Removal
1. Position piston No.1 at TDC as described in Chapter 3, then remove the distributor together with the extension tube as described in Section 5.
2. Remove the generator.
3. Remove the pickup tube/strainer and remove the oil pump gears as described in Chapter 9.
4. To hold the crankshaft while loosening the pulley bolt, engage high gear and have an assistant fully depress the brake pedal. If the engine has been removed from the vehicle, lock the flywheel using the method shown in Illustration 12.10A.
5. Loosen and remove the pulley mounting bolt and washer (see illustration), then separate the pulley from the crankshaft.
6. Loosen and remove all bolts and screws securing the drive chain cover (see illustration). Move the cover down away from the engine. Remove the gasket - it is subject to replacement.
7. Use a flat-head screwdriver to bend back the tab on the camshaft bolt lock washer. To prevent the camshaft from rotating while loosening the bolt, engage top gear and have an assistant fully depress the brake pedal. Alternatively, the sprocket can be blocked with a tool made from two steel strips (one long, one short) and three bolts and nuts. One bolt and nut form the pivot axis, and the remaining two are screwed into the ends of the fork and inserted into the slots in the sprocket, as shown in Illustration 7.20B.
8. Unscrew the camshaft bolt and remove it together with the lock and concave washers. The lock washer must be discarded; it is subject to replacement. Remove the distributor drive gear from the end of the camshaft, remembering its correct location (see illustrations).
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9. Before removing the drive chain and sprockets, note the position of the timing marks on the sprockets and the Woodruff key slots in the crankshaft and camshaft (see Fig. 2A.4).
10. Simultaneously remove the drive chain and sprockets from the crankshaft and camshaft.
11. Remove the Woodruff key from the slot in the crankshaft, making a note of its location. If the Woodruff key is loose in the camshaft, remove it as well.
12. After removing the keys, remove the gasket, guide spacer washer and outer thrust washer from the end of the crankshaft, remembering the location of the spacer and thrust washers.
Inspection
13. Inspect the teeth on both camshaft and crankshaft sprockets for damage or signs of wear. If there is wear or damage on either sprocket, both sprockets and chain should be replaced as a matched set.
14. Inspect the drive chain links for signs of wear on the rollers. The degree of chain wear can be assessed by seeing how much the chain can be bent laterally. If there is excessive lateral play, the chain should be replaced. Note that as a precaution it is recommended that the chain be replaced, regardless of its condition, every 45,000 km or after an engine overhaul. Although not strictly necessary, it is always worth replacing the chain and sprockets as a matched set.
15. Inspect the remaining components for damage and signs of wear and replace as necessary.
Installation
16. Install the outer thrust washer onto the end of the crankshaft, making sure that its oil grooves are facing outwards, then align the locking tab of the washer with the recess in the bottom of the cover, and install the washer in its working position. Install the guide washer on the thrust washer, with the beveled edge inwards, and finally install the gasket (see illustrations).
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17. Install the woodruff key into the slot in the crankshaft, with the tapered end inward (see illustration). Also install the woodruff key into the slot in the camshaft if it was removed.
18. Referring to Fig. 2A.4, install the drive chain onto the camshaft and crankshaft sprockets. The dot on the camshaft sprocket should align with the twelfth roller of the main drive chain, counting from the roller that aligns with the dot on the crankshaft sprocket.
19. Ensure that the Woodruff keys in the crankshaft and camshaft are positioned as shown in Fig. 2A.4. Install the chain and sprocket assembly into place, ensuring that the timing marks on the sprockets are facing outward. Finally, recheck the position of the timing points (see illustrations).
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20. Position the distributor pinion gear on the end of the camshaft, keeping in mind that its flange should face inward, then install the concave washer with its concave side facing outward. Install a new lock washer, aligning its location with the slot in the pinion gear, and install the camshaft bolt. Tighten the bolt to the specified torque Specifications. Secure the bolt by bending the edge of the lock washer up (see illustrations).
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21. Remove any remaining oil and gaskets from the mating surfaces of the timing chain cover and block. Inspect the crankshaft oil seal in the cover for damage or contamination, and replace it if necessary as described in Chapter 11.
22. Install the new gasket into place in the cylinder block, securing it in position with a small amount of grease. Carefully position the timing chain cover into position. Insert the cover mounting bolts and screws, and (where possible) tighten them with the specified tightening force Specificationsusing a sharp knife, carefully trim off the edges of the gasket that protrude outward from the surface underneath the tray (see illustrations).
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23. Align the crankshaft pulley groove with the woodruff key, and carefully install the pulley onto the crankshaft, being careful not to damage the sealing lip of the oil seal. Install the mounting bolt with the washer, and tighten it by hand.
24. Make sure that the locking tabs of the inner and outer thrust washers are inserted into the slots on the right main bearing cap and that the thrust washers are correctly positioned. Tighten the crankshaft pulley bolt to the specified torque Specifications. Note that if the thrust washers are not positioned properly, the crankshaft will lock when tightening the bolt and the thrust washers will be damaged. Make sure the crankshaft rotates freely before proceeding (see illustrations).
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25. Install the gears and oil pump pickup tube/strainer, then install the pan as described in Chapter 10.
26. Install the generator as described in Section 12.
27. Install the distributor as described in Section 5.