Front Cover & Timing Chain: Installation
- To prevent pistons from hitting valves, ensure timing mark and keyway on crankshaft are aligned with split line of main bearing cap. Install camshaft sprocket(s) with the letters FRT (front) facing away from cylinder head. Use a 7/8" (21 mm) wrench to keep camshaft(s) from turning.
- Install and tighten camshaft sprocket bolt(s) to specification. Rotate camshaft(s) until a 3/16" (4.8 mm) drill bit can be inserted through timing pin hole(s) and into cylinder head. See Fig 1 or Fig 2.
- Rotate crankshaft counterclockwise as viewed from front of engine until timing marks at crankshaft sprocket are aligned. Install timing chain, aligning Silver-plated chain links with timing mark(s) on camshaft sprocket(s) and bottom tooth (or teeth) of crankshaft sprocket. See Fig 1 or Fig 2.
- Install fixed chain guide. Slack part of chain should be on tensioner side of cylinder block. Chain should be tight against fixed chain guide. Install pivoting chain guide. Retract tensioner plunger, and pin ratchet lever by inserting a 1/8" (3.2 mm) drill bit into lever locking hole. Install tensioner.
- Remove drill bits from camshaft sprockets and tensioner. Check timing mark alignment. If oil pump and pressure regulator were removed from front cover, install them using special procedures. See OIL PUMP under ENGINE OILING. If front seal was removed, press new seal into front cover using Seal Installer (SA9104E).CAUTION: DO NOT allow RTV sealant to clog oil passage holes, including drain-back hole at bottom of oil seal.
- Install new oil pressure seal (pump outlet) and suction seal (pump inlet) into cavities in cylinder block. Apply a .16" (4 mm) bead of RTV sealant to oil pan sealing surface. Apply a .08" (2 mm) bead of RTV sealant to front cover sealing surface. Apply RTV sealant to bolt hole at top center of front cover. Apply extra RTV sealant to "T" joints (corners of components). Install front cover immediately.
- Install Crankshaft Gear Retainer (SA9104E) to align oil pump drive gear. Tighten front cover bolts to specification. See TORQUE SPECIFICATIONS . Ensure drain-back hole at bottom of front cover oil seal is not clogged (pump 6-12 squirts of engine oil through hole).
- Install cylinder head cover. If silicone isolators are deteriorated, replace them. Tighten cylinder head cover bolts to specification (start at center and work outward). To complete installation, reverse removal procedure. Fill cooling system and crankcase. Check for leaks.