Install crankshaft sprocket on crankshaft.
Make sure mating marks on crankshaft sprocket face front of engine.
Position crankshaft so that No. 1 piston is at TDC and crankshaft key is at 12 o'clock.
Install slack side timing chain guide and timing chain tension guide.
Install timing chain on crankshaft sprocket.
Set timing chain by aligning its mating mark with that on the crankshaft sprocket.
Make sure sprocket's mating mark faces engine front.
Install camshaft sprockets.
Set timing chain by aligning mating marks with those of camshaft sprockets.
Install camshaft sprocket bolts to correct torque.
Apply new engine oil to bolt threads and seat surface.
Install chain tensioner.
Before installing chain tensioner, insert a suitable pin into pin hole of chain tensioner.
After installing chain tensioner, remove the pin.
Install timing chain guide.
Install O-rings to cylinder block.
Before installing front cover, remove all traces of RTV silicone sealant from mating surface using a scraper.
Also remove traces of RTV silicone sealant from mating surface of cylinder block.
Apply a continuous bead of Genuine RTV Silicone Sealant or equivalent to mating surface of front cover. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.
Check alignment of mating marks on chain and crankshaft sprocket.
Align oil drive spacer with oil pump.
Place timing chain to the side of chain guide. This prevents the chain from making contact with water seal area of front cover.
Install front cover.
Make sure two O-rings are present.
Be careful not to damage oil seal when installing front cover.
Install cylinder head bolts at engine front side as shown in Fig. 55.
Tighten bolts (1 - 4): 6.3-8.3 N.M (0.64-0.85 kg.M, 55.8-73.5 in. Lb).
Install oil pump drive spacer.
Install water pump and water pump pulley. Refer to REMOVAL AND INSTALLATION.
Install idler pulley and bracket.
Install RH engine mounting bracket.
Install RH engine mounting.
Install oil pan. Refer to INSTALLATION.
Install crankshaft pulley.
Remove ring gear stopper.
Install starter motor.
Install cylinder head front cover.
Apply RTV silicone sealant to cylinder head front cover.
Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.
Install Camshaft Position sensor (PHASE).
Before installing rocker cover, apply a bead of Genuine RTV Silicone Sealant or equivalent, to mating surface of cylinder head as shown in.
Install rocker cover gasket into rocker cover.
Install rocker cover and tighten in numerical order as shown in
Install spark plugs.
Install ignition coils.
Install front exhaust tube.
Install front/right-side splash undercover.
Install front RH wheel.
Install drive belts.
Adjusting drive belt deflection.
Tuesday, October 13th, 2009 AT 9:09 PM