Work Instructions
No. 164 Grp. 051. Disconnect negative battery terminal.
2. Drain coolant from radiator and engine block.
3. Drain engine oil.
4. Remove V-belts, engine fan and radiator.
5. Remove cruise control actuator from engine.
6. Disconnect alternator with bracket, power steering pump, air pump and air conditioning compressor with bracket. Leaving pipes/hoses connected, move respective components aside.
7. Remove both valve covers.
Figure 1 - Camshaft Retaining Wrench:
8. Hold camshaft with special retaining wrench and loosen stretch bolt on each camshaft sprocket (Figure 1).
Figure 2 - Ignition TDC:
9. Set engine at ignition TDC for cylinder no. 1 (Figure 2). Loosen front crankshaft bolt and the six pulley screws with the aid of the engine locking tool inserted in the ring gear (starter removed), and recheck TDC setting.
NOTE: Do not move crankshaft again until the new timing chain has been installed and properly timed.
Figure 3 - Water Pump Removal:
10. Remove ignition distributor.
11. Remove TDC transmitter.
12. Remove crankshaft pulley and vibration damper.
13. For easier realignment of key, match-mark crankshaft and hub (bolt removed) with a chisel. Pull off hub.
14. Remove water pump (Figure 3).
Figure 4 - Radial Seal:
15. Pull out radial seal (Figure 4).
Figure 5 - Oil Pan Removal:
NOTE: For model 107, it is necessary to remove the front axle/carrier to allow removal of oil pan. For R & R of front axle, refer to M.F. - Front axle, Job no. 33-100.
16. Remove oil pan (Figure 5).
Model 107: Remove the complete oil pan assembly.
Model 126: Remove the lower (small) section of oil pan. Disconnect the upper section of oil pan from crankcase and lower it on subframe.
17. Remove oil pump, remove tensioning spring of oil pump chain.
18. Remove timing chain cover by removing the additional M8 cylinder head screws (Figure 6, arrows).
NOTE: Cut a strip of sheet metal (approximately 70 x 80 mm) bend it slightly and place it between the oil pump chain and crankshaft sprocket to prevent the chain from staying engaged in the sprocket teeth.
To pull off the timing chain cover, lift up the tensioning lever of the oil pump chain.
CAUTION! Do not damage the cylinder head gaskets.
19. Match-mark distributor drive sprocket and timing chain with paint dots.
20. Match-mark camshaft sprockets and timing chain with paint dots.
Figure 7 - Camshaft Sprocket and Timing Chain:
21. Match-mark crankshaft sprocket and timing chain with paint dots (two arrows, Figure 7).
Figure 8 - Timing Chain Cover:
22. Loosen the left slide rail (Figure 8, single arrow).
23. Remove chain tensioner.
24. Remove slide rails inside of cylinder heads.
NOTE: Inspect slide rails and replace if required.
25. Remove camshaft sprockets.
26. Remove timing chain from below.
27. Pull off crankshaft, distributor and intermediate drive sprockets.
28. Transfer the paint dots to the new timing chain (by counting links) and sprockets.
29. Clean all sealing surfaces.
Figure 8 - Timing Chain Cover:
30. Replace O-rings (1 and 2) in timing chain cover (Figure 8).
Figure 9 - Alignment on Crankcase:
31. Install new intermediate, distributor drive, and crankshaft sprockets.
32. With piston number one still positioned at ignition TDC, install the new timing chain together with the camshaft sprockets while matching up all paint dots on chain and sprockets. The mark (2) on the distributor drive sprocket and the lug
(3) on the crankcase must also be aligned for proper ignition timing (Figure 9).
33. Tighten the left slide rail.
34. Install slide rails in cylinder heads.
1 Drive key
2 Timing mark on sprocket 3 Lug on crankcase 4 Reference point to crankcase (to form common center line)
35. Coat sealing surface of timing chain cover with sealing compound and install, and at the same time place the oil pump chain (using the curved sheet metal strip) on the crankshaft sprocket.
Install the new radial seal with installation tool.
Figure 10 - Oil Pan/Crankcase Alignment:
36. For the remaining assembly, follow the steps for disassembly in reverse order.
IMPORTANT: The rear mating surface of the oil pan must be aligned to the rear mating surface of the cylinder crankcase (arrows). If the oil pan is not aligned with the crankcase, noise and vibrations may result (Figure 10).
Crank engine over by hand, and then set at ignition TDC for cylinder no. 1. Check timing marks on camshaft sprockets and distributor rotor for proper alignment.
Check tension of V-belts with belt-tension gauge "Krikit" (refer to instructions in S.I. MBT 13/2, Feb. 1980).
V-belts 9.5 mm = 20-25 kg/45-55 lbs. V-belt 12.5 mm = 40-46 kg/90-100 lbs.
Pressure test cooling system.
Run engine and check for leaks.
Check idle speed, ignition timing and engine operating temperature.