TIMING CHAIN AND GEARS

Distributor - remove

1. Remove distributor cap.
2. Rotate crankshaft until centre line of rotor arm is aligned with No. 1 spark plug segment in distributor cap and No. 1 piston is at TDC.
3. Scribe an alignment mark between distributor body and clamp.
4. Remove nut securing distributor clamp.
5. Remove distributor.
6. Remove clamp.
7. Remove and discard ’O’ ring from distributor.

Sump - remove

1. Remove dipstick.
2. Remove screw securing dipstick tube to LH rocker cover.
3. Remove 16 bolts securing sump to cylinder block.

NOTE: Engine numbers with suffix B, 17 bolts are used to secure sump to cylinder block.

4. Carefully release sump from cylinder block.

Take care not to damage sealing faces of cylinder block and sump.

5. Remove sump.

Timing cover - remove - Engine numbers without suffix B

1. Remove crankshaft pulley bolt and collect spacer washer.
2. Remove crankshaft pulley.
3. Remove bolts and nut securing timing cover to cylinder block.
4. Release and remove timing cover.
5. Remove and discard gasket.
6. Remove and discard oil seal from timing cover.

 

Timing cover - remove - Engine numbers with suffix B

NOTE: Timing cover, oil pump and oil pressure relief valve are only supplied as an assembly.

1. Using assistance, restrain flywheel and remove crankshaft pulley bolt; collect spacer washer.
2. Remove crankshaft pulley.

3. Noting their fitted position, remove bolts securing timing cover to cylinder block; remove cover.

 

 

NOTE: Dowel located.

4. Remove oil pump drive gear.
5. Remove and discard gasket.
6. Remove and discard oil seal from timing cover.

 

 

 

 

 

 

 

 

 

 

 

Timing gears - remove

1. Restrain camshaft gear and remove bolt securing gear, collect washer.
2. Remove distributor drive gear and spacer.
3. Remove timing chain and gears as an assembly.
4. Collect Woodruff keys from camshaft and crankshaft.

 

Timing gears - inspection

1. Thoroughly clean all components.
2. Inspect distributor drive gear for wear.
3. Inspect timing chain links and pins for wear.
4. Inspect timing chain sprockets for wear. Renew parts as necessary.

 

 

 

 

 

Timing gears - refit

1. Clean gear locations on camshaft and crankshaft, fit Woodruff keys.
2. Check camshaft Woodruff key is fully engaged in keyway.

Note: Space between Woodruff key and keyway acts as an oil feed. It is therefore most important that key is properly seated and parallel to axis of camshaft.Overall dimension ’A’ must not exceed 30.15 mm.

3. Temporarily fit crankshaft gear, and if necessary turn crankshaft to bring timing mark on gear to the twelve o’clock position, remove gear.
4. Temporarily fit camshaft gear with marking ’F’ facing forwards.
5. Turn camshaft until mark on camshaft sprocket is at the six o’clock position, remove gear without moving camshaft.

6. Position timing gears on work surface with timing marks upwards and aligned.
7. Fit timing chain around gears, keeping timing marks aligned.
8. Fit gear and chain assembly.

 

NOTE: Timing marks and ’F’ mark on camshaft gear must be facing forwards.

 

9. Fit spacer to camshaft with flange facing forwards.
10. Fit distributor drive gear to camshaft with grooved face towards camshaft gear.
11. Fit camshaft gear bolt and washer, restrain camshaft gear and tighten bolt to correct torque.

 

 

Timing cover - refit - Engine numbers without suffix B

1. Clean sealant from threads of cover bolts.
2. Clean all traces of old gasket material from timing cover and mating face of cylinder block.

Note: Use a plastic scraper.

3. Use a lint free cloth and thoroughly clean oil seal location in timing cover.
4. Lubricate new oil seal sealing surfaces with engine oil.
5. Locate seal to timing cover and press seal in squarely until flush with front face of timing cover.
6. Position new gasket to cylinder block.
7. Coat threads of timing cover bolts with Loctite 242 sealant.
8. Fit timing cover, fit bolts and nut and tighten to correct torque.
9. Fit crankshaft pulley.
10. Fit spacer washer to pulley bolt, fit bolt and tighten to correct torque.

Timing cover - refit - Engine numbers with suffix B

NOTE: Timing cover, oil pump and oil pressure relief valve are only supplied as an assembly.

1. Clean sealant from threads of timing cover bolts.
2. Clean all traces of gasket material from mating faces of timing cover and cylinder block.

Note: Use a plastic scraper.

3. Clean oil seal location in timing cover.
4. Lubricate oil pump gears and oil seal recesss in timing cover with engine oil.
5. Apply Hylosil jointing compound to new timing cover gasket, position gasket to cylinder block.
6. Position oil pump drive gear in timing cover with groove towards front of timing cover.
7. Locate tool LRT-12-090 on timing cover and oil pump drive gear.
8. Position timing cover to cylinder block and at the same time, rotate tool LRT-12-090 until drive gear keyway is aligned with Woodruff key.
9. Fit timing cover to cylinder block.
10. Smear threads of timing cover bolts with Loctite 242 sealant, fit bolts and tighten progressively to the correct torque.

NOTE: Do not fit coolant pump bolts at this stage.

11. Remove tool LRT-12-090.

12. Lubricate new timing cover oil seal with engine oil.
13. Fit timing cover oil seal using tool LRT-12-089.
14. Fit crankshaft pulley, fit bolt and spacer washer; tighten bolt to correct torque.

 

 

Sump - refit

1. Remove all traces of old sealant from mating faces of cylinder block and sump.
2. Clean mating faces with suitable solvent and apply a 2 mm bead of Hylosil white silicone sealant to sump joint face as shown.
3. Fit sump, taking care not to damage sealant bead.
4. Fit sump bolts and working from the centre outwards, tighten progressively to correct torque.
5. Fit and tighten screw securing dipstick tube to LH rocker cover.
6. Fit dipstick.

Distributor - refit

1. Ensure timing pointer is aligned with 30 mark on crankshaft pulley and No.1 piston is on the compression stroke.
2. Engine numbers without suffix B: Position oil pump drive shaft tongue at the ten to four position.
3. Lubricate a new ’O’ ring with engine oil and fit to distributor.

4. Turn distributor drive until rotor arm is approximately 30° anti-clockwise from No.1 spark plug segment in distributor cap.
5. Insert distributor into timing cover, engage drive gear and push distributor down until ’O’ ring enters bore; position distributor clamp on stud.

6. Engine numbers without suffix B: Locate slotted adaptor to oil pump drive shaft tongue.
7. Check that centre line of rotor arm is aligned with No.1 spark plug segment in distributor cap and reference marks on distributor body and
clamp are aligned; reposition distributor if necessary.
8. Remove rotor arm.
9. Rotate distributor to position pick-up opposite nearest reluctor tooth.
10. Fit distributor clamp nut ensuring that counterbored portion is towards clamp; tighten nut.
11. Fit rotor arm.

CAUTION: This distributor setting is to enable engine to be started. When engine is refitted, ignition timing must be set using electronic equipment.

 

 

 

 

 

OIL COOLER ADAPTER - ENGINE NUMBERS WITHOUT SUFFIX B

Oil cooler adapter - remove

1. Remove oil filter element.
2. Mark position of adapter in relation to oil pump cover.
3. Remove centre screw and withdraw adapter.
4. Remove and discard sealing ring.

Oil cooler adapter - refit

1. Thoroughly clean adapter.
2. Position new sealing ring, fit adapter, ensuring marks previously made line up, fit and tighten centre screw.
3. Lubricate sealing ring of oil filter with engine oil.
4. Screw filter on to filter head until it seats then tighten a further half-turn.