Timing Cover: Service and Repair

REMOVE

- Remove the engine/transmission assembly.
- Separate engine and transmission and fit the engine to a suitable stand.
- Remove the fan/clutch unit.
- Remove the camshaft covers.
- Disconnect the thermostat housing to crossover pipe hose.
- Remove the bolts securing the thermostat housing, auxiliary air valve and lifting eyes to the cylinder head. Reposition the housing clear of the cylinder head.
- Remove and discard the gaskets.
- Loosen the air pump/auxiliary pulley adjusting bolt lock nuts.
- Remove the adjusting bolt bracket from the cylinder head.
- Remove the compressor securing bolts, disengage the drive belt from the pulley and remove the compressor.

Camshaft Timing Gauge:

- Rotate the engine and fit Timing Gauge C 3993 to the right hand camshaft recess.
- Remove the rubber grommet from the front of the timing cover.

Timing Chain Tensioner Retracting Tool:

- Insert JD 50 (Release Tool) through the timing cover and release the locking catch on the timing chain tensioner.
- Fit JD 50 (Chain Tension Retainer) and retract the timing chain tensioner until the locking catch is engaged.
- Remove Service Tools JD 50.
- Remove Timing Gauge C 3993.
- Note the two uppermost sprocket retaining bolts on both camshafts and rotate the engine until the two LOWER sprocket retaining bolts become accessible on both camshafts.
- Push back the lock tabs and remove the four accessible retaining bolts.
- Rotate the engine to the camshaft removal position and refit Timing Gauge C 3993 to the RH camshaft.

Sprocket Bolts And Retaining Tool:

- Remove the remaining two LH camshaft sprocket bolts and fit JD 40.
- Remove the remaining two RH camshaft sprocket bolts and fit JD 40.

CAUTION: Do not rotate the engine while the camshaft is disconnected.

Cylinder Head Oil Pipe Banjo Bolts:

- Disconnect the camshaft oil feed pipe assembly. Discard the sealing washers.
- Remove the three LH cylinder head/timing cover securing nuts and washers. Reposition the cable clips away from the studs.
- Progressively loosen the LH cylinder head nuts, commencing at the outer edges and working towards the center of the head.
- Remove the securing nuts and washers and remove the LH cylinder head assembly.

Cylinder Liner Retainers:

- After the cylinder head has been removed, JD 41 cylinder liner retainers, or equivalent, must be fitted to the engine. Failure to carry out this operation will result in the liner seal being broken, causing water leakage into the oil pan.
- Repeat the procedure to remove the RH cylinder head. Fit JD 41 cylinder liner retainers.

Note: Always support the cylinder heads on blocks of wood. This will prevent damage to the valves which, when open, protrude below the cylinder head face.

- Remove the oil pan plug and drain the oil into a suitable container.
- Remove the oil pan securing bolts and remove the oil pan.

Fig. 10 Suction Elbow And Sandwich Plate Removal:

- Remove the suction elbow, remove the sandwich plate securing bolts and remove the plate, noting the different stud lengths.
- Remove the alternator.
- Remove the P/S pump.
- Remove the emission control air pump pulley and remove the air pump.
- Remove the air conditioning compressor and bracket.
- Remove the water pump.
- Remove the crankshaft cone and Woodruff key.
- Remove the alternator and air pump mounting bracket.

Timing Cover:

- Remove the timing cover securing bolts and serrated washers, noting the different bolt lengths and dowel locations.
- Remove the timing cover. Discard the gasket and oil seal.

REFIT

- Clean all components thoroughly and examine all component parts for wear and damage.
- Replace worn or damaged components as necessary.
- Be sure mating faces are clean and grease-free.
- Immerse the new oil seal in clean engine oil. Press the oil seal into the timing cover.
- Refit the timing cover to the engine, using a new gasket. Be sure the oil seal is not damaged or distorted.
- Fit and tighten the securing bolts, Refit the air pump and alternator mounting bracket.
- Refit the crankshaft cone.
- Refit the water pump.
- Refit the air conditioning compressor and bracket.
- Refit the emission control air pump pulley and remove the air pump.
- Refit the P/S pump.
- Refit the alternator.
- Refit the sandwich plate assembly.
- Refit the oil pan.
- Be sure that the cylinder heads and block mating faces are clean and all oil and water galleries are not obstructed.
- Fit a new gasket to the LH cylinder block, ensuring that the side marked 'TOP' is uppermost.
- Fit the LH cylinder head.
- Fit the cylinder head securing nuts and washers.

Fig. 5 Cylinder Head Bolt Tightening Sequence:

- Tighten the cylinder head to block securing nuts in the correct sequence to torque figures given below.
- Tighten the cylinder head to timing cover securing nuts to the torque figures given in DATA. Repeat the procedure to refit the RH cylinder head.
- Fit Timing Gauge C 3993 to the RH camshaft.
- Remove JD 40 from the LH camshaft sprocket and check the alignment of the sprocket retaining bolt holes.

Cam Gear Components:

NOTE: If the camshaft and sprocket holes are not in alignment, remove the coupling to sprocket retaining circlip and disengage the coupling from the splines, at the same time pressing the sprocket on to the camshaft shoulder.

- Rotate the coupling until alignment is obtained.
- Engage the splines and fit two securing bolts using a new tab washer.
- Lock over the tabs and refit the retaining circlip.
- Repeat the procedure for the RH camshaft sprocket.
- Remove Timing Gauge C 3993.
- Rotate the engine until the remaining sprocket securing bolts/tab washers can be fitted.
- Tighten the bolts and lock over the tabs.
- Refit the camshaft oil feed pipe assembly, using new sealing washers.
- Refit the transmission dipstick tube.
- Fit JD 50 (Chain Tension Retainer) and raise the timing chain tensioner slightly.
- Insert JD 50 (Release Tool) through the timing cover and release the locking catch, allowing the tensioner to expand.
- Remove both Service Tools.
- Apply 598 Black Loctite sealant or equivalent, to new rubber grommet and fit to the front of the timing cover.
- Refit the compressor and drive belt.
- Refit the air pump auxiliary pulley adjusting bolt bracket. Adjust the pulley and tighten the locknuts.
- Adjust the valve clearances.
- Refit the fan/clutch assembly.
- Refit the thermostat housing air valve assembly, using new gaskets.
- Apply 598 Black Loctite sealant or equivalent, to the radial edge of a new half moon seal and fit the seal to the camshaft carrier.
- Fit the cam cover using a new gasket.
- Fit and torque tighten the securing nuts/bolts.
- Refit the induction manifolds.
- Refit the engine/transmission assembly.
- Evacuate and charge the air conditioning system
- Refit the air cleaner.
- Reconnect the battery.
- Refit the oil pan plug, using a new washer and refill the engine with clean oil.
- Refill the cooling system.

TORQUE FIGURES
Air pump adjuster bolt/lock nut 20-27 Nm
Banjo connector bolts 12-14 Nm
Camshaft sprocket to camshaft 23-27 Nm
Camshaft cover 11 Nm
Cylinder head to block (9/76"AF) 36 Nm
Cylinder head to block (5/8"AF) 70 Nm
EGR valve to throttle housing 9.5-12 Nm
Elbow to inlet manifold 12.2 Nm
Engine mounting bracket to crossmember 19-24 Nm
Engine mounting tie bolts 34-40 Nm
Exhaust down pipe to manifold 30-35 Nm
Fan/clutch to water pump 23-27 Nm
Fuel pipe unions (5/76" dia.) 8.5-9.5 Nm
Fuel pipe unions (3/8" dia.) 11-13.5 Nm
Fuel pipe unions (1/2" dia.) 27-33 Nm
Heat shield to manifold 23-27 Nm
Hose clips 2.5 Nm
Inlet manifold to cylinder head (nuts) 23-27 Nm
Inlet manifold to cylinder head (bolts) 23-27 Nm
Oil cooler pipes 54-6O Nm
PAS pump to mounting bracket 50 Nm
Rear engine mounting peg 34-40 Nm
Rear engine mounting rubbers 36-43 Nm
Rear engine mounting to body (5/76 bolt) 19-24 Nm
Rear engine mounting to body (3/8 bolt) 36-43 Nm
Silencer to A/C compressor union 34 Nm
Oil pan drain plug 15-18 Nm
Oil pan set screws 16-20 Nm
Thermostat housing to cylinder head 23-27 Nm