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It's very easy to do when you do the following: Make sure crank is TDC (key cutout should be at 12 o'clock position) Balance Chain - TWO chain links are same color, 1 is different (colors vary depending on chain)
Intake balancer sprocket mark/arrow should be at 12 o'clock poison, Exhaust sprocket mark should be at 6 o" clock position
Line up colored link (1 different) with mark on intake balancer sprocket
Line up other colored link (one of the two similar colors) with mark on exhaust balancer sprocket
Wrap chain around water pump sprocket
Line up last colored link (again one of the two similar colors) with mark on crank sprocket (around 6 o'clock position)
Install Balance Shaft Chain guides - easiest to install top guide, right side, then left side. CHAIN WILL FIT IN CENTER GUIDE GROOVES!
Install Balance Shaft tensioner. Confirm all links line up with sprocket marks BEFORE REMOVING PIN FROM TENSIONER. If lined up, remove pin (no boom)
Install oil nozzle
Install smaller crank sprocket to crank shaft.
Cam Chain - Again TWO links are same color, 1 is different (colors vary depending on chain)
Line up colored link (1 that is different) with diamond mark intake sprocket, and fish chain through cam drive chest (through BOTH sides of casting bosses), and get the cain over the crank shaft nose.
Install cam sprocket. Since our engines are VVT, there's a pin that is inserted into the end of the cams (also known as indexing). We made a mark on the outside of the cam sprocket to make it easier to line it up with the cams. Once fully indexed (should do so smoothly), install new sprocket bolt (finger tight).
Install left side tensioner guide
Line up colored link (one of the two similar colors) with diamond mark on exhaust sprocket. Index sprocket onto exhaust cam - you might need to rotate the intake cam counter-clockwise (just a SMALL amount) with a 24mm wrench to get the exhaust sprocket to index. This is easier with a friend!
Confirm that colored link (one of the two similar colors) aligns with crank sprocket mark around 5 o'clock position
Install left hand guide, and install the upper bolt access plug (use thread sealant on threads)
Install primary chain tensioner, and activate by compression about 1/8" to the top of the pivoting tensioner guide (see youtube vid linked above around 13:15 mark).
Install upper guide
Midway through cam chain install
Although the video advises not to rotate the crank (since color marks will not align back up with timing marks), we did it anyway a few rotations just to make sure nothing is hitting. Nothing hit, so it was time to get the engine back on the front cradle, and start putting it back together. We installed:
Re-install water pump cover and lines
New front cover and gasket
Re-install Opel Injectors/rail
re-install LT1 fuel pump
re-install TTR manifold with Performance Autowerks heat spacer (reduces heat transfer between engine and manifold)
Install Performance Autowerks heat spacer between throttle body and manifold
Install new LDK valve cover that I got powder coated black
