W/Z24 Engine

1. Install baffle plate and steel net into engine block.
2. Place upper main bearings into engine block, observing the following:
a. Upper main bearings contain an oil groove.
b. No. 3 main bearing is the thrust bearing.
c. No. 1 and No. 5 bearings are the same type, and No. 2 and No. 4 bearings are the same type.
3. Install crankshaft into engine and install lower main bearings into bearing caps.
4. Install bearing caps observing the following:
a. Apply sealer to both sides of rear main cap and each corner of block.
b. Install bearing caps with arrows pointing toward front of engine.

Fig. 11 Main bearing cap tightening sequence:

c. Tighten to specified torque in sequence, Fig. 11.
d. Make sure crankshaft rotates smoothly and endplay is within specification.
5. Apply sealer to side oil seals and install seals in rear bearing cap, Fig. 11.
6. Lubricate rear oil seal, then install with lip facing out using a seal driver.
7. Install rear end plate and flywheel, then torque flywheel bolts to specifications.
8. Install piston and connecting rod assemblies into engine noting the following.
a. Using piston ring compressor install them into corresponding cylinders with mark on piston facing forwards.
b. Apply engine oil to all sliding parts.
c. Install corresponding connecting rod caps and torque to specifications.
d. Check connecting rod to crankshaft endplay.
9. Thoroughly clean cylinder block and cylinder head mating surfaces.
10. Turn crankshaft until No. 1 piston is at TDC on compression stroke.
11. When installing cylinder head be sure clearance exists between valves and piston heads. If necessary loosen valve adjustments to draw in valves.
12. Temporarily tighten 2 center head bolts slightly. Do not rotate camshaft or crankshaft independently when performing the proceeding steps.
13. Install crankshaft sprocket with timing mark facing front of engine.
14. Install oil pump drive gear so that large chamfered inner side faces rearward.
15. Install timing chain guides.

Fig. 12 Timing chain installation. Z24:

16. Set timing chain on camshaft and crankshaft sprockets aligning matching marks on chain with marks on sprockets, Fig. 12, and install camshaft sprocket with dowel pin in position marked during removal. Torque sprocket bolt to specification.

Fig. 7 Timing Chain Tensioner Installation:

17. Install timing chain tensioner assembly and adjust protrusion of tensioner to 0 inch, Fig. 13. After tensioner has been installed, check amount of timing chain stretch. If timing chain is excessively stretched, remove tensioner and timing chain, remove camshaft sprocket and advance it to the next dowel pin position. Repeat installation procedure outlined above. If dowel pin is already in position No. 3 of camshaft sprocket, replace timing chain and tensioner assembly.
18. Install oil seal in front cover using seal driver, then place front cover gaskets on engine and apply sealer to coolant passages.
19. Install front cover making sure that correct length bolts are used.
20. Apply lithium grease to front seal lip.
21. Torque front cover bolts to specifications.
22. Install crankshaft pulley and torque bolt to specifications.

Fig. 14 Cylinder head bolt tightening sequence:

23. Torque head bolts to specifications in sequence, Fig. 14.
24. Adjust valve clearance to specifications.
25. Install valve rocker cover.
26. Install oil strainer, then install oil pan.
27. Install oil pump and distributor driving spindle in front cover.

Fig. 15 Intake manifold installation:

28. Partially thread intake manifold bolts and nut with washers into lower and center positions on cylinder head, Fig. 15.
29. Install intake manifold and related components in reverse order of removal.
30. With No. 1 piston T.D.C. of the compression stroke, install distributor.
31. Install remaining components in reverse order of removal and install assembly in vehicle.
32. Fill engine oil and coolant to specified levels and make necessary adjustments