Installation

Cam Chain Inspection

Installation

1. Oil Pan Assembly

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

2. Clean and dry the oil pan mating surfaces.

3. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the oil pan and to the inner threads of the bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* Apply liquid gasket about 2.5 mm (0.098 in) diameter bead 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.

4. Install the oil pan on the engine block.

5. Tighten the bolts in three steps. In the final step, torque all bolts, in sequence, to 12 Nm (1.2 kgfm, 9 lbfft). Wipe off the excess liquid gasket on the each side of crankshaft pulley and the flywheel/drive plate.

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 oil pan.

2. Clutch Cover

1. Install the clutch case cover and the transmission mounting bolts.

3. Lower Torque Rod Bracket

1. Install the lower torque rod bracket using new bolts.

4. Subframe Support

1. Using the subframe adapter, raise the front subframe up to the body.

5. Front Sub Frame - Move

REAR

FRONT

1. Loosely install the new front subframe mounting bolts (A) on both sides.

6. Front Subframe Assembly

1. Loosely install the new front subframe mounting bolts (A).

2. Insert the subframe alignment pin (B) through the positioning hole (C) on the right front subframe, and into the positioning hole (D) on the body, then loosely tighten the subframe right front mounting bolt.

3. Insert the subframe alignment pin through the positioning slot on the left front subframe, and into the positioning hole on the body, then loosely tighten the subframe left front mounting bolt.

4. Tighten the subframe mounting bolts to the specified torque values starting with the right front subframe mounting bolt. Use the subframe alignment pin when tightening the front side subframe mounting bolts.

5. Check all of the subframe mounting bolts, and retighten if necessary.

NOTE: Tighten the bolts in the sequence shown.

7. Lower Torque Rod - Reconnection

1. Loosely install the new lower torque rod mounting bolts.

8. Engine Support Hanger

1. Remove the engine support hanger.

2. Remove the universal lifting eyelet.

9. Lower Arm Joint - Reconnection, Both Knuckle Side

1. Connect the lower arm to the knuckle on both sides using new flange bolt and new self-locking nuts.

2. After lightly tightening all three fasteners, tighten them to the specified torque in the following order; the nut on the front (B), the nut on the rear (C), then the bolt (D).

10. Front Stabilizer Ball Joint - Reconnection, Both Lower Arm Side

1. Install the stabilizer link (A) on the stabilizer bar (B) with the joint pins set at the center of their range of movement on both sides.

2. Install the new self-locking nut (C) on both sides.

3. Tighten it to the specified torque while holding the respective joint pin (D) with a hex wrench (E) on both sides.

11. Steering Column Lower Slide Shaft - Release

1. Cut the wire (A).

12. Steering Wheel Release

1. Remove the steering wheel holder tool (A).

13. Steering Joint - Reconnection

1. Set the rack in the straight ahead driving position.

2. Slip the lower end of the steering joint (A) onto the pinion shaft (B).

NOTE:
* Pinion shaft with center guide: Install the steering joint by aligning the center guide (C).
* Pinion shaft without center guide: Position the steering column by aligning the gap (D) within the angle.

3. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft.

4. Loosely install the steering joint bolt (C).

5. Be sure that the joint bolt is securely in the groove in the pinion shaft.

6. Pull on the steering joint to make sure that the steering joint is fully seated.

14. Steering Joint Bolt - Tighten

1. Tighten the steering joint bolt (A) to the specified torque.

15. Steering Joint Cover

1. Install the steering joint cover (A) in the sequence shown.

16. Cam Chain Case

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

2. Remove the old liquid gasket from the chain case mating surfaces, the bolts, and the bolt holes.

3. Clean and dry the chain case mating surfaces.

4. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the chain case 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) and (B).
* Apply a 3.0 mm (0.118 in) diameter bead of liquid gasket along the broken line (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 chain case, 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).
* Apply a 3.0 mm (0.118 in) diameter bead of liquid gasket along the broken line (B).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

6. Install the spacer (A), then install a new O-ring (B) on the chain case. Set the edge of the chain case (C) to the edge of the oil pan (D), then install the chain case on the engine block (E). Wipe off the excess liquid gasket on the oil pan and the chain case mating area.

NOTE:
* When installing the chain case, 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 for at least 3 hours after installing the chain case.

17. Side Engine Mount Bracket, Engine Side

1. Install the side engine mount bracket (A), then tighten the side engine mount bracket mounting bolts.

18. Side Engine Mount

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).

19. Transmission Mount - Loosen

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

20. Lower Torque Rod Mounting Bolt - Loosen

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

21. Side Engine Mount - Tighten

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

22. Transmission Mount - Tighten

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

23. Lower Torque Rod Mounting Bolt - Tighten

1. Loosen the lower torque mount mounting bolt.

2. Tighten the lower torque rod mount mounting bolts in the numbered sequence shown.

24. Air Cleaner Assembly

1. Install the air cleaner (A).

2. Install the harness clamp (B).

3. Connect the intake air pipe (C) and the intake air duct (D).

25. Upper Torque Rod

1. Install the upper torque rod using new bolts.

2. Tighten the upper torque rod mounting bolts in the numbered sequence shown.

26. Crankshaft Pulley

1. Clean the crankshaft pulley (A), the crankshaft (B), the bolt (C), and the washer (D). Lubricate with new engine oil as shown.

2. Install the crankshaft pulley, and hold the pulley with the holder handle (A) and the crankshaft pulley holder (B).

3. Torque the bolt to 50 Nm (5.1 kgfm, 37 lbfft) with a torque wrench and a socket, 19mm(C). Do not use an impact wrench. If the pulley bolt or crankshaft are new, torque the bolt to 177 Nm (18.0 kgfm, 131 lbfft), then remove the bolt and torque it to 50 Nm (5.1 kgfm, 37 lbfft).

4. Tighten the pulley bolt an additional 90 °.

27. VTC Oil Control Solenoid Valve

1. Install the VTC oil control solenoid valve (A) with a new O-ring (B).

NOTE:
* Coat a new O-ring with engine oil.
* Clean and dry the mating surface of the valve.

2. Install the ground cable (C).

28. Cam Chain Case Peripheral Assembly

1. Install the harness clamp.

29. Cylinder Head Cover

1. Check the spark plug seals for damage. If any seals are damaged, replace them.

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

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

3. Install the head cover gasket (A) in the groove of the cylinder head cover (B). Make sure the head cover gasket is seated securely.

4. Remove all of the old liquid gasket from the chain case and the No.5 rocker shaft holder.

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

6. Apply liquid gasket, (P/N 08718-0004 or 08718-0009) on the chain case and the No. 5 rocker shaft holder mating areas (A). Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

7. Set the spark plug seals (A) on the spark plug tubes. Place the cylinder head cover (B) on the cylinder head, then slide the cover slightly back and forth to seat the head cover gasket.

8. Inspect the spark plug seals for damage.

9. Inspect the cover washers (C). Replace any washer that is damaged or deteriorated.

10. Tighten the bolts in two steps. In the final step torque bolts, in sequence, to 12 Nm (1.2 kgfm, 9 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.

30. Ignition Coil

1. Install the ignition coils.

31. Ignition Coil Cover

1. Install the ignition coil cover.

32. Engine Cover

1. Install the engine cover.

33. Under Cowl Panel

1. Install the under cowl panel (A).

34. Center Cowl Cover

1. If necessary, install the hood rear seal (A).

2. Connect the windshield washer tube (B).

3. Install the center cowl cover (C).

35. Both Side Cowl Covers

1. Install the side cowl cover (A).

2. The left side is shown; repeat on the right side.

36. Wiper Arm Assembly

NOTE: Set the wiper arms to the auto-stop position before installation.

1. Install the wiper arms (A).

2. Install the cowl top wiper covers (B).

37. Drive Belt

1. Install the drive belt.

38. Splash Shield

1. Install the splash shield (A).

39. 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.

40. Engine Oil - Replacement

1. Refill the engine with the recommended engine oil.

41. 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.

42. VSA Sensor Neutral Position - Memorization

1. Park the vehicle on a flat and level surface, with the steering wheel in the straight ahead position.

2. Select VSA ADJUSTMENT, then select ALL SENSORS with the HDS, and follow the screen prompts.

NOTE: See the HDS Help menu for specific instructions.

43. Steering Angle Sensor Neutral Position - Clear

1. Select EPS ADJUSTMENT, then select EPS STEERING ANGLE SENSOR VALUE CLEAR and follow the screen prompts on the HDS.

NOTE: See the HDS Help menu for specific instructions.

44. 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.

45. Maintenance Minder Reset

1. After doing all procedures, select the individual maintenance item you wish to reset with the HDS (See the Maintenance Minder General Information).