There is a trick to installing the timing chain not mentioned in the workshop manual.
- Start by removing the tensioner completely from the front cover. Be sure to remove the spring so it doesn't fall on the ground when you have your back turned.
- Install the sprockets just enough to turn the cams.
- Ensure the crank is nowhere near TDC and rotate cams until timing marks are slightly below front cover.
- Remove sprockets.
- While ensuring the chain does not foul on anything, rotate crank (same direction it goes in) to roughly 30 deg before TDC.
- Ensure chain is not engaged on crankshaft sprocket.
- Install exhaust sprocket. Snug bolt but do not tighten.
- Rotate crankshaft to TDC and engage chain at crankshaft, check alignment of exhaust sprocket.
- Install intake sprocket.
- Install tensioner, adjust for 0.5 in. drop of chain between sprockets.
- Rotate crankshaft a couple of turns and come up slowly to TCD. Ensure sprocket marks line up with top edge of front cover.
- Torque sprocket bolts to 26 ft. lbs.