder bore. Carefully push the compression ring in order with a expander.
piston assembly out of the cylinder bore.
7. Ensure that the piston rings can turn freely. The angle
Caution: Please carefully mark each piston and matched between the gaps A and B of the two compression
liner. rings should be 120°and away from the thrust side of
the piston.
7. Fit the connecting rod big end cap to the connecting
rod, and gently tighten the connecting rod bolts. 8. On both sides of the piston pin, the angle of the side
rail gap C and spring gap D should be 30°.
8. Remove the used piston rings with a expander (tool),
and dispose of them.
Refit
1. Clean the ring grooves of the piston and dry the oil
passage with air.
2. Position a new piston ring at 20 mm from the cylinder
bore top surface, and measure the gap.
9. Check the gaps between the new piston rings and ring
grooves (Refer to "Parameter").
Parameter
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Cylinder Head Assembly Refit
10. Fit the piston connecting rod assembly into the special
toolTEN00003 from top to bottom, and align the
guide tool with the cylinder bore. Make sure the arrow
mark "-" on the top surface of the piston faces the
front of the engine.
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11. Firmly press the piston into the cylinder bore.

Tip: It is recommended to replace the piston connecting
rod assembly as a set.
12. Fit the connecting rod cap and tighten the connecting
rod bolts according to the torque chart.
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Crankshaft Inspection cap).
Removal 14. Unscrew the main bearing cap bolts, remove the main
1. Remove the accessory drive belt. bearing cap, and remove the main bearing from the
bearing seat.
15. Remove the crankshaft.
5. Remove the cylinder head assembly.
6. Remove the engine flywheel or the torque converter
drive plate.
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Torque Converter Drive Plate Removal 16. Remove the 2 thrust washers from the fourth main
7. Remove the crankshaft rear oil seal. bearing location.
Crankshaft Rear Oil Seal Removal 17. Remove the main bearings from the cylinder block.
8. Remove the lower crank case assembly. 18. Remove the other half bearings from the connecting
rods.
Lower Crank Case Removal
Refit
9. Fit the crankshaft pulley bolt, and slightly turn it.
1. Clean the mating surfaces of the cylinder block and the
10. Mark the order of cylinders to which the connecting
bearing seats.
rods are fitted on the connecting rod big ends.
2. Clean the pins and the pin holes.
Caution: Keep the connecting rod big end caps, bearings
and bolts in their original refit order. 3. Clean the fitting positions for the bearings and thrust
washers in the cylinder block.
11. Rotate the crankshaft pulley bolt to turn the crankshaft,
setting each connecting rod bolt on the location easy
bearing seats.
to remove.
12. Remove the connecting rod bolts and the lower end
connecting rods and the caps.
cap of the connecting rod (the connecting rod big end
cap); push the piston connecting rod assembly out of
the cylinder bore gently.
Caution: The weight groupings of the piston connecting

rod assemblies on the same engine should be same, fit
them correctly. If the piston connecting rod assembly
in the same group cannot be selected and fitted when
servicing, replace all the piston connecting rod assemblies
13. Remove the connecting rod bearing from the to ensure the piston connecting rod assembly weight is in
connecting rod lower end cap (connecting rod big end the same group.
V 2.0 101
Piston Connecting Rod Assembly Connecting Rod

Assembly
Aftermarket Parts No. Corresponding
Grouping Group No.
A 10050885 25
B 10050886 26
C 10050887 27
9. Check the diameters of the crankshaft main journals
D 10050888 28 (Refer to "Parameter").
E 10050889 29 Parameter
F 10050890 30 10. Determine the proper main bearing to be fitted in
accordance with the selected size and model (Refer
G 10050891 31 to "Parameter").
H 10050893 32 Parameter
6. Clean the crankshaft and check for any damage. Caution: The bearings with oil grooves and oil holes are
fitted in the main bearing holes of the cylinder block, and
7. Align the two connecting rod bearings with the bearing
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bearings without oil grooves and oil holes are fitted in the
grooves, and press them into the connecting rod big
main bearing caps.
end holes respectively. Make sure the end surfaces of
the bearings are flush with the fracture surface of the 11. The matching rule of the main bearing: the upper
connecting rod big end hole as mush as possible. bearings are grouped according to the size of the
cylinder block (A stands for blue and B stands for red).
Caution: The connecting rod bearings are not grouped.
Grade Diameter
Caution: Record the main bearing mark number on the
front of the crankshaft. A 53.690 f ≤ 53.700
8. Record the main bearing mark number from the flange B 53.680 ≤ f ≤ 53.690
face on the rear end of the crankshaft, and the grouping
rules are as follows:
Journal Dia. Grade
f50.000 - f49.993 0
f49.992 - f49.984 1
12. Lower bearings are grouped by the crankshaft sizes (1

stands for blue and 0 stands for red).
13. Clean the sealing surfaces on the cylinder block and the
bearing seats using a piece of cloth free of rough edges
and appropriate solvent.
Tip: Please use SAIC Motor recommended cleaning
solvent to remove the remaining sealer.
14. Fit the selected crankshaft main bearings to the cylinder
block and the bearing seats.
15. Clean both sides of the cylinder block fourth main
bearing and fit new thrust washers to them.
Tip: The oil groove surface of the thrust washer is the
surface contacting with the crankshaft thrust surface,
and never fit it reversely.
16. Fit the crankshaft, apply a proper amount of lubricant
to the main journals, then fit the main bearing caps.
V 2.0 102
Torque: (20 ± 2) Nm + 90°+(45 ± 2)° Crankshaft Rear Oil Seal
17. First apply oil to the connecting rod bearing and the Removal
crankshaft journal for connecting rod, then place 1. Disconnect the battery negative terminal.
the piston connecting rod assembly in the special 2. Remove the transmission case assembly
toolTEN00003 and press it into the cylinder. Fit the
Manual Transmission Case Removal
connecting rod big end cap. Torque: (18 ± 2) Nm +
(90 ± 5)°. Automatic Transmission Removal
3. Remove the manual flywheel or the torque converter
drive plate.
Torque Converter Drive Plate Removal
4. Loosen the 5 bolts around the oil seal.
5. Remove the oil seal and dispose of it.
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plate.
Flywheel Refit
19. Fit the crankshaft rear oil seal.
Refit
1. Clean the mating area for the oil seal of the crankshaft
Cylinder Head Assembly Refit flange face journal to make sure there is no dirt.
2. Insert the crankshaft rear oil seal mounting guide sleeve
special toolTEN00013 into the rear end of crankshaft.
3. Apply clean oil to the oil seal lip.
Caution: Take care to avoid damaging the oil seal lip while
fitting the oil seal.
4. Slowly push the oil seal along the special

toolTEN00013 until the location pin on the oil seal in
the pin hole of the cylinder block.
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Oil Strainer
Removal
5. Slowly pull out the special tool while pressing the oil 5. Remove the timing chain lower cover plate.
seal flange.
6. Tighten all the bolts and the tightening torque is 8-12
6. Remove the oil pump drive chain and drive sprocket.
Nm.
7. Unscrew all the fastening bolts from the lower crank
case to the cylinder block, and remove the lower crank
plate.
case assembly.
Flywheel Refit
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8. Fit the transmission case assembly.
Manual Transmission Case Assembly Refit
Automatic Transmission Case Assembly Refit
9. Connect the battery negative terminal.
8. Unscrew all the bolts from the oil baffle to the lower
crank case, and remove the oil baffle.
9. Remove the oil pump and oil strainer set bolts, and
remove the oil pump with the oil strainer from the
lower crank case.
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10. Disengage the oil pump and oil strainer in the direction
as shown in the illustration. Remove and dispose of
the oil strainer seal ring.
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Refit
1. Clean the oil strainer and joint surface.
2. Lubricate a new O-ring with engine oil, and fit it to
the oil strainer. Insert the oil strainer into a new oil
pump in the opposite direction as shown in the above
illustration.
3. Using the oil pump mounting bolts and oil strainer
mounting bolts, tighten them to 8-12 Nm.
4. Fit the oil baffle and the tightening torque is 8-12 Nm.
5. Fit the lower crank case.
Lower Crank Case Refit
6. Fit the oil pump drive chain and drive sprocket.
7. Adjust the timing chain system.
Timing Chain Refit
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Oil Pump
Removal
6. Use the special toolTEN00006 to secure the oil pump 10. Remove the oil pump and oil strainer set bolts, and
sprocket and remove it. remove the oil pump with the oil strainer from the
lower crank case.
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7. Remove the oil pump drive chain.
8. Unscrew all the fastening bolts from the lower crank 11. Disengage the oil pump and oil strainer in the direction
case to the cylinder block, and remove the lower crank as shown in the illustration. Remove and dispose of
case assembly. the oil strainer seal ring.
9. Unscrew all the bolts from the oil baffle to the lower Refit
crank case, and remove the oil baffle. 1. Clean the oil strainer and joint surface.
2. Lubricate a new O-ring with engine oil, and fit it to
the oil strainer. Insert the oil strainer into a new oil
pump in the opposite direction as shown in the above
illustration.
3. Using the oil pump mounting bolts and oil strainer
V 2.0 106
mounting bolts, tighten them to 8-12 Nm. Oil Control Valve
4. Fit the oil baffle. Removal
5. Fit the lower crank case. 1. Disconnect the battery ground.
Lower Crank Case Refit 2. Disconnect the oil control valve connector.
6. Fit the oil pump drive chain and drive sprocket.

7. Adjust the timing chain system.
Timing Chain Refit
Accessory Drive Belt
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4. Loosen the bolt securing the oil control valve and
remove the oil control valve.
Refit
1. Fit a new oil control valve to the front bearing cap,
tighten it with the bolt, and the tightening torque is
5-7 Nm.
2. Check the oil seal of the oil control valve. If there is
any sign of oil leakage, deterioration or crack, replace it
with a new one. Fit the oil seal of the oil control valve
to the camshaft cover.
V 2.0 107
Engine Oil Filter

Removal
1. Raise the vehicle with a lift.
2. Put a proper container under the drain plug of the
engine oil pan, remove the plug and dispose of the seal
washer. Drain the oil.
Warning: Take extra care when draining the engine oil, as
the oil may be very hot.
Warning: Avoid prolonged or repeated contact between
skin and used engine oil. Used engine oil may contain
harmful contaminants which may cause skin cancer or
other serious skin inflammations.
4. Connect the oil control valve connector.
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3. Clean the area around the filter top, and put a proper
container under the filter to collect the oil that may
spill.
4. Turn the filter counterclockwise to remove it, and
dispose of it.
Refit
1. Clean the mating surface on the filter top.
V 2.0 108
Engine Oil Pressure Inspection
Inspection
2. Disconnect the oil pressure switch connector.
3. Remove the oil pressure switch.
2. Lubricate the seal ring of the filter with clean engine oil.
3. Fit a new filter and tighten it to 16–18 Nm.
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4. Remove the seal ring from the oil pressure switch, and
fit it to the oil pressure gauge connector.
5. Fit the oil pressure gauge connector to the original
position of the oil pressure switch and tighten it.
6. Connect the oil pressure gaugeT10001 and T10002,
and tighten the connector.
7. Check the engine oil, and add oil if necessary.
8. Start and run the engine until it reaches the normal
operating temperature.
4. Clean the oil drain plug and fit a new seal washer.
9. When the engine operates at 3500 rpm, observe the
5. Fit the drain plug and tighten it to 35-40 Nm.
reading of the oil pressure gauge (Refer to "Parameter").
6. Remove the engine oil filler cap and fill oil in the engine
Parameter
to the correct level.
10. Turn off the engine, disconnect the pressure gauge
Lubricant Refill
connector and remove the gauge.
7. Fit the oil filler cap.
11. Unscrew the connector.
12. Wipe up the spilled oil.
9. Start and run the engine until the oil pressure warning
13. Fit the oil pressure switch.
light goes off.
14. Connect the oil pressure switch connector.
10. Check the engine oil level again after stopping the
engine.
11. Check for any sign of oil leakage.
V 2.0 109
Intake Manifold Gasket sensor.

Removal
2. Remove the intake pipe assembly.
Intake Pipe Assembly Removal
3. Disconnect the heater return pipe from the intake
manifold clamps.
7. Press the plastic ring, and disconnect the brake booster

tube from the intake manifold.
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4. Disengage the clamp and disconnect the canister
solenoid valve hose from the intake manifold.
8. Pull out the wire snap fit A from the fuel rail bracket,
and disconnect the injector connector B and canister
solenoid valve connector C.
5. Pull out the C-tube clamp fitted on the intake manifold.

Disengage the clamp and disconnect the partial load
breather tube clamp from the intake manifold.
6. Disconnect the connector from the electronic throttle
V 2.0 110
9. Disconnect the connector from the intake manifold 13. Remove the intake manifold, remove and dispose of
absolute pressure temperature sensor. the 4 seal washers.
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10. Secure a piece of cloth with high absorbency under the Refit
fuel guide rail. 1. Make sure the mating surface is clean and the metal
11. Disconnect the fuel inlet tube from the fuel rail. inserts has been fitted to the intake manifold bolts and
bolt holes.
2. Fit new washers onto the intake manifold.
Tip: Be careful of the error proofing design on the washer.
3. Tighten 5 nuts in the order as shown, and secure
the mounting bolt A from the intake manifold to the
cylinder block.
Caution: Plug the disconnected unions to prevent

contamination entering.
12. First remove the bolt A connecting the intake manifold
and cylinder block, then remove the 5 nuts securing the
intake manifold to the cylinder head in the order as
shown in the illustration.
4. Remove the plugs from the fuel hose and fuel rail.
5. Secure the fuel inlet tube onto the fuel rail.
V 2.0 111
6. Connect the TMAPTMAP sensor connector. Exhaust Manifold Gasket

7. Connect the injector connectors, fit the wire snap fit Removal
to the fuel rail bracket hole and connect the canister 1. Disconnect the battery negative terminal.
solenoid valve connector. 2. Remove the generator.
8. Insert the brake booster tube into the quick joint of
Generator Removal
the intake manifold.
3. Remove the bolts connecting the exhaust manifold and
9. Connect the electronic throttle sensor connector.
front exhaust pipe assembly.
10. Connect the partial load breather tube to the intake
manifold, clamp it with the clamp and insert the C-tube
clamp into the intake manifold mounting hole.
11. Connect the canister solenoid valve hose to the intake
manifold and clamp it with the clamp.
12. Secure the heater return pipe on the intake manifold
clamp.
13. Fit the intake pipe assembly.
Intake Pipe Refit
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4. Disconnect the oxygen sensor connectors.
5. Remove the exhaust manifold housing.
6. Remove the exhaust manifold.
V 2.0 112
7. Remove the exhaust manifold gasket from the mating 5. Fit the exhaust manifold housing.
surfaces of the cylinder head and exhaust manifold, and
dispose of it.
Refit
1. Clean the mating surfaces of the cylinder head and
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exhaust manifold to make sure it is clean and free of
foreign matter.
2. Use the special stud bolt replacerTEN00001 to fit
the stud bolts.
6. Connect the oxygen sensor connectors.

exhaust pipe assembly.
3. Correctly fit the exhaust manifold gasket to the stud

bolts of the cylinder head in the direction determined
by the error proofing design.
4. Fit the exhaust manifold.
V 2.0 113
8. Fit the generator.

Generator Refit
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V 2.0 114
Special Tools Tool Description Picture
Tool Description Picture Number
Number
Crankshaft
TEN00008 Pulley Holding
Tool
TEN00012 Engine Hanger
Pulley Replacer
TEN00009
Holding Tool
Engine Service
T10007
Lift Bracket
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Oil Pump
TEN00006 Sprocket
Holding Tool
Crankshaft Rear
TEN00013 Oil Seal Refit
Guide Sleeve
Camshaft
TEN00005 Sprocket
Locking Tool
Flywheel Timing
TEN00002
Location Pin
Valve Spring
T10005
Compressor
Camshaft
TEN00004
Timing Tool
V 2.0 115
Tool Description Picture Tool Description Picture

Number Number
Engine Oil
Valve Oil Seal
T10006 T10002 Pressure Gauge
Removal Pliers
Adaptor
Valve Oil Seal M8 Stud Bolt

TEN00014 TEN00001
Replacer Replacer
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Camshaft
TEN00003
Timing Tool
Engine Oil
T10001
Pressure Gauge
V 2.0 116

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Engine Mechanical Engine

Pin Journal Diameter 48.000-47.984 mm

Maximum Out-of-round 0.008 mm

1.5VCT - Cylinder Block and Piston

Cylinder Liner Diameter 74.985-75.000 mm

Bore Maximum Diameter of Skirt Gap between Piston and

2nd Compression Ring Nose shape, and surface bonderized

2nd Compression Ring 1.170-1.190 mm

1.5VCT Cylinder Head and Valve

New Exhaust Valve 49.925-50.785

Valve Seat Width

Gap between Rotor and Pump Cover End Surface 0.05-0.086 mm

90004180 Screw - Crankshaft Sensor Signal Plate Once

BLT200011 Bolt - Connecting Rod Once

90003592 Bolt - Oil Pump to Oil Pan Once

90003620 Stud Bolt - Intake Manifold to Cylinder Once

90000829 Bolt - Flywheel Once

Description and Operation

1. Cylinder Block 9. Crankshaft Sensor Signal Plate

1. Ignition Coil 4. Nut - Ignition Coil

1. Cylinder Head 4. Phase Sensor Signal Plate - Camshaft

Lower Crank Case Exploded View

Exhaust Manifold Exploded View

Accessory Belt System

1. Accessory Belt 4. Pulley - PAS Pump

1. Water Temperature Sensor (Oil Temperature Sensor) 9. Cam Phase Sensor

Fuel Rail Assembly

1. Fuel Rail Assembly 4. Clamp - Fuel Injector

Battery Box Removal

7. Drain the cooling system.

5. Remove the air cleaner assembly.

15. Detach the A/C compressor connector and the line.

30. Remove the power assembly mounting.

15. Disengage the A/C compressor connector and line.

5. Remove the air cleaner assembly.

Power Assembly Mounting

4. Remove the wire bracket and other items fitted on the

3. Connect the battery ground.

5. Unscrew the 3 bolts securing the engine mounting RH

7. Remove the flywheel timing pin special tool

6. Remove the flywheel from the crankshaft.

7. Remove the flywheel timing pin special tool

Torque Converter Drive Plate AT

7. Remove the flywheel timing pin special tool

6. Remove the drive plate from the crankshaft.

7. Remove the drive plate timing pin special tool

6. Fit the plug.

3. Fit the bolts securing the timing chain upper cover

5. Remove the bolts securing the timing chain lower cover

6. Remove the timing chain lower cover plate, and then

4. Apply adhesive with a width of about 2.5 mm as shown

5. Fit the timing chain lower cover plate assembly bolts,

6. Fit the crankshaft pulley.

8. Fit the accessory drive belt. Camshaft Cover Removal

9. Use the camshaft lock special toolTEN00004 to lock

to the crankshaft, and dispose of it.

18. Using the oil pump sprocket holding special tool

17. Remove the upper rail.