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Cam Chain Installation

NOTE: Keep the cam chain away from magnetic field.
  1. Set the crankshaft sprocket so that the No. 1 piston is at top dead center (TDC). Align the key (A) on the sprocket and crankshaft with the pointer (B) on the engine block.
    Fig 1: Aligning Key On Sprocket And Crankshaft With Pointer On Engine Block
    G03692279Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Install the cam chain with the colored piece (A) aligned with the punch mark (B) on the crankshaft sprocket.
    Fig 2: Installing Cam Chain With Colored Piece Aligned With Punch Mark On Crankshaft Sprocket
    G03692280Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Install the oil pump chain guide.
    Fig 3: Installing Oil Pump Chain Guide With Torque Specifications
    G03692281Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Install the CKP pulse plate (see CKP PULSE PLATE REPLACEMENT  ).
  5. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal (see CHAIN CASE OIL SEAL INSTALLATION  ).
  6. Remove any old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
  7. Clean and dry the chain case mating surfaces.
  8. Apply liquid gasket, P/N 08717-0004,08718-0001, 08718-0003, or 08718-0009, evenly to the engine block mating surface of the chain case.
    NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
    Fig 4: Identifying Chain Case For Applying Liquid Gasket
    G03692282Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Apply a light coat of new engine oil to the lip of the chain case oil seal, then install the dowel pins (A) and the chain case (B) using a new O-ring (C).
    10. Fig 5: Installing Dowel Pins And Chain Case Using New O-Ring With Torque Specifications
    G03692283Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Install the crankshaft position (CKP) sensor.
  11. Install the crankshaft pulley (see CRANKSHAFT PULLEY REMOVAL AND INSTALLATION  ).
  12. Install the oil pan (see OIL PAN INSTALLATION ).
  13. Install the idler pulley base (A), then install the idler pulley (B).
    Fig 6: Installing Idler Pulley Base And Idler Pulley With Torque Specifications
    G03692284Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Install the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ).
  15. Install the auto-tensioner (see DRIVE BELT AUTO-TENSIONER REPLACEMENT ).
  16. Install the water pump pulley.
    Fig 7: Installing Water Pump Pulley With Torque Specifications
    G03692285Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Connect the water bypass hose (A), and tighten the three bolts (B) securing the water bypass tube.
    Fig 8: Installing Water Bypass Hose And Water Bypass Tube With Torque Specifications
    G03692286Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Install the cylinder head (see CAMSHAFT GEAR INSTALLATION  ) with using the following process by installing the cam chain sprocket assembly.
    • Make sure the crankshaft pulley is at TDC.
    • Place the idler gear/cam chain sprocket assembly and idler gear collar into the cylinder head.
    • Install the cam chain on the sprocket with the one punch mark (A) aligned with the center of the two colored pieces (B).
    • Fit the cam chain sprocket assembly into the cylinder head.
    • Turn the cam chain sprocket assembly counterclockwise to relieve cam chain free play, and check the alignment of the TDC mark (C) on the cam chain sprocket with the cylinder head surface. If the cam chain sprocket is not positioned at TDC, remove the assembly from the cylinder head and reposition the cam chain to bring the cam chain sprocket to TDC.
      Fig 9: Installing Cam Chain On Sprocket With One Punch Mark Aligned With Center Of Two Colored Pieces
      G03692287Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. Install the drive belt (see DRIVE BELT REPLACEMENT ).
  20. Install the vacuum tank.
    Fig 10: Installing Vacuum Tank With Torque Specifications
    G03692288Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. After installation, check that all tubes, hoses, and connectors are installed correctly.
  22. After assembly, wait at least 30 minutes before filling the engine with oil.
  23. Do the battery terminal reconnection procedure. ( see RECONNECTION ).
  24. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
  25. Refill the engine with engine oil (see OIL PRESSURE TEST ).
  26. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see COOLANT REPLACEMENT ).
  27. 2000-2005 models: Do the engine control module (ECM) idle learn procedure (see IDLE SPEED INSPECTION ).
  28. 2006-09 model: Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure (see HDS CLEAR COMMAND ).
  29. Inspect the idle speed:
  30. Inspect the ignition timing (see IGNITION TIMING INSPECTION ).
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