Installation

INSTALLATION

NOTE: If a new Timing Chain cover is being installed, the new Cover does not have Threaded bolt holes for the Water Pump, Belt Tensioner, and Power Steering Pump assembly. New self tapping bolts are necessary for the installation of those components which are listed in the parts catalog.




1. Be sure valve timing is still locked at 40° ATDC.





NOTE: Apply sealer ONLY to the area marked (1) as shown. If porous points are visible at the cylinder heads or at the rear of the engine near the sealing surface of the cylinder head gasket, apply sealant at these points. The sealant must be applied only as a 2.0 mm ± 0.5 mm bead, assembled within 10 minutes, and not be flattened or spread.

2. Apply a 1.5 to 2.0 mm bead of Loctite 5900 or equivalent sealer to the area marked (1) as shown.
3. Position the timing chain cover on the front of the engine.





NOTE: Ensure that the bolts indicated by the arrows are installed with thread sealer prior to assembly.

4. Install the timing chain cover bolts and tighten to 20 Nm (15 ft. lbs.).




5. Install the timing chain tensioner (1). Tighten to 80 Nm (59 ft. lbs.).




6. Remove Special Tool 9102 Flywheel Locking Tool (1) from the engine.
7. Install the starter.
8. Install the upper oil pan.
9. Install the lower oil pan.
10. Install the generator.

NOTE: Apply a thin coat of lubricant to head bolt threads before installing.

11. Install the front cylinder head to timing chain cover bolts. Tighten bolts to 20 Nm (7-15 ft. lbs.).
12. Install the cylinder head covers.
13. Install the AIR pump.




14. Install the power steering pump, return hose (1), and pressure hose (2).
15. Install the lower radiator and heater hoses to the water pump.
16. Install the vibration damper.
17. Install the idler pulley.
18. Install the accessory drive belt tensioner.
19. Install the accessory drive belt.
20. Install the radiator fan.
21. Install the engine cover.
22. Refill all engine fluids to specifications.
23. Connect the negative battery cable.