6
80 Workshop Manual, TSD3450E, Issue 1
2800
To fit
1 Clean thoroughly the contact surfaces of the crankcase and gear case.
2 Fit the two dowels, if they have been removed, and ensure that they protrude from the crankcase by 19,1 +/
- 0,5 mm (0.75 +/- 0.02 in).
3 Ensure that the front surface of the crankcase is clean and fit a new joint to the crankcase.
4 Ensure that the rear face of the gear case is clean and fit the gear case onto the crankcase. Fit the retaining
bolts and tighten to a torque of 50 +/- 10 (37 +/- 7 lbf ft).
5 Check the condition of the shaft for the adjustable idler. If the bearing diameter of the shaft is worn or
damaged, renew the assembly. Apply thread lock compound, 21820 117, to the bolt and five studs, fit the bolt
and nuts and tighten to a torque of 50 +/- 10 (37 +/- 7 lbf ft).
6 Check the condition of the shaft for the main idler. If the bearing diameter of the shaft is worn or damaged,
renew the assembly. Apply thread lock compound, 21820 117, to the bolt and five studs, fit the bolt and nuts
and tighten to a torque of 50 +/- 10 (37 +/- 7 lbf ft).
7 Check the condition of the shaft for the compound idler. Renew the shaft if the bearing diameter is worn or
damaged. Renew the five bolts which retain the shaft. Apply thread lock compound, 21820 117, to the bolts
and tighten to a torque of 50 +/- 10 (37 +/- 7 lbf ft).
8 Fit new ‘O’ ring seals to the camshaft front seal plate. Apply a small amount of engine lubricating oil to the
‘O’ ring seal on the outside of the plate. Fit the seal plate with the face seal against the cylinder head. Insert
the adapter plate and fit the thrust plate. Apply thread lock compound, 21820 117, to the three bolts, fit the
bolts and tighten.
9 Fit the timing gears, Operation 6-2.
10 Fit the sump, Operation 10-3.
11 Fit a new crankshaft front seal and wear sleeve, Operation 5-2.
12 Fit the front engine support, Operation 7-1.
13 Fit the crankshaft vibration damper, Operation 5-4.
14 Fit the coolant pump, Operation 12-13.
15 Fit the camshaft timing sensor to its location behind the top of the gear case and connect the lead.
16 Fit the crankshaft timing sensor to its location behind the bottom of the gear case and connect the lead.
17 Fit the gear case cover, Operation 6-1.
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