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.
(6) St art the engine, a llow to warm , tur n engine
off and inspect for leaks. Care m ust be ta ke to
observe the fuel syst em wa rnin g (Refer t o 14 - F UEL
SYSTEM - WARNING).
INSTALLATION - INTERMEDIATE GEAR
NOTE: Refer to appropriate injector servicing proce-
dures for cleaning of injectors and recesses.
(1) In st all intermediate gear and bushing. Tighten
bolt to 40N·m (30 lbs.ft .)
(2) In st all t he in take cam sh aft (Refer to 9 -
ENGINE/CYLINDER HEAD/CAMSH AFT(S) -
INSTALLATION).
(3) In st all exhaust cam shaft sprocket, not ing
dowel pin alignment. Tigh ten bolt to 18 N·m (159 lbs.
in.).
WARNING: NO FIRE, FLAMES OR SMOKING. SER-
VICE VEHICLE IN WELL VENTILATED AREA. RISK
OF INJURY FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. WEAR PROTECTIVE CLOTH-
ING.
(4) In st all high pr essu re pump (Refer to 14 -
FUE L SYSTE M/FUEL DELIVERY/FUEL INJ EC-
TION P UMP - INSTALLATION).
(5) In st all t op slide r ail (Refer to9-ENGINE/
VALVE TIMING/TIMING BEL T/CHAIN AND
SP ROCKETS - INSTALLATION).
(6) In st all cylinder head front cover (Refer t o 9 -
ENGINE/CYLINDER HE AD - INSTALLATION).
(7) In st all timing cha in tension er with new gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CH AIN AND SPROCKETS - INSTALLA-
TION).
NOTE: Inspect basic position of camshaft and reset
if necessary (Refer to 9 - ENGINE/CYLINDER HEAD/
CAMSHAFT(S) - STANDARD PROCEDURE).
(8) Remove camshaft locking pin.
(9) In st all cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
WARNING: NO FIRE, FLAMES OR SMOKING. SER-
VICE VEHICLE IN WELL VENTILATED AREA. RISK
OF INJURY FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. WEAR PROTECTIVE CLOTH-
ING.
(10) Install fu el high pressu re lines and injector s
(Refer to 14 - FUEL SYSTEM/F UEL INJ ECTION/
FUE L INJ ECTOR - INSTALLATION).
(11) In st all en gine cover (Refer to9-ENGINE -
INSTALLATION).
(12) Connect n egat ive batt ery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(13) Star t engine and inspect for leaks. Care must
be ta ken to observe the fuel system warn ing (Refer to
14 - FUEL SYSTEM - WARNING).
INSTALLATION - TIMING CHAIN TENSIONING
RAIL
NOTE: Carefully clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.
(1) In st all tensionin g ra il on bearing pin
(2) In st all t iming cover (Refer to9-ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).
(3) In st all oil pa n a nd bolts. Tigh ten M6 bolts to
9N·m (80 lbs.in.) an d M8 bolts to 20N·m (15 lbs. ft.).
(4) In st all cylinder head (Refer to9-ENGINE/
CYLINDER H EAD - INSTALLATION).
(5) Reconnect n egat ive batt ery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(6) St art the engine a nd inspect for leaks. Ca re
must be taken to observe t he fu el system warn ing
(Refer to 14 - FUEL SYSTEM - WARNING).
ADJ U ST M EN T S
INSTALLATION - TIMING CHAIN
CAUTION: IT IS ESSENTIAL that the installation pro-
cedure is followed exactly. Failure to do so will
result in severe engine damage.
CAUTION: Cover timing case recesses to prevent
foreign material from entering engine.
VA ENGINE 9 - 77
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