Cam Chain Installation

Cam Chain Installation

NOTE: Keep the cam chain away from magnetic fields.

1. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the oil pump.





2. Set the No. 1 piston at TDC. The "UP" mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the cylinder head.





3. Install the cam chain on the crankshaft sprocket with the colored piece (A) aligned with the TDC mark (B) on the crankshaft sprocket.





4. Install the cam chain on the camshaft sprocket with the pointer (A) aligned with the center of the two colored pieces (B).





5. Apply new engine oil to the threads of the cam chain tensioner mounting bolt (A).





6. Install the cam chain tensioner (B) and the cam chain guide (C).
7. Install the cam chain tensioner slider, and tighten the lower side bolt loosely.





8. Apply new engine oil to the sliding surface of the cam chain tensioner slider (A).





9. Turn the cam chain tensioner clockwise to compress the cam chain tensioner slider. Install the remaining bolt, then tighten the two bolts.
10. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal.
11. Remove any old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
12. Clean and dry the chain case mating surfaces.
13. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0002, 08718-0003, or 08718-0009, to the cylinder head and engine block mating surface of the chain case.

NOTE:
^ Apply a 1.5 mm wide bead of liquid gasket along the broken lines (A).
^ Apply a 3.0 mm wide bead of liquid gasket to the engine block upper surface contact areas (B) on the chain case.
^ Do not install components if too much time has passed after applying the1iquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.





14. Install the crankshaft position (CKP) pulse plate (A) and the chain case (B).

NOTE:
^ Wait at least 30 minutes before filling the engine with oil.
^ Do not run the engine for at least 3 hours after installing the chain case.





15. Install the harness clamps (A) and the dipstick tube mounting bolt (B), then connect the CKP sensor connector (C).





16. Install the side engine mount bracket (A), then tighten the mounting bolts and nut in the numbered sequence shown.





17. Install the ground cable (B).
18. Remove the jack and the wood block.
19. Install the oil pan.
20. Install the crankshaft pulley.
21. Install the cylinder head cover.
22. Install the water pump pulley.
23. Install the drive belt.
24. Install the splash shield and the engine undercover.
25. Install the front wheels.
26. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.