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Installation






Camshaft Inspection

Installation

1. Camshaft





1. Install the camshaft (A).

2. Install the camshaft thrust cover (B) with a new O-ring (C).

2. Camshaft Sprocket





1. Install the camshaft sprocket.

2. Apply new engine oil to the threads of the camshaft sprocket mounting bolt.

3. Install the camshaft sprocket mounting bolt.

4. Hold the camshaft with a 27 mm open-end wrench.

5. Tighten the camshaft sprocket mounting bolt.








3. Rocker Arm Assembly - Reassembly

NOTE:
* If reused, the rocker arms must be installed in their original locations.
* When removing, or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders and the rocker arms on the shaft.
* Bundle the intake and the exhaust rocker arms with rubber bands to keep them together as a set, and remove the bands after the intake and exhaust rocker arms have been installed.
* Prior to reassembling, clean all the parts in solvent, dry them, and apply new engine oil to all contact points, the bearing surface, and the lost motion assembly.
* When replacing the rocker arm assembly, remove the fastening hardware from the new rocker arm assembly.





4. Rocker Arm Assembly





1. If the rocker arm assembly is disassembled, reassemble the rocker arm assembly.

2. Install the oil control orifice (A) with a new O-ring (B).

3. Install the rocker arm assembly (C).

4. Install the lost motion assembles (D) and the lost motion holder (E).

NOTE: Apply new engine oil to the lost motion assembly.





5. Tighten each bolts two turns at a time in sequence.








5. Set The Crankshaft To Top Dead Center





1. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.

6. Set The No.1 Piston at Top Dead Center (Without Cam Chain Case/Oil Pump)





1. Set the camshaft to TDC. The "UP" mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.

7. Cam Chain





1. Install the cam chain on the crankshaft sprocket with the colored piece (A) aligned with the mark (B) on the crankshaft sprocket.





2. Install the cam chain on the camshaft sprocket with the colored link plate (A) aligned with the mark (B) on the camshaft sprocket.





3. Install the cam chain guide (A) and the cam chain tensioner arm (B).

8. Cam Chain Auto-Tensioner





1. Compress the cam chain auto-tensioner when replacing the cam chain. Remove the pin (A) from the auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock, then press the rod (C), and set the first cam (D) to the first edge of the rack (E). Insert the 1.0 mm (1/32 in) diameter pin back into the holes (F).

NOTE: If the chain tensioner is not set up as described, the tensioner will be damaged.





2. Install the cam chain auto-tensioner.





3. Remove the pin from the cam chain auto-tensioner.

9. Engine Oil Pump Assembly





1. Check the oil pump oil seal for damage. If the oil seal is damaged, replace the oil seal.

2. Remove all of the old liquid gasket from the oil pump mating surfaces, the bolts, and the bolt holes.

3. Clean and dry the oil pump mating surfaces.

4. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the oil pump, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A), (B), and (C).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





5. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the oil pan mating surface of the oil pump, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

* Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.









6. Set the edge of the oil pump (A) on the edge of the oil pan (B) with new O-rings (C).

7. Install the oil pump on the engine block (D).

8. Loosely install the dowel bolts (E), then tighten the 8mmbolts (F), the 6 mm bolts (G) and the dowel bolts.

9. Wipe off the excess liquid gasket on the oil pan and oil pump mating surface.

NOTE:
* When installing the oil pump, do not slide the bottom surface onto the oil pan mounting surface.
* Wait at least 30 minutes before filling the engine with oil.
* Do not run the engine within 3 hours after installing the oil pump.

10. Mounting Bracket, Engine Side





1. Install the new side engine mount mounting bolts (A) and the side engine mount bracket (B) using a nut and a new bolt, then loosely install the new side engine mount bracket mounting bolts and nut (C).

2. Install the ground cable (D).

11. Engine Jack Support (State Of A Low Vehicle)

1. Remove the jack and the wood block.

12. Transmission Mount Bracket Mounting Bolt - Loosen

M/T





A/T





1. Loosen the transmission mount bracket mounting bolt and nuts (A).

13. Lower Torque Rod - Loosen





1. Loosen the lower torque rod mounting bolt (A).

14. Side Engine Mount - Tighten





1. Tighten the side engine mount bracket mounting bolt and nut.

15. Transmission Mount Bracket Mounting Bolt - Tighten

1. Tighten the transmission mount bracket mounting bolt and nuts.

M/T





A/T





16. Lower Torque Rod Mounting Bolt - Tighten





1. Tighten the lower torque rod mounting bolt.

17. Crankshaft Pulley





1. Clean the crankshaft pulley (A), the crankshaft (B), the bolt (C), and the washer (D).

2. Lubricate with new engine oil as shown.





3. Install the crankshaft pulley (A) onto the crankshaft (B) by aligning the flat sides (C) of the pulley with the flat sides (D) of the inner oil pump gear.









When a new crankshaft or a new pulley bolt is installed

4. Hold the pulley with the holder handle (A) and crankshaft pulley holder (B), torque the bolt to 180 Nm (18.4 kgfm, 133 lbfft) with a torque wrench and a socket (C), then remove the bolt.

5. Torque the bolt to 50 Nm (5.1 kgfm, 37 lbfft) with a torque wrench and a socket.

NOTE: Tighten the crankshaft pulley bolt. Do not use an impact wrench.

6. Tighten the bolt an additional 82 °.









When the crankshaft or the pulley bolt is reused

7. Hold the pulley with the holder handle (A) and crankshaft pulley holder (B), then torque the bolt to 70 Nm (7.1 kgfm, 52 lbfft) with a torque wrench and a socket (C).

NOTE: Tighten the crankshaft pulley bolt. Do not use an impact wrench.

8. Tighten the bolt an additional 90 °.

18. Valve Clearance Adjustment





1. Set the No. 1 piston at top dead center (TDC). The "UP" mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.

2. Select the correct feeler gauge for the valve clearance you are going to check.
















3. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem on the No. 1 cylinder, and slide it back and forth; you should feel a slight amount of drag.





4. If you feel too much or too little drag, loosen the locknut, and turn the adjusting screw (A) until the drag on the feeler gauge is correct.

5. Tighten the locknut to the specified torque, and recheck the clearance. Repeat the adjustment if necessary.












6. Rotate the crankshaft clockwise. Align the No. 3 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.

7. Check and, if necessary, adjust the valve clearance on the No. 3 cylinder.





8. Rotate the crankshaft clockwise. Align the No. 4 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.

9. Check and, if necessary, adjust the valve clearance on the No. 4 cylinder.





10. Rotate the crankshaft clockwise. Align the No. 2 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.

11. Check and, if necessary, adjust the valve clearance on the No. 2 cylinder.

19. Cylinder Head Cover and/or Packing





1. Thoroughly clean the head cover gasket and the groove.

NOTE: Check and, if necessary, replace the head cover gasket.

2. Install the head cover gasket (A) in the groove of the cylinder head cover (B).

3. Make sure the head cover gasket is seated securely.

4. Clean the head cover contacting surfaces with a shop towel.





5. Remove the old liquid gasket from the top edge matting surfaces of the oil pump (A) and cylinder head (B).

6. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the chain case contact areas. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* Apply a 5 mm (0.20 in) diameter bead of liquid gasket to the mating surfaces (C).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





7. Install the cylinder head cover.

8. Tighten the bolts in two steps. In the final step, torque all bolts in sequence to 10 Nm (1.0 kgfm, 7 lbfft).

NOTE:
* Wait at least 30 minutes before filling the engine with oil.
* Do not run the engine for at least 3 hours after installing the head cover.





9. Connect the breather hose (A).

10. Install the dipstick (B).

20. Cylinder Head Cover Peripheral Assembly





1. Install the harness holders (A).

2. Connect the connecters (B).

21. Engine Cover





1. Install the engine cover.

22. Auto Tensioner Assembly





1. Install the drive belt auto-tensioner.

23. Water Pump Pulley





1. Install the water pump pulley.

24. Alternator





1. Install the alternator.





2. Connect the connector and the cable. Make sure the crimped side of the ring terminal faces away from the alternator when you connect it.

3. Install the harness connector (A) and the harness clamps (B).

25. Drive Belt





1. Move the auto-tensioner (A) counterclockwise.

2. Install the drive belt (B).

26. Water Pump Pulley Mounting Bolt - Tighten





1. Tighten the water pump pulley mounting bolts.

27. Splash Shield

1. Install the splash shield (A).





28. Tire and Wheel-Installation, Front Right





1. Install the right front wheel.

NOTE: Before installing the wheel, clean the mating surfaces between the brake disc and the inside of the wheel.

29. Battery





1. Install the battery (A) and the battery setting plate (B).

NOTE: Do not deform the battery setting plate by over-tightening the nuts.

30. Battery Terminal - Reconnection





NOTE: If the battery performs abnormally, test the battery.

1. Clean the battery terminals.

2. Connect the positive cable (A) to the battery.

NOTE: Always connect the positive side first.

3. Connect the negative cable and battery sensor (B) to the battery.

4. Apply multipurpose grease to the terminals to prevent corrosion.

31. HDS DLC - Connection





1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.

2. Turn the ignition switch to ON (II).

3. Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.

32. CKP Pattern Clear/CKP Pattern Learn

1. Select CRANK PATTERN in the ADJUSTMENT MENU with the HDS.

2. Select CRANK PATTERN CLEAR, and clear the CKP pattern.

3. Select CRANK PATTERN LEARNING with the HDS, and follow the screen prompts.
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