Part One
Cylinder Head Inspection for Warpage
Installation
1. 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.
2. Cylinder Head Assembly
1. Clean the cylinder head and the engine block surface.
2. Install a new coolant separator (A) in the engine block whenever the engine block is replaced.
3. Install the new cylinder head gasket (B) and the dowel pins (C) on the engine block. Always use a new cylinder head gasket.
4. Install the cylinder head on the engine block.
5. Measure the diameter of each cylinder head bolt at point A and point B.
6. If either diameter is less than 10.6 mm (0.417 in), replace the cylinder head bolt.
7. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.
8. Torque the cylinder head bolts in sequence to 40 Nm (4.1 kgfm, 30 lbfft). Use a beam-type torque wrench. When using a preset click-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 from the first step.
9. After torquing, tighten all cylinder head bolts in two steps (90 ° per step using the sequence shown in step 8). If you are using a new cylinder head bolt, tighten the bolt an extra 60 °.
NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 5 of the procedure. Do not loosen it back to the specified angle.
3. 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).
4. 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.
5. 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.
6. 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).
7. Engine Jack Support (State Of A Low Vehicle)
1. Remove the jack and the wood block.
8. Transmission Mount Bracket Mounting Bolt - Loosen
M/T
A/T
1. Loosen the transmission mount bracket mounting bolt and nuts (A).
9. Lower Torque Rod - Loosen
1. Loosen the lower torque rod mounting bolt (A).
10. Side Engine Mount - Tighten
1. Tighten the side engine mount bracket mounting bolt and nut.
11. Transmission Mount Bracket Mounting Bolt - Tighten
1. Tighten the transmission mount bracket mounting bolt and nuts.
M/T
A/T
12. Lower Torque Rod Mounting Bolt - Tighten
1. Tighten the lower torque rod mounting bolt.
13. 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 °.