Installation

CAUTION: Check that No. 1 cylinder is at Top Dead Center (TDC) and that the weights of the No. 1 and No. 2 balance shafts are at the bottom side.

1. Install No. 4 vibration damper.
Install the No. 4 damper with the 2 bolts.
2. Install No. 2 timing chain, No. 2 crankshaft timing sprocket, balance shaft drive gear and shaft.





(a) Install the No. 2 timing chain by matching its mark links with the timing marks on the No. 2 crankshaft timing sprocket and balance shaft timing sprocket.
(b) Fit the other mark link of No. 2 timing chain onto the sprocket behind the large timing mark of the balance shaft drive gear.
(c) Insert the balance shaft drive gear shaft through the balance shaft drive gear so that it fits into the thrust plate hole.
Then align the small timing mark of the balance shaft drive gear with the timing mark of the balance shaft timing gear.
(d) Install the bolt to the balance shaft drive gear and tighten it.
Torque: 25 Nm (18 ft. lbs.)





(e) Check that each timing mark is matched with the corresponding mark link.
3. Install No. 2, No. 3 vibration dampers and No. 2 chain tensioner.

CAUTION: Assemble the chain tensioner with the pin installed, then remove the pin after assembly. When doing this, avoid pushing the No. 2 vibration damper against the chain.





(a) Install the No. 2 chain tensioner with the nut.
Torque: 18 Nm (13 ft. lbs.)
(b) Install No. 3 damper with the 2 bolts.
Torque: 18 Nm (13 ft. lbs.)
(c) Install No. 2 damper with the bolt.
Torque: 27 Nm (20 ft. lbs.)





(d) Remove a pin from the No. 2 chain tensioner and free the plunger.





4. Install No. 1 timing chain tensioner slipper and No. 1 vibration damper.
(a) Install the No. 1 damper with the bolt and nut.
Torque: 29 Nm (22 ft. lbs.)
(b) Install the slipper with the bolt.
Torque: 27 Nm (20 ft. lbs.)
(c) Check that the slipper moves smoothly.





5. Install crankshaft timing gear.





NOTE: If necessary, install the gear with Special Service Tool (SST) Upper Ball Joint Dust Cover Replacer # 09636 - 20010 or equivalent.

6. Install No. 1 timing chain and camshaft timing gear.





(a) Align the timing mark between the mark link of the No. 1 timing chain, and install the No. 1 timing chain to the timing gear.
(b) Align the timing mark of the crankshaft timing gear with the mark link of the No. 1 timing chain and install the No. 1 timing chain.





(c) Tie the No. 1 timing chain with a cord as shown in the illustration, and make sure it doesn't come loose.
7. Install timing chain cover.
(a) Install 3 new gaskets to the cylinder block and water bypass pipe.





(b) Install the timing chain cover with the 9 bolts and 2 nuts.
Torque:
Bolt:
12 mm head A: 20 Nm (14 ft. lbs.)
12 mm head B: 24.5 Nm (18 ft. lbs.)
14 mm head: 44 Nm (32 ft. lbs.)
Nut: 20 Nm (14 ft. lbs.)





(c) Install the 2 timing chain cover bolts.
Torque: 18 Nm (13 ft. lbs.)
(d) Install the 2 water bypass pipe nuts.
Torque: 20 Nm (14 ft. lbs.)
(e) Remove the cord from the chain.
8. Install crankshaft pulley.
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.





(b) Using SST Crankshaft Pulley Holding Tool # 09213 - 54015, Companion Flange Holding Tool # 09330 - 00021 or equivalents, install and torque the pulley bolt.
Torque: 260 Nm (193 ft. lbs.)
(c) w/ A/C: Install the No. 3 and No. 2 crankshaft pulleys with the 4 bolts.
Torque: 25 Nm (18 ft. lbs.)
9. Install oil strainer.
Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 18 Nm (13 ft. lbs.)
10. Install oil pan.
(a) Remove any old packing Formed In Place Gasket (FIPG) material and be careful not to drop any oil on the contact surface of the oil pan.
- Using a razor blade and gasket scraper, remove all the old packing FIPG material from the gasket surfaces and sealing grooves.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.

CAUTION: Do not use a solvent which will affect the painted surfaces.





(b) Apply seal packing to the oil pan as shown in the illustration.
Seal packing: Part No. 08826 - 00080 or equivalent.
- Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening or 3 - 4 mm (0.012 - 0.016 inch) opening.

NOTE: Avoid applying an excessive amount to the surface.

- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.
(c) Install the oil pan with the 16 bolts and 2 nuts.
Torque: 12.5 Nm (9 ft. lbs.)
11. Install flywheel housing under cover and dust seal.
12. Install crankshaft position sensor.
Install a new O-ring.
Torque: 8.5 Nm (74 inch lbs.)
13. Install generator, adjusting bar and bracket.





(a) Install the bracket with the 3 bolts.
Torque:
Bolt A: 74.5 Nm (55 ft. lbs.)
Bolt B: 18 Nm (13 ft. lbs.)
(b) Install the adjusting bar with the bolt.
Torque: 63.5 Nm (47 ft. lbs.)
(c) Install the generator with the pivot bolt and lock bolt.
14. w/ A/C: Install A/C compressor and bracket.
(a) Install the A/C compressor bracket with the 4 bolts.
Torque: 44 Nm (32 ft. lbs.)
(b) Install the A/C compressor with the 4 bolts.
Torque: 25 Nm (18 ft. lbs.)
15. Install cylinder head assembly.
16. Install water pump pulley, fan with fluid coupling and drive belt for generator.
17. Install front differential and drive shafts assembly.
18. Fill with engine oil.
19. Start engine and check for leaks.
20. Install engine under cover.
21. Vehicle road test.
Check for abnormal noise, shock slippage, correct shift points and smooth operation.
22. Recheck engine coolant and engine oil level.