Installation

CAUTION: After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.
When installing rocker arms, camshafts, chain tensioner, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.
Apply new engine oil to bolt threads and seat surfaces when installing, camshaft sprockets, crankshaft pulley, and camshaft brackets.

TIMING CHAIN:

Installation
1. Install crankshaft sprocket on crankshaft.
Make sure that mating marks on crankshaft sprocket face front of engine.

Fig. 9 Timing Chain Alignment:

2. Position crankshaft so that No. 1 piston is set at TDC and key way is at 12 o'clock. Fit timing chain on crankshaft sprocket, aligning the mating marks.






3. Install timing chain and timing chain guides.

Mating Mark Colors On Timing Chain:

4. Install camshaft sprockets and timing chain on them. Line up mating marks on timing chain with mating marks on camshaft sprockets.






Lock camshafts as shown in figure and tighten to specified torque.

Camshaft Torque:............137 - 157 Nm (14.0 - 16.0 kg-m, 101 - 116 ft. lbs.)

Apply new engine oil to threads and seating surfaces of camshaft sprocket bolts before installing them.

Fig. 19 Chain Tensioner Installation:

5. Install chain tensioner.
Make sure the camshaft sprockets are tightened completely. Press cam stopper down and "press-in" sleeve until hook can be engaged on pin. When tensioner is bolted in position the hook will release automatically. Make sure arrow "A" points toward engine front.





6. Use a scraper to remove old liquid gasket from mating surface of front cover.
Also remove old liquid gasket from mating surface of cylinder block.

Timing Chain Cover:

7. Apply a continuous bead of liquid gasket to front cover.
Also apply liquid gasket to matching surface to cylinder head gasket.
Use Genuine RTV silicone sealant part No. 999MP-A7007 or equivalent.
Be sure to install new front oil seal in the right direction.

8. Install oil pump drive spacer.






9. Install front cover.






Wipe off excessive liquid gasket.






10. Install cylinder head outside bolts.






11. Install RH engine mounting and bracket.
12. Install generator bracket and generator.
13. Install A/C compressor bracket and compressor.






14. Install crankshaft pulley.
15. Set No. 1 piston at TDC of its compression stroke.






16. Install oil strainer.
17. Install oil pans.
18. Remove old liquid gasket from mating surfaces of rocker cover and cylinder head.

Rocker Cover:

19. Apply a continuous bead of liquid gasket to rocker cover gasket and cylinder head as shown in the illustrations.
Use Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent.






20. Install rocker cover and oil separator.
Be sure to install washers between bolts and rocker cover.


Tightening Procedure
STEP 1:.......Tighten bolts 1 - 10 - 11 - 13 - 8 in that order.
STEP 2:.......Tighten bolts 1 - 13 in that order.
TORQUE.......8 - 10 Nm (0.8 - 1.0 kg-m, 69 - 87 inch lbs.)

21. Install the following parts:
- Spark plugs and leads
- Water pump pulley and drive belts.
- Front RH wheel
- Engine under cover

22. Connect the following:
- Vacuum hoses
- Wire harnesses and connectors