Part 2

Replacement Continued





31. INSTALL CHAIN SUB-ASSEMBLY
a. Set the No.1 cylinder to TDC/ compression.
(1) Align the timing marks of the camshaft timing gears and bearing caps.





(2) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.





b. Align the yellow mark link with the timing mark of the crankshaft timing link.





c. Align the orange mark links with the timing marks of the camshaft timing gears, and install the chain.
32. INSTALL CHAIN VIBRATION DAMPER NO.2
a. Install the 2 chain vibration dampers No.2.
33. INSTALL IDLE SPROCKET ASSEMBLY
a. Apply a light coat of engine oil to rotating surface of the idle gear shaft No.1.





b. Temporarily install the idle gear shaft No.1 together with idle gear shaft No.2 while aligning the knock pin of the idle gear shaft No.1 with the knock pin groove of the cylinder block.

NOTICE: Be careful of the idle gear direction.

c. Using 10 mm hexagon wrench, tighten the idle gear shaft No.2.
Torque: 60 Nm (612 kgf-cm, 44 ft. lbs.)
d. Remove the bar from the chain tensioner.
34. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
SST 09226-10010
35. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
36. INSTALL WT SENSOR
37. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
38. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
39. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
40. INSTALL IGNITION COIL ASSEMBLY
41. INSTALL INTAKE AIR SURGE TANK
42. INSTALL OIL PAN SUB-ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.





b. Install a new O-ring onto the oil pump.





c. Apply a continuous bead of the seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) to the oil pan as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE: Install the oil pan within 3 minutes of applying the seal packing. Tighten the oil pan bolts and nuts within 15 minutes of installing the oil pan. Otherwise, the seal packing must be removed and reapplied.





d. Install the oil pan with the 17 bolts and 2 nuts, and tighten the bolts and nuts uniformly in several steps.
Torque:
10 Nm (102 kgf-cm, 7.4 ft. lbs.) for 10 mm (0.39 inch) head
21 Nm (214 kgf-cm, 16 ft. lbs.) for 12 mm (0.47 inch) head





HINT: Each bolt length is as follows:





43. INSTALL OIL STRAINER SUB-ASSEMBLY
a. Install a new gasket and the oil strainer with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
44. INSTALL OIL PAN SUB-ASSEMBLY NO.2
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No.2.





b. Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE: Install the oil pan No.2 within 3 minutes of applying the seal packing. Tighten the oil pan No.2 bolts and nut within 15 minutes of installing the oil pan. Otherwise, the seal packing must be removed and reapplied.





c. Install the oil pan No.2 with the 15 bolts and 2 nuts. Tight en the bolts and nuts uniformly in several steps.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolts
10 Nm (102 kgf-cm, 7.4 ft. lbs.) for nuts





45. INSTALL CRANKSHAFT PULLEY
a. Using SST, install the pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 250 Nm (2,549 kgf-cm, 184 ft. lbs.)





46. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1
a. Install the idler pulley with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

HINT: DOUBLE is marked on the idler pulley No.1 to distinguish it from the idler pulley No.2.





47. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
a. Install the 2 idler pulleys with the 2 bolts.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)





48. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

NOTICE: A bolt in position A is not reusable.





HINT: Each bolt length is as above.

a. Use a new bolt in position A.
b. Finger-tighten the bolts in positions A and E and install the bracket.
c. Tighten the bolts in positions A and E.
Torque: 36 Nm (267 kgf-cm, 27 ft. lbs.)
d. Tighten the bolts in positions B. C and D.
Torque: 36 Nm (267 kgf-cm, 27 ft. lbs.)
49. INSTALL WATER INLET





50. INSTALL OIL LEVEL GAUGE GUIDE
a. Install a new O-ring onto the oil level gauge guide.
b. Apply a light coat of engine oil to the O-ring.
c. Push the oil level gauge guide end into the guide hole of the oil pan.
d. Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
e. Install the oil level gauge guide.
51. INSTALL ENGINE ASSEMBLY
52. INSTALL BATTERY
53. ADD ENGINE COOLANT
54. ADD ENGINE OIL
55. CHECK FOR ENGINE COOLANT LEAKAGE
56. CHECK FOR ENGINE OIL LEAKAGE
57. CHECK FOR FUEL LEAKAGE
58. CHECK FOR EXHAUST GAS LEAKAGE
59. INSPECT IGNITION TIMING
SST 09843-18040
60. INSPECT ENGINE IDLING SPEED
SST 09843-18030
61. INSPECT CO/HC