Repair procedures: Installation

Install the jack to the upper oil pan.

Fig 1: Identifying 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 2: Identifying Crankshaft Timing Mark
Install the tensioner adapter assembly (A).

Fig 3: Identifying Tensioner Adapter Assembly
Install the crankshaft sprocket (A) (LH camshaft drive).

Fig 4: 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 5: Identifying LH Timing Chain Guide
Install the LH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.

Crankshaft sprocket → Timing chain guide → Exhaust camshaft sprocket → Intake camshaft sprocket.

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

Fig 6: Identifying Timing Chain Guide Sprockets Timing Mark

Fig 7: Identifying Timing Chain
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 chain tensioner (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 Timing Chain Tensioner Arm And 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 9: Identifying Cam-To-Cam Guide
Install the crankshaft sprocket (A) (O/P & RH camshaft drive).

Fig 10: Identifying Crankshaft Sprocket
Install the oil pump chain (B) and the 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 11: 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 12: 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 below procedure.

Crankshaft sprocket → Intake camshaft sprocket → Exhaust camshaft sprocket.

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

Fig 13: Identifying Timing Chain Sprockets Timing Mark (1 Of 2)

Fig 14: Identifying Timing Chain Sprockets Timing Mark (2 Of 2)
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 15: Identifying Timing Chain Auto Tensioner And Timing Chain Tensioner Arm
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 16: Identifying 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 17: 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 18: Identifying Oil Pump Chain Tensioner Assembly
Pull out the pins of hydraulic tensioner (LH & RH).

Fig 19: Pulling Out Pins Of Hydraulic Tensioner (1 Of 2)

Fig 20: Pulling Out Pins Of Hydraulic Tensioner (2 Of 2)
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 21: Identifying Oil Pump Chain Cover And Mounting Bolts
After rotating the 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 TB 1217H 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 22: Identifying Timing Chain Cover
3. After applying liquid sealant TB1217H on 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 23: Identifying Timing Chain Cover Liquid Sealant TB1217H Applying Dimensions
4. Install the new gasket (A) to the timing chain cover.
  
  Fig 24: Identifying Timing Chain Cover 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
  1. B(17):
    18.62 ~ 21.56 N.m (1.9 ~ 2.2 kgf.m, 13.74 ~ 15.91 lb-ft)
  2. C(4):
    9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  3. D(1):
    58.80 ~ 68.80 N.m (6.0 ~ 7.0 kgf.m, 43.40 ~ 50.63 lb-ft)
  4. E(1):
    58.80 ~ 68.80 N.m (6.0 ~ 7.0 kgf.m, 43.40 ~ 50.63 lb-ft)
  5. F(2):
    24.50 ~ 26.46 N.m (2.5 ~ 2.7 kgf.m, 18.08 ~ 19.53 lb-ft)
  6. G(4):
    21.56 ~ 23.52 N.m (2.2 ~ 2.4 kgf.m, 15.91 ~ 17.36 lb-ft)
  7. H(1):
    9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  8. I(1):
    9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  9. J(1):
    9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  10. K(4):
    9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  11. L(1):
    21.56 ~ 26.46 N.m (2.2 ~ 2.7 kgf.m, 15.91 ~ 19.53 lb-ft)
    
    - New bolt
    
    Fig 25: Identifying Cylinder Block Mounting 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 26: 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 27: Identifying Drive Belt Auto Tensioner And Mounting Bolt
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 28: Identifying Drive Belt Idler
Install the alternator (A).
Tightening torque

26.48 ~ 33.34 N.m (2.7 ~ 3.4 kgf.m, 19.53 ~ 24.59 lb-ft)

Fig 29: Identifying Alternator
Install the air conditioner compressor (A).

Fig 30: Identifying Air Conditioner Compressor
Install the power steering pump (A). (Refer to POWER STEERING OIL PUMP )

Fig 31: Identifying Power Steering Pump
Lower the engine assembly by using the jack.
Using SST (09231-3C100), install timing chain cover oil seal.

Fig 32: 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 33: 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 34: 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 35: 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 36: Identifying Front Plate Of Holder And Holder Nuts
5. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
  
  Fig 37: Installing SST (09231-3D100) Using Mounting Bolts
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 38: 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 39: Identifying Cylinder Head Cover Sealant Applying Area
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 40: 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 41: Identifying Ignition Coil Connector, Condenser Connector And Wiring Bracket
7. Install the connector bracket (A) from the LH cylinder head cover.
  
  Fig 42: Identifying Cylinder Head Cover Connector Bracket
Install the surge tank.
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)
  
  [3.3L]
  
  Fig 43: Identifying Surge Tank Stay (3.3L)
  
  Fig 44: Identifying Surge Tank Stay (3.8L)
2. Install the connector bracket (A) on the surge tank.
  Tightening torque
  
  6.86 ~ 10.78 N.m (0.7 ~ 1.1 kgf.m, 5.06 ~ 7.96 lb-ft)
  
  Fig 45: 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)
  
  [3.3L]
  
  Fig 46: Identifying Surge Tank Stay (3.3L)
  
  Fig 47: Identifying Surge Tank Stay (3.8L)
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).
  Tightening torque
  
  15.68 ~ 25.48 N.m (1.6 ~ 2.6 kgf.m, 11.57 ~ 18.80 lb-ft)
  
  Fig 48: Identifying Water Hoses, ETC Bracket And PCV Hose
8. Connect the PCSV connector (A), the MAP sensor connector (B) and the PCSV hose (C).
  [3.3L]
  
  Fig 49: Identifying PCSV Connector, MAP Sensor Connector And PCSV Hose (3.3L)
  
  Fig 50: Identifying PCSV Connector, MAP Sensor Connector And PCSV Hose (3.8L)
9. Connect the ETC connector (A) and the knock sensor connector (B).
  
  Fig 51: Identifying ETC Connector And Knock Sensor Connector
10. Connect the LH CMPS (A) and oil pressure switch connector (B).
  
  Fig 52: Identifying LH CMPS And Oil Pressure Switch Connector
11. Install the wiring harness protector (E), and connect the LH ignition connector (A), injector connector(B), condenser connector (C) and ground (D).
  
  Fig 53: Identifying Wiring Harness Protector, LH Ignition Connector, Injector Connector, Condenser Connector And Ground
12. Connect the OCV connector (A) and knock sensor connector(B).
13. Connect the LH front oxygen sensor connector (C), alternator connector (B) and air compressor connector (E).
  
  Fig 54: Identifying OCV Connector And Knock Sensor Connector, LH Front Oxygen Sensor Connector, Alternator Connector And Air Compressor Connector
14. Connect the RH injector connector (A) and the ignition coil connector (B).
  [3.3L]
  
  Fig 55: Identifying RH Injector Connector And Ignition Coil Connector (3.3L)
  
  Fig 56: Identifying RH Injector Connector And Ignition Coil Connector (3.8L)
15. Connect the power steering oil pressure sensor connector (A).
  
  Fig 57: Identifying Power Steering Oil Pressure Sensor Connector
16. Connect the RH oxygen sensor connector (A) and VIS solenoid valve connector (B).
  
  Fig 58: Identifying RH Oxygen Sensor Connector And VIS Solenoid Valve Connector (3.8L)
17. Connect the RH oxygen sensor connector (A).
  [3.3L]
  
  Fig 59: Identifying RH Oxygen Sensor Connector (3.3L)
Install the no.1 engine mounting (A) through the lower position of A/C pipe line.
Tightening torque

49.03 ~ 63.74 N.m (5.0 ~ 6.5 kgf.m, 36.17 ~ 47.01 lb-ft)

Fig 60: Identifying Engine Mounting
Install the A/C pipe bracket mounting bolt (A).

Fig 61: Identifying A/C Pipe Bracket Mounting Bolt
Install the engine coolant reservoir tank (A).
Install the engine mounting bracket (B).
Tightening torque

63.74 ~ 83.36 N.m (6.5 ~ 8.5 kgf.m, 47.01 ~ 61.48 lb-ft)

Fig 62: Identifying Engine Coolant Reservoir Tank And Engine Mounting Bracket
Install the transaxle mounting bolts (A).
Tightening torque

49.03 ~ 63.74 N.m (5.0 ~ 6.5 kgf.m, 36.17 ~ 47.01 lb-ft)

Fig 63: Identifying Transaxle Mounting Bolts
Remove the jack from the upper oil pan.

Fig 64: Identifying Upper Oil Pan
Install the 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 TB 1217H should be applied on oil pan.
  The part must be assembled within 5 minutes after the sealant was applied.
  
  Bead width : 2.5 mm (0.1 in.).
  
  But marked area (*) to be 5.0 mm (0.2 in.)
  
  Fig 65: Identifying Lower Oil Pan Sealant Applying Area
  CAUTION:
  - Make clean the sealing face before assembling two parts.
  - Remove harmful foreign matters on the sealing face before applying sealant.
  - When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
  - To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
3. Install the oil pan (A).
  Uniformly tighten the bolts in several passes.
  
  Tightening torque
  
  9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  Fig 66: Identifying Oil Pan
Install the upper radiator hose (A).

Fig 67: Identifying Upper Radiator Hose
Install the side cover (A).

Fig 68: Identifying Side Cover
Install the under cover (A).

Fig 69: Identifying Under Cover
Install the front wheels.
Install the intake air hose and air cleaner assembly.
1. Install the intake air hose (C) and air cleaner (D).
2. Connect the ECM connector.
3. Connect the breather hose (B) to air cleaner hose.
4. Connect the AFS connector (A).
  
  Fig 70: Identifying Intake Air Hose And Air Cleaner, Breather Hose And AFS Connector
Install the air duct.

Fig 71: Identifying Air Duct
Install the engine cover.
Connect the negative terminal to the battery.
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.