Installation

TIMING CHAIN INSTALLATION
1. 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. 48 Alignment Of Timing Marks:

5. Using straight edge to check alignment of timing marks Fig. 48.
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.
8. Check camshaft end play. 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.

Fig. 45 Timing Chain Case Cover Gaskets And O-rings:

2. Use a new cover gasket and 0-rings. Fig. 45.
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. 45. Do not install front crankshaft seal into timing chain cover at this time.

Fig. 44 Timing Chain Case Cover:

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 bolts Fig. 44. Snug the two bottom screws and the top center screwy. Ensure the cover is seated to the block then torque all other screws to 27 Nm (20 ft.lbs.).

Fig. 46 Crankshaft Oil Seal - Installation:

7. Install crankshaft oil seal Fig. 46.

Fig. 47 Crankshaft Damper - Installation:

8. Install crankshaft damper Fig. 47.
9. Install tensioner pulley bracket.
10. Install cam sensor.
11. Install accessory drive belts, Refer to Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair.
12. Install oil pump pick-up torque bolt to 28 Nm (250 in. lbs.) and oil pan, torque bolts to 12 Nm (105 in. lbs.).
13. Install the transmission supports brackets and inspection cover.
14. Connect the the sway bar.

Fig. 42 Fan Module:

15. Install Fan Module Fig. 42.
15. Fill crankcase with oil to proper level.
16. Connect battery.