Installation
NOTE: Lightly oil all bolt and stud threads before installation except those specifying special sealant.1. Clean all gasket surfaces on the front cover, cylinder block, and fuel pump.
If re-using the front cover, replace the crankshaft front oil seal.
2. If a new front cover is to be installed:
Install the oil pump, oil filter adapter and intermediate shaft.
Clean the water pump gasket surface. Position a new water pump gasket on the front cover and install the water pump Install the pump attaching bolts and tighten to 20-30 Nm (15-22 lb-ft).
3. Rotate the crankshaft as necessary to position piston No.1 at TDC and the crankshaft keyway at the 12 o'clock position.
4. Lubricate the timing chain with clean engine oil.
Install the camshaft sprocket, crankshaft sprocket and timing chain.
Make sure the timing marks are positioned across from each other.
5. Install the camshaft sprocket attaching bolts.
Tighten the attaching bolts to 20-30 Nm (15-22 lb-ft).
6. Install the camshaft thrust button and spring.
Lubricate the thrust button with polyethylene grease before installation.
The thrust button and spring must be bottomed out in the camshaft seat and must not be allowed to fall out during installation of the front cover.
7. Lubricate the crankshaft front oil seal with clean engine oil.
8. Position a new cover gasket on the cylinder block and install the front cover/water pump assembly using the dowels for proper alignment.
Contact Adhesive or equivalent is recommended to hold the gasket in position while the front cover is installed.
9. Position the ignition timing indicator.
10. Install the front cover attaching bolts and tighten to 20-30 Nm (15-22 b-ft).
NOTE: The threads of the cover attaching bolt shown must be coated with Pipe Sealant or equivalent before installation.
11. Raise the vehicle.
12. Install the oil pan.
13. Connect the radiator lower hose. Tighten the clamp securely.
14. Install the oil filter.
15. Turn the crankshaft clockwise 180° to position the fuel pump eccentric away from the fuel pump actuating arm. Failure to turn the crankshaft can result in the threads being stripped out of the cover when the fuel pump attaching bolts are installed.
16. Position a new gasket on the fuel pump and install the pump.
Tighten the attaching bolts to 20-30 Nm (15-22 lb-ft). Install the pump crash shield, if so equipped. Tighten the attaching nuts to 20-30 Nm (15-22 lb-ft).
17. Connect the fuel line to the pump.
16. Coat the crankshaft damper sealing surface with clean engine oil.
19. Position the crankshaft pulley key in the crankshaft keyway.
20. Install the damper using Seal/Damper Installer or equivalent.
21. Install the damper washer and attaching bolt. Tighten the bolt to 125-165 Nm (93-121 lb-ft).
22. Install the crankshaft pulley. Tighten the attaching bolts to 26-28 Nm (19-28 lb-ft).
23. Turn the crankshaft 180° counterclockwise to bring piston No.1 back to TDC.
24. Lower the vehicle.
25. Connect the coolant by-pass. Tighten the clamp securely.
26. If equipped with tripminder, install the fuel flow meter support bracket. Tighten the bracket-to-flow meter attaching nuts to 5-7 Nm (4-5 lb-ft). Tighten the bracket-to-front cover attaching nuts to 20-30 Nm (15-22 lb-ft).
27. Install the distributor with the rotor pointing at the No.1 distributor cap tower.
28. Install the distributor cap and coil wire.
29. Connect the radiator upper hose at the thermostat housing. Tighten the clamp securely.
30. Connect the heater hose. Tighten the clamp securely.
31. If equipped with air conditioning, install the compressor and mounting brackets. Tighten the attaching bolts to specification.
32. If equipped with power steering install the pump and mounting brackets. Tighten the attaching bolts to specification.
Timing Mark Alignment:
33. Position the accessory drive belt over the pulleys.
34. Install the water pump pulley, fan/clutch assembly and fan shroud. Cross-tighten the fan/cutch assembly attaching bolts to 16-24 Nm (12-18 lb-ft).
CAUTION: Examine the fan for possible cracks, separation, oil damage before Installation. Replace the fan If necessary.
35. Position the fan shroud on the radiator and install the attaching screws.
36. Position the accessory drive belt over the water pump pulley and tension the belt.
37. Connect the cable to the battery negative terminal.
38. Fill the crankcase to the proper level with the specified oil.
39. Fill the cooling system with the specified coolant.
CAUTION: This engine has an aluminum cylinder head and requires a special unique corrosion Inhibited coolant formulation to avoid radiator damage.
40. Start the engine and check for coolant, oil or fuel leaks.
41. Check the ignition timing and curb idle speed - adjust as required. Tighten distributor hold-down bolt 27-40 Nm (20-29 lb-ft).
42. Install the air cleaner assembly and air intake duct.