after the head gasket and head bolts installed

[240dann]

ok so i just installed my head gasket and head bolts but before i even removed the head to change those, i noticed that after i removed the upper timing chain, the engine was slightly away from tdc. now that i have the head and head bolts installed i have a numerous amount of problems....well...since i did not remove the intake collector, i am having trouble intalling the intake manifold and i am also having trouble intalling the exhaust headers onto the head. along with that, i cant get the idler sprocket and bolt into the head(seems like it wont pull up enough), what do i do timing-wise?? one more question....do i have to remove the intake collector???? does n e one have a number they can give me to call them so i can get a lil help, im just really confused

[240dann]

well i meant the upper half of the intake manifold

[moso]

loosen the plate that holds the lower part of the intake to the block, that should help you get the intake back on. remove the exhaust manifold from the down pipe and attach the manifold to the head before reconnecting the rest of the exhaust. if you have cams in the head remove them. remove the front cover (remember the oil pickup attaches to the front cover inside the oil pan). reset the motor to TDC. install the lower timing chain and idler gear. install the cams in the correct position for TDC (remember the KA motor is an interference motor and you can bend valves by installing the cams with incorrect timing) install the upper chain and cam gears. reinstall front cover and valve cover. start motor.

alternatively you can use this picture and a fair amount of brain power to line the timing chain up properly without removing the front cover. but do this at your own risk (duh!)