TIMING CHAIN ASSEMBLY

1. Assemble in the order indicated in the table.

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Camshaft (LH) Assembly Note

1. Turn the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position.

2. Install the camshafts (LH).

(1) Position the intake camshaft so that the mark is at 9 o'clock direction.

(2) Position the exhaust camshaft so that the mark is at 12 o'clock direction.

Caution

• Do not install thrust caps 1L and 5L at this time, or damage to the thrust caps may occur.

Note

• Tighten the camshafts caps at specified torque after assembling the timing chain.

• The camshaft bearing caps are numbered to make sure they are assembled in their original positions.

3. Hand tighten the camshaft (LH) caps in their original positions.

Timing Chain (LH) Assembly Note

1. Install the timing chain (LH) by aligning the colored links on the timing chain (LH) with the marks on the timing sprockets.

Note

• If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the timing chain.

1. Mark any link to use as the crankshaft timing mark.

2. Count 29 links from the crankshaft timing mark and mark as the exhaust camshaft sprocket timing mark.

3. Continue counting to 42 mark the link as the intake camshaft sprocket timing mark.

Caution

• Install the camshaft bearing thrust caps after installing the other bearing caps, or damage to the thrust caps may occur.

2. Align the camshaft end play using the camshaft bearing thrust caps 1L and 5L, and tighten the other bearing caps.

3. Tighten the bearing caps in the order indicated in the figure in several passes.

Water pump drive pulley on intake camshaft side

Water pump drive pulley on exhaust camshaft side

Camshaft (RH) Assembly Note

1. Turn the crankshaft clockwise to position the crankshaft keyway in the 3 o'clock position.

2. Install the camshafts (RH).

(1) Position the exhaust camshaft so that the mark is at 12 o'clock direction.

(2) Position the intake camshaft so that the mark is at 3 o'clock direction.

Caution

• Do not install thrust caps 5R and 1R at this time, or damage to the thrust caps may occur.

Note

• Tighten the camshafts caps at specified torque after assembling the timing chain.

• The camshaft bearing caps are numbered to make sure they are assembled in their original positions.

3. Hand tighten the camshaft caps (RH) in their original positions.

Timing Chain (RH) Assembly Note

1. Install the timing chain (RH) by aligning the colored links on the timing chain (RH) with the marks on the timing sprockets.

Note

• If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the timing chain.

1. Mark any link to use as the crankshaft timing mark.

2. Count 29 links from the crankshaft timing mark and mark as the exhaust camshaft sprocket timing mark.

3. Continue counting to 42 mark the link as the intake camshaft sprocket timing mark.

Caution

• Install the camshaft bearing thrust caps after installing the other bearing caps, or damage to the thrust caps may occur.

2. Align the camshaft end play using the camshaft bearing thrust caps 1R and 5R, and tighten the other bearing caps.

3. Tighten the bearing caps in the order indicated in the figure in several passes.

4. Install the chain tensioner and remove the retaining wire.

5. Turn the crankshaft clockwise 1 and 2/3 turns to position the crankshaft keyway in the 11 o'clock position.

6. Verify that marks on the camshaft sprockets are aligned.

Crankshaft Position (CKP) Sensor Pulse Wheel Assembly Note

1. Using the keyway marked 25/34Y (blue paint stripe), install the rotor with the indentation towards the front.

Engine Front Cover Assembly Note

1. Apply a 6 mm {0.24 in} dot of silicon sealant as indicated in the figure (mating faces).

2. Tighten the bolts and studs in the order indicated in the figure.

3. Assemble the front oil seal using part A of the SST [303-335 (49 UN30 3335)] and the SST [303-102 (49 UN01 002)] in the following order.

(1) Apply clean engine oil to the oil seal.

(2) Push the oil seal slightly in by hand.

(3) Compress the oil seal using the SSTs.

Crankshaft Pulley Assembly Note

1. Using the silicone sealant, seal the keyway in the crankshaft pulley.

2. Install the crankshaft pulley using the SST and washer of crankshaft pulley lock bolt washer.

3. Hold the crankshaft using the SST.

4. Tighten the crankshaft pulley lock bolt in four steps.

(1) Tighten to 120 N·m {12.2 kgf·m, 88.5 ft·lbf}.

(2) Loosen 360° (one full turn) in reverse order.

(3) Tighten 47-53 N·m {4.8-5.4 kgf·m, 35-39 ft·lbf}.

(4) Tighten 85°-95°.

Oil Pan Assembly Note

1. Apply silicone sealant to the mating faces as indicated in the figure.

10 mm {0.39 in}

2. Install the oil pan with a new gasket.

3. Install the bolts and studs as indicated in the figure.

4. Align the cylinder block and the rear face of the oil pan using the straight edge.

5. Tighten the bolts and studs in the order indicated in the figure.

6. Measure the height between the cylinder block and the oil pan.

• If the clearance is 0- -0.25 mm {0- -0.009 in}, oil pan assembly is completed.

• If the clearance is -0.26- -0.50 mm {-0.010- -0.019 in}, install the 0.25 mm {0.0098 in} shim (silver) to the oil pan.

• If the clearance is -0.51- -0.75 mm {-0.020- -0.030 in}, install the 0.50 mm {0.0020 in} shim (gold) to the oil pan.

• If the clearance is more than -0.75 mm{-0.030 in}, or the oil pan is higher than the cylinder block, reinstall the oil pan.

Camshaft Oil Seal Housing Assembly Note

1. Apply clean engine oil to the oil seal.

2. Install the camshaft oil seal using the SSTs.

Water Pump Drive Pulley Assembly Note

1. Install the water pump pulley using the SST.

Water Pump Drive Belt Assembly Note

1. Secure the water pump drive pulley and the belt using a tie wrap.

Note

• It is acceptable to use a tie wrap with a releasable lock.

2. Rotate the crankshaft verifying that the belt engages properly.

3. Verify that the belt is installed securely in the pulley groove.

Caution

• If the belt slips while rotating the crankshaft, verify that the belt engages properly by rotating the crankshaft further.

4. Remove the tie wrap.

Caution

• To prevent damage to the belt when removing the tie wrap, cut the tie wrap at the pulley side using a nipper or scissors.

Cylinder Head Cover Assembly Note

1. Apply silicone sealant to the mating faces as indicated in the figure.

2. Install the cylinder head cover with a new gasket.

3. Tighten the bolts in the order indicated in the figure.