Repair Procedure: Installation

Install the jack to the upper oil pan.
The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.

Fig 1: Identifying Key And Timing Mark
Install the tensioner adapter assembly (A).

Fig 2: Identifying Tensioner Adapter Assembly
Install the crankshaft sprocket (A) (LH camshaft drive).

Fig 3: Identifying Crankshaft Sprocket
Install the LH timing chain guide (A).
Tightening torque:

19.60 ~ 24.50 N.m (2.0 ~ 2.5 kgf.m, 14.17 ~ 18.08 lb-ft)

Fig 4: Identifying LH Timing Chain Guide
Install LH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below.

Crankshaft sprocket → Timing chain guide → Exhaust camshaft sprocket (C) → Intake camshaft sprocket (D).

The timing mark of each sprocket should be matched with timing mark (color link) of timing chain at installing timing chain.

Fig 5: Identifying Camshaft Sprockets

Fig 6: Identifying Timing Mark
Install the LH timing chain tensioner arm (B).
Tightening torque:

18.62 ~ 21.56 N.m (1.9 ~ 2.2 kgf.m, 13.74 ~ 15.91 lb-ft)
Install the LH chain tensioner (A).
Tightening torque:

9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 7: Identifying LH Timing Chain Tensioner Arm And LH Chain Tensioner
Install the LH cam-to-cam guide (A).
Tightening torque:

9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 8: Identifying LH Cam-To-Cam Guide
Install the crankshaft sprocket (A) (Oil pump & RH camshaft drive).

Fig 9: Identifying Crankshaft Sprocket
Install the oil pump chain (B) and oil pump sprocket (A).
Tightening torque:

18.62 ~ 21.56 N.m (1.9 ~ 2.2 kgf.m, 13.74 ~ 15.91 lb-ft)

Fig 10: Identifying Oil Pump Chain And Oil Pump Sprocket
Install the RH timing chain guide (A).
Tightening torque:

19.60 ~ 24.50 N.m (2.0 ~ 2.5 kgf.m, 14.17 ~ 18.08 lb-ft)

Fig 11: Identifying RH Timing Chain Guide
Install the RH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below.

Crankshaft sprocket (A) → Intake camshaft sprocket (B) → Exhaust camshaft sprocket (C).

The timing mark of each sprocket should be matched with timing mark (color link) of timing chain at installing timing chain.

Fig 12: Identifying Crankshaft Sprocket

Fig 13: Identifying Intake Camshaft Sprocket And Exhaust Camshaft Sprocket
Install the RH timing chain tensioner arm (B).
Tightening torque:

18.62 ~ 21.56 N.m (1.9 ~ 2.2 kgf.m, 13.74 ~ 15.91 lb-ft)
Install the RH timing chain auto tensioner (A).
Tightening torque:

9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 14: Identifying RH Timing Chain Tensioner Arm And RH Timing Chain Auto Tensioner
Install the RH cam-to-cam guide (A).
Tightening torque:

9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 15: Identifying RH Cam-To-Cam Guide
Install the oil pump chain guide (A).
Tightening torque:

9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 16: Identifying Oil Pump Chain Guide
Install the oil pump chain tensioner assembly (A).
Tightening torque:

9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 17: Identifying Oil Pump Chain Tensioner Assembly
Pull out the pins of hydraulic tensioners (LH & RH).

Fig 18: Pulling Out Pins Of Hydraulic Tensioners (LH)

Fig 19: Pulling Out Pins Of Hydraulic Tensioners (RH)
Install the oil pump chain cover (A).
Tightening torque:

9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 20: Identifying Oil Pump Chain Cover
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
NOTE: Always turn the crankshaft clockwise.
Install the timing chain cover.
1. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and ETC.
2. Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between cylinder head and cylinder block.
  The part must be assembled within 5 minutes after sealant was applied.
  
  Bead width: 2.5 mm (0.1 in.)
  
  Fig 21: Identifying Cylinder Head And Cylinder Block Sealant
3. After applying liquid sealant TB1217H on the timing chain cover.
  The part must be assembled within 5 minutes after sealant was applied.
  
  Sealant should be applied without discontinuity.
  
  Bead width: 2.5 mm (0.1 in.)
  
  Fig 22: Identifying Liquid Sealant TB1217H On Timing Chain Cover
4. Install the new gasket (A) to the timing chain cover.
  
  Fig 23: Identifying New Gasket
  
  NOTE: During timing cover installation, care not to take off applied sealant on the timing cover by contact with other parts.
5. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position.
  Tightening torque:
  
  B(17): 18.62 ~ 21.56 N.m (1.9 ~ 2.2 kgf.m, 13.74 ~ 15.91 lb-ft)
  
  C(4): 9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  D(1): 58.80 ~ 68.80 N.m (6.0 ~ 7.0 kgf.m, 43.40 ~ 50.63 lb-ft)
  
  E(1): 58.80 ~ 68.80 N.m (6.0 ~ 7.0 kgf.m, 43.40 ~ 50.63 lb-ft)
  
  F(2): 24.50 ~ 26.46 N.m (2.5 ~ 2.7 kgf.m, 18.08 ~ 19.53 lb-ft)
  
  G(4): 21.56 ~ 23.52 N.m (2.2 ~ 2.4 kgf.m, 15.91 ~ 17.36 lb-ft)
  
  H(1): 9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  I(1): 9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  J(1): 9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  K(4): 9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  L(1): 21.56 ~ 26.46 N.m (2.2 ~ 2.7 kgf.m, 15.91 ~ 19.53 lb-ft) - New bolt
  
  Fig 24: Identifying Dowel Pins
6. The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
Install the water pump pulley (A).
Tightening torque:

7.84 ~ 9.80 N.m (0.8 ~ 1.0 kgf.m, 5.78 ~ 7.23 lb-ft)

Fig 25: Identifying Water Pump Pulley
Install the drive belt auto tensioner (A).
Tightening torque:

Bolt (B): 81.39 ~ 85.32 N.m (8.3 ~ 8.7 kgf.m, 60.03 ~ 62.93 lb-ft)

Bolt (C): 17.64 ~ 21.56 N.m (1.8 ~ 2.2 kgf.m, 13.02 ~ 15.91 lb-ft)

Fig 26: Identifying Drive Belt Auto Tensioner
Install the drive belt idler (A).
Tightening torque:

52.92 ~ 57.82 N.m (5.4 ~ 5.9 kgf.m, 39.06 ~ 42.67 lb-ft)

Fig 27: Identifying Drive Belt Idler
Lower the engine assembly by using the jack.
Using SST (09231-3C100), install timing chain cover oil seal.

Fig 28: Installing Timing Chain Cover Oil Seal Using SST (09231-3C100)
Install the crankshaft damper pulley (A).
Tightening torque:

284.2~303.8 N.m (29.0~31.0 kgf.m, 209.76~224.22 lb-ft)

Fig 29: Identifying Crankshaft Damper Pulley
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-3C300) to hold the ring gear after removing the starter.
  
  Fig 30: Holding Ring Gear Using SST (09231-3C300)
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the front muffler. (Refer to Intake And Exhaust system)
2. Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B).
  
  Fig 31: Identifying Dust Cover And Transaxle Mounting Bolts
3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
4. Fasten the two transaxle mounting bolts in the original mounted holes.
  
  Fig 32: Identifying Holder Nuts, Front Plate Holder And Ring Gear Teeth
5. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
Fig 33: Identifying SST (09231-3D100)
Install the drive belt (A).
Crankshaft pulley → A/C pulley → idler pulley → alternator pulley → water pump pulley → P/S pump pulley → tensioner pulley.

Rotate auto tensioner arm in the counterclockwise moving auto tensioner pulley bolt with wrench.

After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.

Fig 34: Identifying Drive Belt
Install the cylinder head cover.
1. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
2. After applying sealant (TB1217H), it should be assembled within 5 minutes.
  Bead width : 2.5 mm (0.1 in.)
  
  Fig 35: Identifying Sealant (TB1217H)
3. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
4. Install the cylinder head cover bolts as following method.
  Tightening torque:
  
  9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  Fig 36: Identifying Cylinder Head Cover Bolts Tightening Sequence
  
  CAUTION: Do not reuse cylinder head cover gasket.
5. Install the ignition coil.
6. Connect the RH ignition coil connector (A), the condenser connector (B) and install the wiring bracket (C).
  
  Fig 37: Identifying RH Ignition Coil Connector, Condenser Connector And Wiring Bracket
7. Install the connector bracket (A) to the LH cylinder head cover.
Fig 38: Identifying Connector Bracket
Install the surge tank and wiring connectors.
1. Install the surge tank (A).
  Tightening torque:
  
  9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  Fig 39: Identifying Surge Tank
2. Install the connector bracket (A) to the surge tank.
  Tightening torque:
  
  6.86 ~ 10.78 N.m (0.7 ~ 1.1 kgf.m, 5.06 ~ 7.96 lb-ft)
  
  Fig 40: Identifying Connector Bracket
3. Install the surge tank stay.
  Tightening torque:
  
  27.44 ~ 31.36 N.m (2.8 ~ 3.2 kgf.m, 20.25 ~ 23.14 lb-ft)
  
  Fig 41: Identifying Surge Tank Stay
4. Connect the brake vacuum hose.
5. Connect the PCV hose (C).
6. Connect the water hoses (B) to the ETC.
7. Install the ETC bracket (A).
  
  Fig 42: Identifying ETC Bracket, Water Hoses And PCV Hose
8. Connect the LH CMPS connector (A) and oil pressure switch connector (B).
  
  Fig 43: Identifying LH CMPS Connector And Oil Pressure Switch Connector
9. Install the wiring harness protector (E) and connect the LH ignition coil connector (A), injector connector (B), condenser connector (C) and ground (D).
  
  Fig 44: Identifying Wiring Harness Protector, LH Ignition Coil Connector, Injector Connector, Condenser Connector And Ground
10. Connect the LH front oxygen sensor connector (A).
  
  Fig 45: Identifying LH Front Oxygen Sensor Connector
11. Connect the OCV connector (A) and knock sensor connector (B).
  
  Fig 46: Identifying OCV Connector And Knock Sensor Connector
12. Connect the ETC connector (A) and knock sensor connector (B).
  
  Fig 47: Identifying ETC Connector And Knock Sensor Connector
13. Connect the PCSV connector (A), MAP sensor connector (B) and PCSV hose.
  
  Fig 48: Identifying PCSV Connector And MAP Sensor Connector
14. Connect the RH injector connector (A) and ignition coil connector (B).
  
  Fig 49: Identifying RH Injector Connector And Ignition Coil Connector
15. Connect the RH oxygen sensor connector (A) and tighten the power steering hose mounting bolts (B).
  
  Fig 50: Identifying RH Oxygen Sensor Connector And Power Steering Hose Mounting Bolts
Install the engine mounting bracket (A).
Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

Fig 51: Identifying Engine Mounting Bracket
Install the coolant reservoir tank.
Remove the jack from the upper oil pan.
Install lower oil pan.
1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. Before assembling the oil pan, the liquid sealant TB1217H should be applied on oil pan.
  Bead width: 2.5 mm (0.1 in.).
  
  But marked area (*) to be 5.0 mm (0.2 in.)
  
  Fig 52: Identifying Oil Pan Liquid Sealant TB1217H
  1. Make clean the sealing face before assembling two parts.
  2. Remove harmful foreign matters on the sealing face before applying sealant.
  3. When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
  4. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
3. Install the lower oil pan (A).
  Tightening torque:
  
  9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  Fig 53: Identifying Lower Oil Pan
Install the side cover.
Tightening torque:

8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~7.9 lb-ft)
Install the under cover (A).
Tightening torque:

8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~7.9 lb-ft)

Fig 54: Identifying Under Cover
Install the RH front wheel.
Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Install the intake air hose and air cleaner assembly.
1. Install the intake air hose and air cleaner assembly (C).
2. Connect the breather hose (B) to the air intake hose.
3. Connect the MAF sensor connector (A).
Fig 55: Identifying Intake Air Hose And Air Cleaner Assembly, Breather Hose And MAF Sensor Connector
Install the engine cover (A).

Fig 56: Identifying Engine Cover
Connect the battery negative cable (A).

Fig 57: Identifying Battery Negative Cable
NOTE:
- Refill engine with engine oil.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.