Cam Chain Installation
Cam Chain InstallationSpecial Tools Required
^ Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket
^ Holder handle 07JAB-001020B
^ Holder attachment, 50 mm 07NAB-001040A
1. Set the crankshaft sprocket so that the No.1 Piston is at Top Dead Center (TDC). Align the key (A) on the sprocket and crankshaft with the pointer (B) on the engine block.
2. Install the cam chain with the colored piece (A) aligned with the punch mark (B) on the crankshaft sprocket.
3. Install the oil pump chain guide.
4. Remove any old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
5. Clean and dry the chain case mating surfaces.
6. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the cylinder block mating surface of the chain case.
NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
7. Install the dowel pins (A) and chain case (B) using a new O-ring (C).
8. Remove any old liquid gasket from the oil pan mating surfaces, bolts, and bolt holes.
9. Clean and dry the oil pan mating surfaces.
10. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the cylinder block mating surface of the oil pan. Install the oil pan.
NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
11. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 12 Nm (1.2 kgf-m, 8.7 ft. lbs.).
12. Clean the bolt (A), washer (B), pulley (C), and crankshaft (D). Lubricate with new engine oil as shown.
13. Install the crankshaft pulley, and tighten the bolt to 245 Nm (25.0 kgf-m, 181 ft. lbs.). Do not use an impact wrench.
^ 1 Hold the pulley with the holder handle (A) and holder attachment (B).
^ 2 Tighten the bolt with a torque wrench and heavy duty 19 mm socket (C).
14. Measure the diameter of each cylinder head bolt at point A and point B. If either diameter is less than 11.5 mm (0.45 inch), replace the cylinder head bolt.
15. Clean the cylinder head and engine block surfaces.
16. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, to the shaded areas of the cylinder head gasket mating surface of the block and chain case.
17. Install the dowel pins and new cylinder head gasket.
18. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, to the cylinder head mating surface of the engine block and chain case within 5 mm from the edge of the cylinder head gasket.
19. Install the cylinder head on the engine block.
20. Apply engine oil to the threads and under the heads of all the cylinder head bolts.
21. Tighten the cylinder head bolts in sequence to 29 Nm (3.0 kgf-m, 22 ft. lbs.). Use a beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it.
22. Tighten all cylinder head bolts in two steps 90° per step). If you are using a new cylinder head bolt, tighten the bolt an extra 90°.
23. Tighten the 8 mm bolts to 22 Nm (2.2 kgf-m, 161 ft. lbs.).
24. Make sure the crankshaft pulley is at TDC.
25. Place the idler gear/cam chain sprocket assembly and idler gear collar into the cylinder head.
26. Install the cam chain on the sprocket with the punch mark (A) aligned with the center of the two colored pieces (B).
27. Fit the cam chain sprocket assembly into the cylinder head.
28. Turn the assembly counterclockwise to relieve cam chain free play, and check the alignment of the TDC marks (C) on the cam chain sprocket with the cylinder head surface. If the cam chain sprocket is not positioned at TDC, remove the assembly from the cylinder head and reposition the cam chain to bring the cam chain sprocket to TDC.
29. Apply engine oil to the idler gear center bolt threads. Install a new O-ring on the bolt.
30. Install the washer on the idler gear, and tighten the idler gear center bolt.
31. Clamp the cam chain auto-tensioner in a soft-jawed vise.
32. Turn the 5 x 0.8 mm bolt clockwise to compress the bottom of the auto-tensioner, then insert the set pin.
33. Remove the 5 x 0.8 mm bolt from the maintenance hole. Install a new O-ring, then install the nozzle and end cover.
34. Install the cam chain auto-tensioner in the cylinder head with new O-rings.
35. Remove the maintenance bolt from the cylinder head.
36. Remove the set pin from the cam chain autotensioner. Reinstall the maintenance bolt with new washer.
37. Install the rocker arm assembly.
38. Check the alignment of the TDC marks on the cam chain sprocket with the cylinder head surface.
39. Align the TDC marks on the intake camshaft gear and the exhaust camshaft gear, and install the camshafts.
40. Apply engine oil to the bolt threads of all the camshaft holder bolts.
41. Put the camshaft holders on the cylinder head, then tighten all bolts to 22 Nm (2.2 kgf-m, 16 ft. lbs.).
42. Make sure the camshaft gears are at TDC.
43. Adjust the valve clearance.
44. Install the cylinder head cover.
45. Install the exhaust manifold using new gaskets and new self-locking nuts.
46. Install the exhaust manifold bracket. Make sure the smooth sides of the washers face the exhaust manifold bracket.
47. Put the exhaust manifold cover on the exhaust manifold.
48. Install the heat shield.
49. Tighten the four bolts securing the exhaust manifold cover.
50. Install the water bypass hose, and tighten the two bolts securing the intake manifold bracket.
51. Install the water outlet cover.
52. Install the air hose, and tighten the bolt securing the intake manifold bracket.
53. Install the Evaporative Emission (EVAP) canister hose.
54. Install the fuel feed hose, fuel return hose, and brake booster hose.
55. Install the idler pulley base (A), then install the idler pulley (B).
56. Install the alternator.
57. Install the auto-tensioner.
58. Install the water pump pulley.
59. Install the water bypass hose (A), and tighten the three bolts (B) securing the water bypass tube.
60. Install the drive belt.
61. Install the vacuum tank.
62. Install the air cleaner housing/intake air duct assembly, then install the vacuum hoses. Connect the air control solenoid valve connector.
63. Install the throttle cable, then adjust it.
64. After installation, check that all tubes, hoses, and connectors are installed correctly.
65. After assembly, wait at least 30 minutes before filling the engine with oil.
66. Connect the battery cables.
67. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
68. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
69. Do the Engine Control Module (ECM) idle learn procedure.
70. Inspect the idle speed.
71. Inspect the ignition timing.
72. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
73. Set the clock.