Cam Chain Installation

Cam Chain Installation

NOTE: Keep the cam chain away from magnetic field.





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. Install the CKP pulse plate.
5. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal.
6. Remove any old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
7. Clean and dry the chain case mating surfaces.





8. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the engine 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.





9. Install the dowel pins (A) and chain case (B) using a new O-ring (C).
10. Install the crankshaft pulley.
11. Install the oil pan.





12. Install the idler pulley base (A), then install the idler pulley (B).
13. Install the alternator.
14. Install the auto-tensioner.





15. Install the water pump pulley.





16. Install the water bypass hose (A), and tighten the three bolts (B) securing the water bypass tube.





17. Install the cylinder head with using the following process by installing the cam chain sprocket assembly.
^ 1 Make sure the crankshaft pulley is at TDC.
^ 2 Place the idler gear/cam chain sprocket assembly and idler gear collar into the cylinder head.
^ 3 Install the cam chain on the sprocket with the one punch mark (A) aligned with the center of the two colored pieces (B).
^ 4 Fit the cam chain sprocket assembly into the cylinder head.
^ 5 Turn the cam chain sprocket assembly counterclockwise to relieve cam chain free play, and check the alignment of the TDC mark (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.

18. Install the drive belt.





19. Install the vacuum tank.
20. After installation, check that all tubes, hoses, and connectors are installed correctly.
21. After assembly, wait at least 30 minutes before filling the engine with oil.
22. Connect the positive cable to the battery, then connect the negative cable.
23. 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.
24. Refill the engine with engine oil.
25. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
26. 2000-2005 models: Do the engine control module (ECM) idle learn procedure.
27. 2006 model: Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.
28. Inspect the idle speed.
29. Inspect the ignition timing.
30. Enter the anti-theft code for the radio, then enter the audio presets.
31. Set the clock.