the sprockets back into mesh with the chain
so that the timing dots, although further apart
are still adjacent to each other (see
illustrations).
23 Check that the engine is still positioned at
TDC for No 1 piston (Section 3). In this
position the crankshaft Woodruff key should
be at the 12 o’clock position and the camshaft
Woodruff key should be at the 2 o’clock
position.
24 Fit the timing chain and sprocket assembly
onto the camshaft and crankshaft, keeping the
timing marks adjacent. If the camshaft and
crankshaft have been positioned accurately, it
will be found that the keyways on the
sprockets will match the position of the keys,
although it may be necessary to rotate the
camshaft a fraction to ensure accurate lining-
up of the camshaft sprocket.
25 Press the sprockets into position on the
crankshaft and camshaft as far as they will go.
Note: If new sprockets are being fitted they
should be checked for alignment before being
finally fitted to the engine. Place the sprockets
in position without the timing chain and place
the straight edge of a steel ruler from the side
of the camshaft gear teeth to the crankshaft
sprocket and measure the gap between the
steel rule and the sprocket (see illustration).
If a gap exists a suitable number of packing
washers must be placed on the crankshaft
nose to bring the crankshaft sprocket onto the
same plane as the camshaft sprocket.
26 Fit the oil thrower to the crankshaft with
the concave side forward.
27 Fit the locking washer to the camshaft
sprocket with its locating tab in the sprocket
keyway.
28 Screw on the camshaft sprocket retaining
nut and tighten securely.
29 Bend up the locking tab of the locking
washer to hold the camshaft retaining nut
securely.
30 On engines with a separate timing chain
tensioner, refit the tensioner and retaining bolt
ensuring that there is a washer on each side
of the tensioner arm.
31 Generously oil the chain and sprockets.
32 Apply a bead of RTV sealant to each side
of the new gasket, on the lower half of the
gasket only. Place the gasket on the timing
cover then quickly position the timing cover
on the engine.
33 Screw in the timing cover retaining bolts
with the flat washer next to the cover flange
and under the spring washer. Tighten the
respective bolts to the specified torque.
34 Fit the crankshaft pulley to the nose of the
crankshaft, ensuring that the keyway engages
with the Woodruff key.
35 Fit the crankshaft retaining bolt locking
washer and screw in the crankshaft pulley
retaining bolt. Tighten to the specified torque
while using the same method to prevent
crankshaft rotation as was used for removal.
36 Where removed, refit the radiator lower
mounting bracket and secure the bracket to
the engine/transmission and subframe.
Remove the jack under the engine.
37 Refit the fan to the water pump spindle
and secure with the four bolts securely
tightened.
38 Refit the radiator as described in Chapter 3
and the fan belt as described in Chapter 1.
39 Refit the components removed when
setting the engine at TDC, then reconnect the
battery.
6 Rocker shaft assembly -
removal, inspection and
refitting
3
General information
1 The rocker shaft assembly is secured to the
top of the cylinder head by the cylinder head
inner studs and nuts. Although in theory it is
possible to undo the head nuts and remove the
rocker shaft assembly without removing the
head, in practice, this is not recommended.
2A•6 Engine in-car repair procedures
5.22a Timing dots on sprockets aligned
with chain fitted
5.22b Timing mark locations relative to keyways
1 Timing dot on camshaft sprocket 2 Timing dot on crankshaft sprocket
5.25 Timing sprocket alignment -
double row type shown
1 Camshaft sprocket
2 Woodruff key
3 Straight edge
4 Crankshaft
sprocket
5 Inset: shims
Note that with single row type, it is
important to align the sides of the teeth and
not the raised hub of the sprocket
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