Installation

NOTE:
^ When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.
^ Apply new engine oil to bolt threads and seat surfaces when installing cylinder head, camshaft sprockets, crankshaft pulley, and camshaft brackets.





1. Install crankshaft sprocket on crankshaft. Make sure that mating marks on crankshaft sprocket face front of engine.





2. Position crankshaft so that No. 1 piston is set at TDC on compression stroke.





3. Install lower chain guide on dowel pin, with front mark on the guide facing upside.





4. Align the marks on RH and LH intake camshaft sprockets 2ND, exhaust camshaft sprockets 2ND and camshaft chain, as shown.
5. Put LH camshaft dowel pin into camshaft sprocket dowel groove and install these on camshaft. Tighten LH exhaust camshaft sprocket 2ND bolt.
6. Put RH camshaft dowel pin in camshaft sprocket dowel groove and install sprocket on camshaft.
7. Tighten RH exhaust camshaft sprocket 2ND bolt.
^ Make sure that the timing marks on RH and LH intake camshaft sprockets 2ND are aligned with the camshaft chain mark.
^ Lubricate threads and seat surfaces of camshaft sprocket bolts with new engine oil.





^ Be careful not to confuse intake and exhaust camshaft sprockets 2ND (their thicknesses are different).





8. Remove RH and LH camshaft chain tensioner stopper pins.





9. Align mating mark on crankshaft sprocket with matchmark on chain as shown.
10. Attach lower timing chain on the water pump sprocket.
11. Install RH and LH camshaft sprockets 1ST onto camshafts by matching sprocket dowel grooves with camshaft.
12. Tighten RH and LH camshaft sprocket 1ST bolts.

NOTE: Lubricate threads and seat surfaces of the bolts with new engine oil.

13. Install timing chain. Make sure that mating marks on crankshaft sprocket and RH and LH camshaft sprockets are aligned with matchmarks on timing chain.





14. Install internal chain guide.
15. Install upper chain guide.
16. Install timing chain tensioner and slack side chain guide.




17. Wipe off the protruding sealant and apply liquid gasket to front timing chain case.
18. Install rear case pin into dowel pin hole on front timing chain case.





19. Tighten bolts to the specified torque in order shown in the figure. Leave the bolts unattended for 30 minutes or more after tightening.
20. Apply a continuous bead of liquid gasket to mating surface of water pump cover.
21. Install water pump cover.




22. Use genuine liquid gasket or equivalent and apply to the RH and LH rocker covers.
23. Install RH and LH rocker covers and tighten as follows:








^ Tighten in numerical order as shown in the figure.
^ Tighten bolts (1) to (10) in that order to 1 to 3 Nm (9 to 26 inch lbs.).
^ Tighten bolts (1) to (10) as indicated in figure to 5.4 to 7.4 Nm (47.7 to 65.1 inch lbs.).





24. Install intake manifold and tighten intake manifold nuts and bolts to specifications.
25. Install fuel tube assembly.





26. Install intake manifold collector gasket, with its front mark facing forwards.
27. Install intake manifold collector, supports and intake manifold collector bolt.





28. Install EGR guide tube as follows:
^ Tighten all bolts to 9 - 10 Nm (6.5 - 8.0 ft. lbs.).
^ Tighten all bolts to 21 - 26 Nm (15 - 20 ft. lbs.).
29. Install RH and LH ignition coils.
30. Install rocker cover ornament on left side.





31. Install crankshaft pulley to crankshaft.

NOTE: Lubricate thread and seat surface of the bolt with new engine oil.

a. Tighten to 39 to 49 Nm (29 to 36 ft. lbs.).





b. Put a paint mark on the crankshaft pulley.
c. Again tighten by turning 60 to 66°, about the angle from one hexagon bolt head corner to another.





32. Install Camshaft Position Sensor (PHASE), Crankshaft Position Sensors (REF)/(POS) and the front heated oxygen sensor (left bank) harness clamp. Make sure that POS sensor and the front heated oxygen sensor (left bank) harness clamp are installed correctly as shown in figure.
33. Reinstall removed parts in reverse order of removal.

NOTE:
^ When installing fuel tube assembly, refer to Powertrain Management.
^ After installing the tensioner, race the engine at about 3,000 RPM under no load to purge air from the high-pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.