Installation
TIMING CHAIN INSTALLATION1. Position a new crankshaft sprocket on the shaft, install sprocket with suitable tool and mallet. Be sure sprocket is seated into position.
2. Rotate crankshaft so the timing arrow is to the 12 o'clock position.
3. Place timing chain around camshaft sprocket and place the timing mark to the 6 o'clock position.
4. Align the dark colored links with the dot on the camshaft sprocket, place timing chain around crankshaft sprocket with the dark colored link lined up with the dot on the sprocket and install camshaft sprocket into position.
Fig. 49 Alignment Of Timing Marks:
5. Using straight edge to check alignment of timing marks Fig. 49.
6. Install camshaft bolt and washer. Tighten to 54 Nm (40 ft. lbs.).
7. Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up remove cam sprocket and realign.
Fig. 50 Camshaft Thrust Plate:
8. Check camshaft endplay With new thrust plate the specification is 0.0127 to 0.304 mm (0.005 to 0.012 inches.). Old thrust plate specification is 0.31 mm (0.012 in.) maximum. If not within these limits install new thrust plate.
TIMING COVER INSTALLATION
1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. Crankshaft oil seal must be removed to insure correct oil pump engagement.
NOTE: Do not use a sealer on cover gasket.
Fig. 46 Timing Cover Rear Surface:
2. Use a new cover gasket, O-rings Fig. 46. Adhere new gasket to timing cover, making sure that the lower edge of the gasket flush to 0.5 mm (0.020 in.) passed the lower edge of the cover. Refer to oil pan sealing outlined in this section.
3. Rotate crankshaft so that the oil pump drive flats are vertical.
4. Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats Fig. 46.
5. Install cover onto crankshaft. Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result.
6. Install chain case cover screws and torque to 27 Nm (20 ft.lbs.).
Fig. 47 Installation Of Crankshaft Front Oil Seal:
7. Install crankshaft oil seal Fig. 47.
Fig. 48 Installation Of Crankshaft Pulley:
8. Install crankshaft pulley Fig. 48.
9. Install engine bracket Fig. 44 torque screws to 54 Nm (40 ft.lbs.).
10. Install idler pulley on engine bracket.
11. Install cam sensor.
12. Install A/C compressor mounting bracket.
13. Install A/C compressor.
14. Install drive belt. Refer to Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair for installation procedure.
15. Install inner splash shield and wheel.
16. Install oil pump pick-up and oil pan and transmission inspection cover if removed.
17. Install engine mount.
18. Fill crankcase with oil to proper level.
19. Fill cooling system. Refer to Cooling System/Service and Repair for procedure.
20. Connect battery