Installation

1. Install crankshaft timing gear.
(a) Turn the crankshaft until the shaft key is on the top.
(b) Slide the gear over the key on the crankshaft.

NOTE: If the gear is difficult to install by hand, install it using Special Service Tool (SST) Front Hub Inner Bearing Cone Replacer # 09608-06041 or equivalent.

2. Install No. 2 timing chain and idle gear.
(a) Place the No. 2 timing chain on the idle gear.
(b) Place the No. 2 timing chain on the crankshaft gear.

(d) Loosen the bolt (A) so that the chain guide presses against the chain.

(e) Check that the spring is operating normally against the chain guide by pressing on the chain with your finger and then releasing your finger.

(f) With the chain guide pressing against the chain, torque the bolts to hold the chain guide in place.
Torque: 20 Nm (200 kg.cm, 14 ft. lbs.)
3. Install oil jet.
Install a new gasket and the oil jet with the bolt.
Torque: 18 Nm (185 kg.cm, 13 ft. lbs.)
4. Install chain damper and slipper.
(a) Install the chain damper with the 2 bolts.
Torque: 18 Nm (185 kg.cm, 13 ft. lbs.)
(b) Install the chain slipper with the bolt.
Torque: 27 Nm (270 kg.cm, 20 ft. lbs.)
5. Place No. 1 timing chain and camshaft timing gear.
(a) Place the timing chain on the camshaft timing gear so that the timing mark is between 2 bright chain links.

(b) Place the timing chain on the crankshaft timing gear with the single bright link indicated in the illustration aligned with the timing mark on the crankshaft timing gear.
(c) Make sure the chain is positioned between the damper and slipper.
(d) Turn the camshaft timing gear counterclockwise to take the slack out of the chain.

(e) Tie the timing chain with a cord as shown in the illustration and make sure it doesn't come loose.
6. Install timing chain case.
(a) Clean the gasket surface.
(b) Install 2 gaskets over the dowels.
(c) Slide on the chain case over the dowels.

(d) Install the bolts and nuts as shown and torque them.
Torque:
A 20 Nm (200 kg.cm, 14 ft. lbs.)
B 28 Nm (290 kg.cm, 21 ft. lbs.)
C 44 Nm (440 kg.cm, 32 ft. lbs.)

(e) Install and torque the 3 bolts.
Torque: 18 Nm (185 kg.cm, 13 ft. lbs.)
7. Install oil filter bracket with oil filter.

(a) Place a new O-ring into the groove of the timing chain case.
(b) Install the oil filter bracket with the 3 bolts.
Torque: 20 Nm (200 kg.cm, 14 ft. lbs.)
8. Install baffle plate and No. 2 oil dipstick guide.
(a) Install the baffle plate with the 3 nuts.
Torque: 5 Nm (50 kg.cm, 43 inch lbs.)
(b) Install the No. 2 oil dipstick guide with the 2 bolts.
Torque: 18 Nm (185 kg.cm, 13 ft. lbs.)
9. Install crankcase.
(a) Remove any old packing material and be careful not to drop any oil on the contacting surfaces of the crankcase and cylinder block.
- Using a razor blade and gasket scraper, remove all the packing Formed In Place Gasket (FIPG) material from the gasket surfaces.
- Thoroughly clean all components to remove all the loose material.
- Clean both sealing surfaces with a non-residue solvent.

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

(b) Apply seal packing to the joint part of the cylinder block and timing chain case, cylinder block and rear oil seal retainer.
Seal packing: Part No.08826-00080 or equivalent.

(c) Apply seal packing to the crankcase as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent.
- Install a nozzle that has been cut to a 3-4 mm (0.12-0.16 inch) opening.

NOTE: Avoid applying an excess amount to the surface. Be especially careful near oil passages.

- Parts must be assembled within 5 minutes of application. Otherwise, the material must be removed and re-applied.
- Immediately remove the nozzle from tube and reinstall the cap.
(d) Install the crankcase over the studs on the block with the 16 bolts and 2 nuts. Torque the bolts and nuts.
Torque: 12.5 Nm (130 kg.cm, 9 ft. lbs.)
10. Install crankshaft position sensor.
Torque: 8.5 Nm (85 kg.cm, 74 inch lbs.)
11. Install ventilation case.

(a) Install a new gasket on the ventilation case.

(b) Install the ventilation case to the crankcase with the 3 bolts.
Torque: 7.5 Nm (80 kg.cm, 69 inch lbs.)

CAUTION: Tighten the bolt (A) last out of the 3 bolts.

12. Install No. 1 oil dipstick guide.
Install a new gasket and No. 1 oil dipstick guide.
Torque: 29 Nm (300 kg.cm, 22 ft. lbs.)
13. Install No. 2 engine hanger.

Install the No. 2 engine hanger with the 4 bolts.
Torque:
Ventilation side: 7.5 Nm (80 kg.cm, 69 inch lbs.)
Cylinder block side: 37 Nm (380 kg.cm, 27 ft. lbs.)
14. Install engine oil dipstick.
15. Install oil pressure switch.
(a) Clean the threads of adhesive and foreign material.

(b) Apply adhesive to 2 or 3 threads of the switch end.
Adhesive: Part No.08833-00080, adhesive 1344, THREE BOND 1344, LOCTITE 242 or equivalent.
(c) Install the oil pressure switch.
Torque: 15 Nm (150 kg.cm, 11 ft. lbs.)
16. Install LH engine mounting.
(a) Install the LH engine mounting with the 3 bolts.
Torque: 41 Nm (420 kg.cm, 30 ft. lbs.)
(b) Install the LH mounting stay with the 2 bolts.
Torque: 37 Nm (380 kg.cm, 27 ft. lbs.)
17. Install crankshaft pulley.

(a) Install crankshaft pulley to the crankshaft with the spline teeth of the crankshaft pulley engaged with the large teeth of the oil pump.
(b) Rotate the crankshaft pulley to left and right and check that the key groove of the crankshaft pulley correctly fits the crankshaft key.
(c) Install the crankshaft pulley bolt.

(d) Using SST Crankshaft Pulley Holding Tool # 09213-58012 and Companion Flange Holding Tool # 09330-00021 or equivalents, torque the bolt.
Torque: 260 Nm (2,650 kg.cm, 192 ft. lbs.)
18. Remove cord from timing chain.