Part 2

Replacement Continued





38. 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.
39. INSTALL CHAIN VIBRATION DAMPER NO.2
a. Install the 2 chain vibration dampers No.2.
40. 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 the 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.
41. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
SST 09226-10010
42. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
43. INSTALL WT SENSOR
44. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
47. INSTALL IGNITION COIL ASSEMBLY
48. INSTALL INTAKE AIR SURGE TANK
49. 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 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 above.





e. Install the 4 housing bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
f. Install the flywheel housing under cover.





50. 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.)
51. 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 nuts within 15 minutes of installing the oil pan No.2. Otherwise, the seal packing must be removed and reapplied.





c. Install the oil pan No.2 with the 10 bolts and 2 nuts. Tighten 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 inch lbs.) for nut





52. 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.)





53. 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.





54. 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.)





55. 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.)
56. INSTALL COOLER COMPRESSOR ASSEMBLY
57. INSTALL GENERATOR ASSEMBLY





58. INSTALL PUMP ASSEMBLY, VANE
a. Install the vane pump with the 2 bolts.
b. Connect the power steering pressure switch connector.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

NOTICE: Do not hit the pulley with other parts when installing the vane pump.

c. Connect the power steering pressure switch connector.
59. INSTALL WATER INLET





60. 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.
61. INSTALL AIR CLEANER ASSEMBLY
62. INSTALL FAN SHROUD
63. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH
64. INSTALL DIFFERENTIAL CARRIER ASSEMBLY FRONT (4WD DRIVE TYPE)
65. INSTALL POWER STEERING LINK ASSEMBLY
66. INSTALL BATTERY
67. ADD ENGINE OIL
68. ADD ENGINE COOLANT
69. ADD DIFFERENTIAL OIL (4WD DRIVE TYPE)
70. INSPECT DIFFERENTIAL OIL (4WD DRIVE TYPE)
71. ADD POWER STEERING FLUID
72. BLEED POWER STEERING FLUID
73. CHECK FOR ENGINE OIL LEAKAGE
74. CHECK FOR ENGINE COOLANT LEAKAGE
75. CHECK POWER STEERING FLUID LEAKAGE
76. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
77. INSTALL V-BANK COVER
78. INSPECT IGNITION TIMING
SST 09843-18040