INSTALLATION
CAUTION: Care must be taken to closley inspect
the gasket area around the time case cover to cyl-
inder head gasket coolant port. If damage is found,
replace the cylinder head gasket. Failure to do so
may result in engine damage.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during assembly.
(1) In spect cylinder hea d gasket and oil pan gas-
ket . If da maged, replace.
(2) Replace the front cra nksh aft seal (Refer t o 9 -
ENGINE/ENGINE BLOCK/CRANKSH AFT OIL
SE AL - FRONT - INSTALLATION).
(3) In st all ancilla ry componen ts to timing case
cover.
(4) Apply sealant to the mar ked surfaces with a
bead thickness of 1.5 ± 0.5 m m (Fig. 74).
NOTE: Install timing cover within 10 minutes after
applying sealant. Do not spread sealant bead.
NOTE: Do not seal pressurized oil galleries to the
crankcase. Sealant applied at these points is
entrained by the oil flow and blocks the oil supply
passages.
(5) Position an d insta ll timin g ca se cover. Tight en
bolts t o 20 N·m (177 lbs in) (Fig. 73).
(6) In st all th e M8 bolts of cylinder head on timin g
case cover. Tighten bolts to 20 N·m (177 lbs in) (Fig.
73).
(7) In st all tim ing chain ten sioner with n ew seal
(Refer t o 9 - ENGINE/VALVE TIMING/TMNG BELT/
CHAIN TENSIONER&P ULLE Y - INSTALLATION).
(8) Position and install t he oil pan. Tigh ten M6
bolts to 9 N·m (80 lbs in) and M8 bolts to 20 N·m
(177 lbs in).
(9) In st all belt /pulley vibr ation dam per. Tighten
M8.8 bolt in t wo sta ges, 200N·m (147 lbs ft.) then
90°, M10.9 bolt 325N·m (240 lbs ft) th en 90°.
(10) Remove th e engine support fixtur e.
(11) In st all generat or (Refer to 8 - ELE CTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(12) Install the air conditionin g compr essor.
(13) Install the power steerin g pump.
(14) Install water pump (Refer to7-COOLING/
ENGINE/WATER P UMP - INSTALLATION).
(15) Connect coolant hose t o oil-water hea t
excha nger.
(16) Install high pressu re fuel pum p (Refer to 14 -
FUE L SYSTE M/FUEL DELIVERY/FUEL PUMP -
INSTALLATION).
(17) Apply sea lan t to lower por tion of, and install,
front cover to cylinder block. Tighten bolts to 20N·m
(177 lbs in) (Refer t o 9 - ENGINE/CYLINDE R HEAD
- INSTALLATION).
(18) Remove retainin g lock for cran ksha ft/starter
ring gear.
(19) Tighten t he oil dr ain plu g to 30N·m (265 lbs
in).
(20) Install a new oil filter. tigh ten screw cap for
filt er to 25N·m (221 lbs. in.).
(21) Install the accessory drive belt.
(22) Install t he radiat or assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION).
(23) Install air int ake hose.
(24) Fill coolant to th e proper level, with the
pr oper coolant (Refer t o 7 - COOLING/E NGINE/
COOLANT - STANDARD P ROCEDURE).
(25) Fill the crankcase with t he cor rect oil, to the
pr oper level. Refer to owners manual for specifica -
tions.
(26) Connect t he negat ive batt ery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
CAUTION: DO NOT pressure test cooling system
until the engine reaches operating temperature.
Fig. 74 TIMING CHAIN COVER SEALING SURFACE
1 - TIMING CHAIN COVER
2 - SEALANT BEAD
VA ENGINE 9 - 71
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