Timing Chain: Installation

1. Align the camshaft knock pin with the knock pin groove on the sprocket side with the timing mark, and slide on the camshaft timing sprocket and VVT timing sprocket.
   Fig 1: Identifying Camshaft & VVT Timing Sprocket Timing Marks

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2. Temporarily install the timing sprocket bolt.
3. Hold the hexagon wrench head portion of the camshaft with a wrench, and tighten the timing sprocket bolt.Torque: 54 N.m (550 kgf.cm, 40 ft.lbf)  .
   Fig 2: Locating Hexagon Wrench Head Portion Of Camshaft & Timing Sprocket Bolts

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1. Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing sprockets.
   Fig 3: Aligning Camshaft Point Marks

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2. Using a crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
   Fig 4: Identifying Crankshaft Set Key

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Torque: 9 N.m (92 kgf.cm, 80 in..lbf) 

Fig 5: Locating Chain Vibration Damper Mounting Bolts

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NOTE:

If necessary, install the sprocket with SST# 09223-22010.

Fig 6: Aligning Crankshaft Timing Sprocket & Chain Alignment Marks
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Fig 7: Identifying SST# 09223-22010
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1. Install the timing chain on the crankshaft timing sprocket with the #1 mark link aligned with the timing mark on the crankshaft timing sprocket.
2. Install the timing chain on the camshaft timing sprocket and VVT timing sprocket with the #53 and #67 mark links aligned with the timing marks on the camshaft timing sprocket and VVT timing sprocket.
   Fig 8: Aligning Camshaft Timing Sprocket & VVT Timing Sprocket Timing Marks

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3. Check that the tension between the VVT timing sprocket and crankshaft timing sprocket.

Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf). 

Check that the slipper is held on the cylinder head stopper.

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
   • Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-residue solvent, clean both sealing surfaces.
NOTE:
• Avoid applying an excessive amount to the surface.
• Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening.
• Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
• Immediately remove nozzle from the tube and reinstall cap.
Fig 11: Identifying Legend Locations For Seal Packing Application Positions
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Fig 12: Seal packing Legend & Position Specifications
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2. Apply seal packing to the timing chain cover as shown in the illustration.Seal packing: Part No. 08826-00100 or equivalent  .
NOTE:
• Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening.
• Avoid applying an excessive amount to the surface.
• Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
• Immediately remove nozzle from the tube and reinstall cap.
Fig 13: Identifying Seal Packing Application Positions
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3. Apply seal packing to 2 locations as shown in the illustration.Seal packing: Part No. 08826-00080 or equivalent  .
NOTE:
• Pay attention not to wrap the chain and slipper over the chain cover seal line.
• After installing the chain cover, must install the mounting bracket and water pump within 15 minutes.
4. Install the timing chain cover, O-ring and water pump with the 17 bolts and nut in locations called out in Fig 14. Uniformly tighten the bolts and nut in several passes.

   Torque:

   1. 9 N.m (92 kgf.cm, 80 in..lbf) for 10 mm head (C)  .
   2. 13 N.m (133 kgf.cm, 10 in..lbf) for 10 mm head (A)  .
   3. 11 N.m (113 kgf.cm, 8 ft.lbf) for 10 mm head (others)  .
   4. 18.5 N.m (189 kgf.cm, 14 ft.lbf) for 12 mm head  .

   Each bolt length in indicated in the illustration.

   1. Bolt "A" 45 mm (1.77 in.).
   2. Bolt "B" 35 mm (1.38 in.).
   3. Bolt "C" 30 mm (1.18 in.).
   4. Bolt "D" 25 mm (0.98 in.).
      Fig 14: Identifying Bolt Locations

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5. Using a torx wench socket (E8), install the stud bolt. Torque: 9.3 N.m (95 kgf.cm, 82 in..lbf)  .

NOTE: Do not apply seal packing to 2 or 3 threads of the bolt end.
Fig 15: Locating Crankshaft Position Sensor, Drive Belt Tensioner & Mounting Bracket Bolts
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1. Apply seal packing to threads of the mounting bolt. Seal packing: Part No. 08826-00080 or equivalent  .
2. Install the mounting bracket with the 3 bolts. Torque: 47 N.m (479 kgf.cm, 35 ft.lbf)  .

1. Install the drive belt tensioner with the bolt and nut.

   Torque:

   1. 69 N.m (704 kgf.cm, 51 ft.lbf) for bolt  .
   2. 29 N.m (296 kgf.cm, 21 ft.lbf) for nut  .
NOTE: Take 3 seconds or more for 1 full stroke.
2. Hook the tool on the hexagonal portion of the drive belt tensioner bracket and operate drive belt tensioner 3 times with full stroke.

Torque: 9 N.m (92 kgf.cm, 80 in..lbf). 

1. Clean the crankshaft pulley inside.
2. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
3. Using SST, install the pulley bolt.Torque: 138 N.m (1,409 kgf.cm, 102 ft.lbf)  . SST 09213-70011, 09330-00021.
   Fig 16: Installing Crankshaft Pulley Bolt

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1. Check the chain tensioner. See  4 in INSPECTION under TIMING CHAIN.
2. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.
   Fig 17: Locating Chain Tensioner Hook & Pin

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NOTE:
• In case that the hook is released while pushing in, apply the hook again and push the tensioner in.
• Pay attention not to catch the O-ring as it is built in the chain tensioner previously.
Fig 18: Installing Chain Tensioner
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3. Push the chain tensioner into the timing chain cover, and install the 2 nuts.Torque: 9 N.m (92 kgf.cm, 80 in..lbf)  .

1. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
   Fig 19: Confirming Chain Tension (1 Of 2)

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NOTE: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released from the knock pin and the plunger springs out.
Fig 20: Confirming Chain Tensioner Plunger Position
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Fig 21: Confirming Chain Tension (2 Of 2)
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2. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.

CAUTION: Always turn the crankshaft clockwise.
1. Turn the crankshaft pulley, and align its groove with timing mark 0° of the timing chain cover.
2. Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration.
   Fig 22: Identifying Correct Camshaft & VVT Timing Sprocket Point Marks Alignment

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   If not, turn the crankshaft 1 revolution (360°) and align the marks as above.

1. Remove any old packing (FIPG) material.
NOTE: Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied.
Fig 23: Identifying Seal Packing Application Points
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2. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent  .
3. Install the gasket to the cylinder head cover.

   If the gasket has damage, replace a new one.

4. Install the cylinder head cover and cable bracket with the 9 bolts, 2 seal washers and 2 nuts.

   Uniformly tighten the bolts and nuts, in the several passes, in the sequence shown.

   Fig 24: Identifying Cylinder Head Cover & Cable Bracket Bolt & Nut Tightening Sequence

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   Torque:

   1. 11 N.m (113 kgf.cm, 8 ft.lbf) for without washer  .
   2. 9 N.m (92 kgf.cm, 80 in..lbf) for with washer  .
5. Connect the 2 PCV hoses to the cylinder head cover.
6. Install the 4 ignition coils with 4 bolts.
7. Install the engine wire with 2 bolts.
8. Connect the ignition coil connectors.
9. Install the No. 2 cylinder head cover with 2 nuts and 2 clips.

1. Install the RH engine mounting insulator with the 4 bolts and 2 nuts.
   Fig 25: Identifying Engine Mounting Insulator Bolt & Nut Placement

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   Torque:

   1. 63.7 N.m (650 kgf.cm, 47 ft.lbf) for bolt A  .
   2. 25.5 N.m (260 kgf.cm, 19 ft.lbf) for bolt B  .
   3. 52.0 N.m (530 kgf.cm, 38 ft.lbf) for nut  .
2. With A/C: Install the bolt holding the A/C piping clamp to the RH engine mounting insulator.

1. Install the PS pump with the 2 through bolts and nuts.Torque: 37 N.m (370 kgf.cm, 27 ft.lbf)  .
2. Install the PS pump pulley with the pulley nut.
3. Using SST, torque the pulley nut. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf)  . SST 09960-10010 (09962-01000, 09963-01000).
   Fig 26: Installing Power Steering Pump Pulley

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4. Connect the PS oil pressure switch connector.