Cam Chain Installation
Cam Chain Installation
NOTE: Keep the cam chain away from magnetic field.
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 the crankshaft with the pointer (B) on the engine 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. Install the CKP pulse plate. CKP Pulse Plate Replacement
5. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal. Cam Chain Case Oil Seal Installation
6. Remove all of the old liquid gasket from the chain case mating surfaces, the bolts, and the bolt holes.
7. Clean and dry the chain case mating surfaces.
8. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the engine block mating surface of the chain case and to the inside edge of the threaded 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 the old residue.
9. Apply a light coat of new engine oil to the lip of the chain case oil seal, then install the dowel pins (A) and the chain case (B) using a new O-ring (C).
10. Install the crankshaft position (CKP) sensor.
11. Install the crankshaft pulley. Service and Repair
12. Install the oil pan. Engine Oil Pan Installation
13. Install the idler pulley base (A), then install the idler pulley (B).
14. Install the alternator. Removal and Replacement
15. Install the auto-tensioner. Drive Belt Auto-Tensioner Replacement
16. Install the water pump pulley.
17. Connect the water bypass hose (A), and tighten the three bolts (B) securing the water bypass tube.
18. Install the cylinder head Camshaft Gear Installation using the following process by installing the cam chain sprocket assembly.
-1 Make sure the crankshaft pulley is at TDC.
Place the idler gear/cam chain sprocket assembly and the idler gear collar into the cylinder head.
-3 Install the cam chain on the sprocket with the one punch mark (A) aligned with the center of the two colored pieces (B).
Fit the cam chain sprocket assembly into the cylinder head.
-5 Turn the cam chain sprocket assembly counterclockwise to relieve cam chain free play, and check the alignment of the TDC mark (C) on the cam chain sprocket with the cylinder head surface. If the cam chain sprocket is not positioned at TDC, remove the assembly from the cylinder head and reposition the cam chain to bring the cam chain sprocket to TDC.
19. Install the drive belt. Testing and Inspection
20. Install the vacuum tank.
21. After installation, check that all tubes, hoses, and connectors are installed correctly.
22. After assembly, wait at least 30 minutes before filling the engine with oil.
23. Do the battery terminal reconnection procedure. Procedures
24. Inspect for fuel leaks. Turn the ignition switch to ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation three times, then check for fuel leakage at any point in the fuel line.
25. Refill the engine with the recommended engine oil. Testing and Inspection
26. Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open. Service and Repair
27. '00-05 models: Do the engine control module (ECM) idle learn procedure.
28. '06-09 models: Do the CKP pattern clear/CKP pattern learn procedure. Initial Inspection and Diagnostic Overview
29. Inspect the idle speed:
- '00-05 models
- '06-09 models Testing and Inspection
30. Inspect the ignition timing. Testing and Inspection
