1A08-1U-11L(01-10).

fm 59 ページ ２０１１年１２月１４日 水曜日 午後２時２２分

MECHANICAL
2. Hold the camshaft using a wrench on the cast
hexagon, and tighten the actuator installation bolt.

Tightening torque
Electric variable valve timing actuator
(intake side): 102—114 N·m {10.5—11.6
kgf·m, 76—84 ft·lbf}
Hydraulic variable valve timing actuator 01-10
(exhaust side): 75—85 N·m {7.7—8.6 kgf·m,
56—62 ft·lbf}

End Of Sie bpe2ue00000073

TIMING CHAIN ASSEMBLY

id011000505600

Caution
• If the camshaft is rotated with the timing chain removed and the piston at the top dead center
position, the valve may contact the piston and the engine could be damaged. When rotating the
camshaft with the timing chain removed, rotate it after lowering the piston from the top dead
center position.
• When rotating the camshaft using a
WRENCH
wrench on the cast hexagon, the wrench CAMSHAFT
may contact the rocker arm and damage CAST HEXAGON
the rocker arm. To prevent damage to the
rocker arm when holding the camshaft on
the cast hexagon, use the wrench at
engine rear side as shown in the figure to
secure a clearance between the cam.

ROCKER ARM CONTACT

SECURE CLEARANCE ENGINE REAR

DOES NOT CONTACT

am3uuw00008968

Note
• Width at the cast hexagon of the camshaft is CAMSHAFT
22—24 mm {0.87—0.94 in}.

CAST HEXAGON

22—24 mm
{0.87—0.94 in}

am3uuw00009029

01-10–59
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MECHANICAL
1. Assemble in the order indicated in the table.

21 A
4.5—7.0
{46—71,
40—61}

22

8.0—9.0
{82—91,
9—12 71—79}
{92—122,
80—106}

SEALANT
20
12

B
R A

14 11 19
15—20 N·m
{1.6—2.0 kgf·m,
12—14 ft·lbf}
20—26 N·m SEALANT

{2.1—2.6 kgf·m,
15—19 ft·lbf}

15
R
SST
OIL
18
17 16
SST
90—110 N·m
{9.2—11 kgf·m,
67—81 ft·lbf}
+55—65°
7 1
B
10 2
9

SEALANT

13
B
B
B
6 3 4 5
SST

20—30 N·m
{2.1—3.0 kgf·m,
B : 8—11 {82—112, 71—97} 15—22 ft·lbf} N·m {kgf·cm, in·lbf}

bpe2ue00000121

1 Key 2 Oil pump drive sprocket

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MECHANICAL
3 Oil pump chain 14 Electric variable valve timing motor/driver
4 Oil pump driven sprocket (See 01-10-69 Electric Variable Valve Timing Motor/
(See 01-10-61 Oil Pump Driven Sprocket Assembly Driver Assembly Note.)
Note.) 15 Front oil seal
5 Oil pump chain tensioner (See 01-10-70 Front Oil Seal Assembly Note.)
6 Crankshaft sprocket 16 Crankshaft pulley
7 Timing chain 17 Crankshaft pulley lock bolt
(See 01-10-62 Timing Chain Assembly Note.) (See 01-10-71 Crankshaft Pulley Lock Bolt Assembly 01-10
Note.)
8 Chain guide (No.2)
(See 01-10-62 Timing Chain Assembly Note.) 18 Water pump pulley
(See 01-10-72 Water Pump Pulley Assembly Note.)
9 Tensioner arm
(See 01-10-62 Timing Chain Assembly Note.) 19 Spark plug
10 Chain tensioner 20 Oil shower pipe
(See 01-10-62 Timing Chain Assembly Note.) (See 01-10-73 Oil Shower Pipe Installation Note.)
11 Chain guide (No.1) 21 Cylinder head cover
(See 01-10-62 Timing Chain Assembly Note.) (See 01-10-73 Cylinder Head Cover Installation
Note.)
12 Engine front cover
(See 01-10-64 Engine Front Cover Assembly Note.) 22 Dipstick
13 Oil pan
(See 01-10-68 Oil Pan Assembly Note.)

Oil Pump Driven Sprocket Assembly Note

1. Hold the crankshaft using the SST.
2. Install the oil pump driven sprocket.

Tightening torque
20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}

49 E011 1A0

bpe2ue00000077

01-10–61
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MECHANICAL
Timing Chain Assembly Note
1. Verify that the timing marks and the key are aligned to the position shown in the figure.

TIMING CHAIN ALIGNMENT MARK

PIN

CYLINDER
HEAD
UPPER
SURFACE

TIMING MARK

KEY

bpe2ue00000122

• If they are not in the position shown in the figure, rotate the camshaft and crankshaft to set the cylinder No.1
top dead center (TDC).

01-10–62
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MECHANICAL
2. Install the timing chain while aligning the marks on each sprocket and the timing chain as shown in the figure.

HYDRAULIC VARIABLE VALVE TIMING

ACTUATOR TIMING CHAIN ALIGNMENT MARK
TIMING CHAIN
ALIGNMENT MARK
(ORANGE)

PIN 01-10

CYLINDER
HEAD
UPPER
SURFACE
TIMING MARK

CRANKSHAFT SPROCKET TIMING CHAIN

TIMING CHAIN ALIGNMENT MARK
ALIGNMENT MARK (YELLOW)

bpe2ue00000123

3. Install the chain guide (No.2).

4. Install the tensioner arm.
5. Install the chain tensioner.
6. After installing the chain tensioner, remove the installed wire or paper clip, and then apply tension to the timing
chain.
• If a new chain tensioner is used, remove the
installed stopper.
7. Install the chain guide (No.1).
8. Verify that there is no looseness in the timing
chain, and re-verify that each sprocket is in the
specified location.
STOPPER

LINK PLATE

am3uuw00008861

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MECHANICAL
9. Rotate the crankshaft clockwise two turns and inspect the valve timing.

TIMING CHAIN ALIGNMENT MARK

PIN

CYLINDER
HEAD
UPPER
SURFACE

TIMING MARK

KEY

bpe2ue00000124

Engine Front Cover Assembly Note

Note
• For a new engine front cover, the positioning
pins in the two locations shown in the figure
project to the outside of the engine.
VIEW FROM A
ENGINE OUTSIDE

POSITIONING
PIN

SEAL SIDE

POSITIONING PIN

A
bpe2ue00000125

01-10–64
1A08-1U-11L(01-10).fm 65 ページ ２０１１年１２月１４日 水曜日 午後２時２２分

MECHANICAL
1. If the engine front cover is newly replaced, tap the
positioning pins in the two locations to the seal
surface side.
2. Completely clean and remove any oil, dirt, sealant
or other foreign material that may be adhering to
the engine front cover, cylinder head, and cylinder
block.
3. When reusing the engine front cover installation 01-10
bolts, clean any old sealant from the bolts.

Caution
• Apply the silicon sealant in a single,
unbroken line. ENGINE OUTSIDE
• To prevent silicone sealant from
hardening, adhere the engine front cover
to the cylinder block within 10 min. after 0—1 mm
{0—0.03 in}
silicone sealant is applied. Tighten the
installation bolts completely soon after
adhering.
• Using bolts with the old seal adhering POSITIONING
PIN SEAL SIDE
could cause cracks in the cylinder head
and cylinder block. WOOD SLAB
POSITIONING PIN

bpe2ue00000126

DAMAGE

OLD SEALANT

bpe2ue00000127

01-10–65
1A08-1U-11L(01-10).fm 66 ページ ２０１１年１２月１４日 水曜日 午後２時２２分

MECHANICAL
4. Apply silicone sealant to the engine front cover as shown in the figure.
A
SEALANT

10 {0.39}

10 {0.39}
B

10 {0.39}

C
D D
B
10 {0.39}

A SECTION D-D
0.5—1.5 mm
{0.02—0.05 in}
90°
10 {0.39} SEALANT

B
B

C 32.5 {1.28}
C
ENGINE FRONT
COVER
B 10 {0.39}
B
10 {0.39}

mm {in}
bpe2ue00000078

Bead thickness
A: 2—6 mm {0.1—0.2 in}
B: 4—6 mm {0.16—0.23 in}
C: 4—8 mm {0.2—0.3 in}

01-10–66
1A08-1U-11L(01-10).fm 67 ページ ２０１１年１２月１４日 水曜日 午後２時２２分

MECHANICAL
5. Apply silicone sealant to the areas shown in the
figure.

Caution
• Apply the silicone sealant so that it goes
into the cylinder head gasket. A

6. Install the engine front cover to the engine. 01-10

Note
• Temporarily install an appropriate bolt to the VIEW FROM A
drive belt auto tensioner installation bolt hole SEALANT
to prevent:
— A silicone sealant adhesion malfunction
in the drive belt auto tensioner
installation bolt hole.
— A bolt mis-installation due to silicone CYLINDER HEAD
sealant hardening. SEALANT

CYLINDER BLOCK CYLINDER

HEAD
GASKET

am3uuw00008866

7. Prepare an appropriate M8 X 1.25 bolt (length 40

mm {1.6 in}).

DRIVE BELT AUTO

TENSIONER
INSTALLATION BOLT HOLE

am3uuw00008867

01-10–67
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MECHANICAL
8. Tighten the engine front cover installation bolts in
the order shown in the figure. 15 19 16 20

Tightening torque
20—26 N·m {2.1—2.6 kgf·cm, 15—19 in·lbf}

9. Remove the bolt installed to the drive belt auto

tensioner installation bolt hole when installing the 1
drive belt auto tensioner. 11
12
7 8
4 5
3 2
10 9 M8×1.25,
BOLT WITH LENGTH 40 mm
WASHER {1.6 in}

6 13
14
17
22 18 21
bpe2ue00000079

Oil Pan Assembly Note

1. Completely clean and remove any oil, dirt, sealant or other foreign material that may be adhering to the cylinder
block and oil pan.
2. When reusing the oil pan installation bolts, clean any old sealant from the bolts.

Caution
• Apply the silicon sealant in a single, unbroken line around the whole perimeter.
• To prevent silicone sealant from hardening, adhere the oil pan to the cylinder block within 10 min.
after silicone sealant is applied. Tighten the installation bolts completely soon after adhering.
• Using bolts with the old seal adhering
could cause cracks in the cylinder block,
etc.
DAMAGE

OLD SEALANT

am6zzw00002304

01-10–68
1A08-1U-11L(01-10).fm 69 ページ ２０１１年１２月１４日 水曜日 午後２時２２分

MECHANICAL
3. Apply silicone sealant to the oil pan along the inside of the bolt holes as shown in the figure.
SEALANT

SECTION A-A

SEALANT
01-10

A A

OIL PAN

bpe2ue00000080

Thickness
2.0—6.0 mm {0.08—0.23 in}

4. Install the oil pan to the cylinder block.

5. Tighten the bolts in the order shown in the figure.
11 7 3 2 6
Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf} 13
10
17
16
18
15
14

12 8 4 1 5 9
am3uuw00008918

Electric Variable Valve Timing Motor/Driver Assembly Note

1. Install a new O-ring to the O-ring installation groove of the engine front cover.

Caution
• To prevent damage to the electric
variable valve timing motor/driver, do not
apply excessive force (force of 100 N
{10.2 kgf, 22.5 lbf} or more) to the shaded
areas shown in the figure.

bpe2ue00000128

01-10–69
1A08-1U-11L(01-10).fm 70 ページ ２０１１年１２月１４日 水曜日 午後２時２２分

MECHANICAL
2. Install the electric variable valve timing motor/driver using the following procedures.

Note
• The eccentric shaft on the electric variable
valve timing actuator side can be rotated to
JOINT GROOVE
the left and right.
• The electric variable valve timing motor/
driver can be assembled with the joint
groove of the eccentric shaft in any position, ECCENTRIC
and it will not lead to vehicle damage or SHAFT
performance reduction.

ELECTRIC VALIABLE VALVE TIMING ACTUATOR

am3uuw00009042

(1) Before installation, rotate the joint of the end

of the electric variable valve timing motor so
that it is aligned to the joint groove on the JOINT JOINT GROOVE
electric variable valve timing actuator side.
(2) Engage the joint on the end of the electric
variable valve timing motor with the joint
groove on the electric variable valve timing
actuator side.
(3) Attach the seal surface.
(4) Tighten the electric variable valve timing
motor/driver installation bolts.

Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf} ELECTRIC VARIABLE ELECTRIC VARIABLE
VALVE TIMING VALVE TIMING ACTUATOR
MOTOR/DRIVER

am3uuw00009043

Front Oil Seal Assembly Note

1. Apply clean engine oil to the inner surface of a new front oil seal.
2. Insert the front oil seal into the engine front cover by hand.
3. Tap the oil seal in evenly using the SST and a
hammer.

49 G028 205 A

VIEW FROM A
ENGINE FRONT COVER

HAMMER

49 G028 205

am3uuw00008830

01-10–70
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MECHANICAL

B
Front oil seal press-in amount
0—0.5 mm {0—0.019 in}
FRONT OIL SEAL

01-10

B
SECTION B-B

ENGINE FRONT
COVER
0—0.5 mm
{0—0.019 in}

FRONT OIL SEAL

am3uuw00008831

Crankshaft Pulley Lock Bolt Assembly Note

1. Hold the crankshaft using the SST.
2. Tighten the crankshaft pulley lock bolt in the order
shown in the following two steps.

Tightening procedure
Step 1: 90—110 N·m {9.2—11 kgf·m, 67—81
ft·lbf}
Step 2: 55—65°

49 E011 1A0

bpe2ue00000077

01-10–71
1A08-1U-11L(01-10).fm 72 ページ ２０１１年１２月１４日 水曜日 午後２時２２分

MECHANICAL
Water Pump Pulley Assembly Note

Caution
• Be careful not to damage the belt groove and surface of the water pump pulley when using tools,
otherwise it will cause wear, breakage, abnormal noise of the drive belt (stretch belt), damage to
the pulley, and rust.

1. Install the water pump pulley to the water pump and temporarily tighten the bolt.
2. Align the water pump pulley hole with the water
pump hole as shown in the figure.
WATER PUMP
HOLE HOLE

WATER PUMP PULLEY

bpe2ue00000081

3. Insert an appropriate bolt (length 70 mm {2.8 in})

WATER PUMP PULLEY
into the water pump hole shown in the figure and
lock the water pump pulley against rotation.
4. Completely tighten the water pump pulley bolt to
the specified torque.

Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

5. Remove the bolt used for locking the water pump

pulley against rotation.

BOLT

am3uuw00008874

01-10–72
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MECHANICAL
Oil Shower Pipe Installation Note

Caution
• If the bolt is tightened with oil adhering to
the bolt and the oil shower pipe BOLT OIL SHOWER PIPE
connector seat shown in the figure, the
axial force of the bolt will strengthen and
could cause the connector seat to 01-10
deform. Before installing, remove oil from
the bolt and the oil shower pipe
connector seat.

CONNECTOR SEAT

am3uuw00008876

1. Install the oil shower pipe in the order shown in 3 2

the figure.
1

OIL SHOWER
3 2 PIPE
bpe2ue00000129

Tightening torque
Installation position Tightening torque
1 9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}
2, 3 8.0—9.0 N·m {82—91 kgf·cm, 71—79 in·lbf}

Cylinder Head Cover Installation Note

Caution
• To assure the sealing performance of the cylinder head cover, be careful of the following:
— Verify that the cylinder head cover gasket is inserted into the cylinder head cover groove and
install the cylinder head cover.
— Completely clean and remove any oil, dirt, sealant or other foreign material from the seal
surface.
• To prevent silicone sealant from hardening, adhere the cylinder head cover and the cylinder head
within 10 min. after silicone sealant is applied. Tighten the installation bolts completely soon after
adhering.

1. Insert a new cylinder head cover gasket into the cylinder head cover groove.

01-10–73
1A08-1U-11L(01-10).fm 74 ページ ２０１１年１２月１４日 水曜日 午後２時２２分

MECHANICAL
2. Apply silicone sealant to the areas shown in the figure.
ENGINE FRONT SIDE

SEALANT

CYLINDER HEAD

VIEW FROM A
2—6 mm 4—5 mm
3—13 mm 3—13 mm
{0.1—0.2 in} {0.16—0.19 in}
{0.2—0.5 in} {0.2—0.5 in}

ENGINE FRONT COVER

SEALANT

ENGINE CYLINDER
FRONT HEAD
COVER

ENGINE FRONT
COVER MATCHING
2—6 mm 4—5 mm SURFACE
{0.1—0.2 in} {0.16—0.19 in}
A

ENGINE REAR SIDE

EXHAUST-SIDE REAR
CAMSHAFT CAP

VIEW FROM B
2—6 mm 2—6 mm
B
4—5 mm {0.1—0.2 in} {0.1—0.2 in}
SEALANT
{0.16—0.19 in}

EXHAUST-SIDE
REAR CAMSHAFT
CAP

2—6 mm
CYLINDER HEAD
{0.1—0.2 in}
CYLINDER HEAD

bpe2ue00000082

3. Tighten the cylinder head cover bolts in the order

shown in the figure. 15 8 7 3 4
9
Tightening torque
4.5—7.0 N·m {46—71 kgf·cm, 40—61 in·lbf} 14
10
End Of Sie 13

11
12
6 2 1 5
am3uuw00008879

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TECHNICAL DATA
01-50 TECHNICAL DATA
ENGINE TECHNICAL DATA . . . . . . . . . . 01-50–1

End of Toc
ENGINE TECHNICAL DATA
WM: ENGINE

id015000800100
01-50
Item Specification
OCV coil resistance 6.9—7.5 ohms [20°C {68°F}]
Maximum distortion, head gasket side of the cylinder
0.05 mm {0.002 in}
head
IN: 0.10 mm {0.0039 in}
Maximum distortion, manifold side
EX: 0.05 mm {0.002 in}
IN: Cutting not authorized
Maximum cutting length, manifold side
EX: 0.20 mm {0.0079 in}
Standard valve seat contact width 1.41 mm {0.0555 in}
Valve seat angle 45°
IN: 48.73—50.27 mm {1.919—1.979 in}
Standard valve seat sinkage amount (Dimension L)
EX: 48.73—50.27 mm {1.919—1.979 in}
IN: 1.75—1.95 mm {0.0689—0.0767 in}
Standard valve head margin thickness
EX: 1.95—2.15 mm {0.0768—0.0846 in}
IN: 106.55—107.15 mm {4.1949—4.2185 in}
Standard valve length
EX: 116.55—117.15 mm {4.5886—4.6122 in}
IN: 106.33 mm {4.1862 in}
Minimum valve length
EX: 116.33 mm {4.5799 in}
IN: 5.470—5.485 mm {0.2154—0.2159 in}
Standard valve stem diameter
EX: 5.465—5.480 mm {0.2152—0.2157 in}
IN: 5.424 mm {0.2135 in}
Minimum valve stem diameter
EX: 5.419 mm {0.2133 in}
IN: 5.510—5.530 mm {0.2170—0.2177 in}
Standard valve guide inner diameter
EX: 5.510—5.530 mm {0.2170—0.2177 in}
IN: 0.025—0.060 mm {0.0010—0.0023 in}
Standard clearance between valve stem and guide
EX: 0.030—0.065 mm {0.0012—0.0025 in}
Maximum clearance between valve stem and guide 0.10 mm {0.0039 in}
IN: 16.4—17.0 mm {0.646—0.669 in}
Standard valve guide projection height
EX: 16.4—17.0 mm {0.646—0.669 in}
IN: When pressurized with spring force of 190—210 N {19.4—21.4
kgf, 42.8—47.2 lbf}, spring height is 38.0 mm {1.50 in}
Valve spring installation height
EX: When pressurized with spring force of 228—252 N {23.3—25.6
kgf, 51.3—56.6 lbf}, spring height is 38.0 mm {1.50 in}
IN: 2.0 ° (1.6 mm {0.063 in})
Maximum valve spring off-square
EX: 2.0 ° (1.7 mm {0.067 in})
Maximum camshaft runout 0.030 mm {0.0012 in}
IN: 41.57 mm {1.637 in}
Standard cam height
EX: 40.37 mm {1.589 in}
IN: 41.50 mm {1.634 in}
Minimum cam height
EX: 40.30 mm {1.587 in}
Standard camshaft journal diameter 24.96—24.98 mm {0.9827—0.9834 in}
Minimum camshaft journal diameter 24.93 mm {0.9815 in}
Standard camshaft journal oil clearance 0.035—0.080 mm {0.0014—0.0031 in}
Maximum camshaft journal oil clearance 0.090 mm {0.0035 in}
Standard camshaft end play 0.07—0.22 mm {0.003—0.008 in}
Maximum camshaft end play 0.23 mm {0.0091 in}
Maximum distortion, head gasket side of the cylinder
0.10 mm {0.0039 in}
block
Standard cylinder bore diameter 83.50—83.53 mm {3.2875—3.2885 in}
Air pressure 180—220 kPa {1.84—2.24 kgf/cm2, 26.2—31.9 psi}
Standard piston outer diameter 83.465—83.495 mm {3.2861—3.2872 in}
Standard clearance between piston and cylinder 0.025—0.045 mm {0.0010—0.0017 in}

01-50–1

Copyright 2013 Service Repair Solutions, Inc.