Cam Chain Installation

Cam Chain Installation

Special Tools Required
- Holder handle 07JAB-001020A
- Holder attachment, 50 mm 07JAB-001040A
- Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket





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 cylinder 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 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, part No. 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the bolt holes.

NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.





7. Install the dowel pins (A) and chain case (B) using a new O-ring (C).
8. Remove 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, part No. 08718-0009, evenly to the cylinder block mating surface of the oil pan and to the inner threads of the bolt holes. Install the oil pan.

NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing 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 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.
14. Measure the diameter of each cylinder head bolt at point A and point B (see step 1). If either diameter is less than 11.5 mm (0.45 inch), replace the cylinder head bolt.
15. Clean the cylinder head and block surfaces.
16. Apply liquid gasket, part No.08718-0009, to the shaded areas of the cylinder head gasket mating surface of the block and chain case (see step 3).
17. Install the dowel pins and new cylinder head gasket (see step 4).
18. Apply liquid gasket, part No. 08718-0009, to the cylinder head mating surface of the block and chain case within 5 mm from the edge of the cylinder head gasket (see step 5).
19. Install the cylinder head on the 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 (see step 8).
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° (see step 9).
23. Tighten the 8 mm bolts to 22 Nm (2.2 kgf-m, 16 ft. lbs.).
24. Make sure the crankshaft pulley is at TDC (see step 11).
25. Place the idler gear/idler gear collar assembly into the cylinder head (see step 12).





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 idler gear collar into the cylinder head.
28. Turn the idler gear 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 idler gear 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 (see step 16).
31. Clamp the cam chain auto-tensioner in a soft-jawed vise (see step 17).
32. Turn the 5 x 0.8 mm bolt clockwise to compress the bottom of the auto-tensioner, then insert the set pin (see step 18).
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 (see step 19).
34. Install the cam chain auto-tensioner in the cylinder head with new O-rings (see step 20).
35. Remove the maintenance bolt from the cylinder head (see step 21).
36. Remove the set pin from the cam chain auto-tensioner. Reinstall the maintenance bolt with new washer (see step 22).
37. Install the rocker arm assembly.
38. Check the alignment of the TDC marks on the cam chain sprocket with the cylinder head surface (see step 23).
39. Align the TDC marks on the intake camshaft gear and the exhaust camshaft gear, and install the camshafts (see step 25).
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.) (see step 27).
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 (see step 31).
46. Install the exhaust manifold bracket. Make sure the smooth sides of the washers face the exhaust manifold bracket (see step 32).
47. Put the exhaust manifold cover on the exhaust manifold.
48. Install the heat shield (see step 34).
49. Tighten the four bolts securing the exhaust manifold cover (see step 35).
50. Install the water bypass hose, and tighten the two bolts securing the intake manifold bracket (see step 37).
51. Install the water outlet cover (see step 38).
52. Install the air hose, and tighten the bolt securing the intake manifold bracket (see step 39).
53. Install the Evaporative Emission (EVAP) control canister hose (see step 40).
54. Install the fuel feed hose, fuel return hose and brake booster hose (see step 41).





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 alternator-compressor 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 (see step 43).
63. Install the throttle cable, then adjust the cable.
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. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
67. Inspect for fuel leaks. Turn ON (II) the ignition switch (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. Inspect the idle speed.
69. Inspect the ignition timing.
70. Enter the anti-theft code for the radio, then enter the customer's radio station presets.