Table of contents: Removal - 8-valve engines 🠇 Removal - 16-valve engines 🠇 Refitting - 8-valve engines 🠇 Refitting - 16-valve engines 🠇
Note: This Section describes the removal and refitting of the components concerned as individual operations. If more than one of them is to be removed at the same time, start by removing the timing belt as described in Section 6; remove the actual component as described below, ignoring the preliminary dismantling steps.
Removal - 8-valve engines
1. Disconnect the battery negative terminal (refer to "Disconnecting the battery").
Camshaft sprocket
2. On engines with a three-piece timing belt cover arrangement, remove the centre cover as described in Section 5. On engines with a two-piece cover, remove the lower cover.
3. Position the engine assembly/valve timing holes as described in Section 3, and lock both the camshaft sprocket and flywheel in position. Do not attempt to rotate the engine whilst the tools are in position.
4. With reference to Section 6, loosen the timing belt tensioner pulley retaining nut. Pivot the pulley approximately 60° in a clockwise direction, using a key fitted to the hole in the pulley hub, then retighten the retaining nut. On early engines, an 8 mm square section key will be required, and on later engines with an automatic tensioner, an Allen key will be needed.
5. Disengage the timing belt from the sprocket, and move the belt clear, taking care not to bend or twist it sharply. Remove the locking pin from the camshaft sprocket.
6. Slacken the camshaft sprocket retaining bolt and remove it, along with its washer. Do not attempt to use the sprocket locking pin to prevent the sprocket from rotating whilst the bolt is slackened.
7. With the retaining bolt removed, slide the sprocket off the end of the camshaft. If the locating peg is a loose fit in the rear of the sprocket, remove it for safe-keeping. Examine the camshaft oil seal for signs of oil leakage and, if necessary, renew it as described in Section 8.
Crankshaft sprocket
8. Remove the centre and lower timing belt covers as described in Section 5, then position the engine assembly/valve timing holes as described in Section 3, and lock both the camshaft sprocket and flywheel in position. Do not attempt to rotate the engine whilst the tools are in position.
9. Loosen the timing belt tensioner pulley retaining nut. Rotate the pulley in a clockwise direction, using a suitable square-section key fitted to the hole in the pulley hub, then retighten the retaining nut.
10. To prevent crankshaft rotation whilst the sprocket retaining bolt is slackened, select top gear, and have an assistant apply the brakes firmly. If the engine has been removed from the vehicle, lock the flywheel ring gear, using an arrangement similar to that shown (see illustration). Do not be tempted to use the flywheel locking pin to prevent the crankshaft from rotating; temporarily remove the locking pin from the rear of the flywheel prior to slackening the pulley bolt, then refit it once the bolt has been slackened.
11. Unscrew the retaining bolt and washer, then slide the sprocket off the end of the crankshaft (see illustrations). Refit the locating pin through the timing hole into the rear of the flywheel.
12. If the Woodruff key is a loose fit in the crankshaft, remove it and store it with the sprocket for safe-keeping. If necessary, also slide the flanged spacer off the end of the crankshaft (see illustration). Examine the crankshaft oil seal for signs of oil leakage and, if necessary, renew as described in Section 16.
Tensioner pulley
13. Remove the centre timing belt cover as described in Section 5, then position the engine assembly/valve timing holes as described in Section 3, and lock both the camshaft sprocket and flywheel in position. Do not attempt to rotate the engine whilst the tools are in position.
14. Slacken and remove the timing belt tensioner pulley retaining nut, and slide the pulley off its mounting stud. Examine the mounting stud for signs of damage and, if necessary, renew it.
Removal - 16-valve engines
15. Disconnect the battery negative terminal (refer to "Disconnecting the battery").
Camshaft sprockets
16. Remove the cylinder head cover over the camshaft being worked on as described in Section 4.
17. Remove the timing belt upper cover as described in Section 5, then position the engine assembly/valve timing holes as described in Section 3, and lock the flywheel in position. Do not attempt to rotate the engine whilst the tool is in position.
18. Loosen the timing belt tensioner pulley retaining bolt and pivot the pulley in a clockwise direction, using a suitable square section key fitted to the hole in the pulley hub, then retighten the retaining bolt.
19. Disengage the timing belt from the camshaft sprockets and position it clear, taking care not to bend or twist the belt sharply.
20. Slacken the sprocket hub centre retaining bolt. To prevent the sprocket rotating as the bolt is slackened, hold the camshaft using a suitable spanner engaged with the square section provided (see illustration).
21. Remove the previously slackened hub retaining bolt and withdraw the sprocket and hub from the end of the camshaft. Suitably mark the sprockets "inlet" and/or "exhaust" if both are being removed.
Crankshaft sprocket
22. Remove the timing belt covers as described in Section 5.
23. Position the engine assembly/valve timing holes as described in Section 3, and lock both the camshaft sprocket and flywheel in position. Do not attempt to rotate the engine whilst the tools are in position.
24. Loosen the timing belt tensioner pulley retaining bolt and pivot the pulley in a clockwise direction, using a suitable squaresection key fitted to the hole in the pulley hub, then retighten the retaining bolt.
25. To prevent crankshaft rotation whilst the sprocket retaining bolt is slackened, select top gear, and have an assistant apply the brakes firmly. If the engine has been removed from the vehicle, lock the flywheel ring gear, using an arrangement similar to that shown (see illustration 7.10). Do not be tempted to use the flywheel locking pin to prevent the crankshaft from rotating; temporarily remove the locking pin from the rear of the flywheel prior to slackening the pulley bolt, then refit it once the bolt has been slackened.
26. Unscrew the retaining bolt and washer, then slide the sprocket off the end of the crankshaft. Refit the locating pin to the rear of the timing hole in the rear of the flywheel.
27. If the Woodruff key is a loose fit in the crankshaft, remove it and store it with the sprocket for safe-keeping. If necessary, also slide the flanged spacer off the end of the crankshaft. Examine the crankshaft oil seal for signs of oil leakage and, if necessary, renew as described in Section 16.
Tensioner and idler pulleys
28. Remove the timing belt covers as described in Section 5.
29. Position the engine assembly/valve timing holes as described in Section 3, and lock both the camshaft sprocket and flywheel in position. Do not attempt to rotate the engine whilst the tools are in position.
30. Loosen the timing belt tensioner pulley retaining bolt and pivot the pulley in a clockwise direction, using a suitable squaresection key fitted to the hole in the pulley hub, then retighten the retaining bolt.
31. Check that the camshaft sprocket locking pins are still in position, then disengage the timing belt from the camshaft sprockets and position it clear, taking care not to bend or twist the belt sharply.
32. Undo the tensioner and idler pulley retaining bolts and remove them from the engine.
Inspection
33. Clean the sprockets thoroughly, and renew any that show signs of wear, damage or cracks.
34. Clean the tensioner (and idler) assembly, but do not use any strong solvent which may enter the pulley bearing. Check that the pulley rotates freely about its hub, with no sign of stiffness or free play. Renew the tensioner/idler pulley if there is any doubt about its condition, or if there are any obvious signs of wear or damage.
Refitting - 8-valve engines
Camshaft sprocket
35. Refit the locating peg (where removed) to the rear of the sprocket, then locate the sprocket on the end of the camshaft. Ensure that the locating peg is correctly engaged with the cut-out in the end of the camshaft.
36. Refit the sprocket retaining bolt and washer. Tighten the bolt to the specified torque, whilst retaining the sprocket with the tool used on removal.
37. Realign the timing hole in the camshaft sprocket (see Section 3) with the corresponding hole in the cylinder head, and refit the locking pin.
38. Refit the timing belt to the camshaft sprocket. Ensure that the "front run" of the belt is taut - ie, ensure that any slack is on the tensioner pulley side of the belt. Do not twist the belt sharply while refitting it, and ensure that the belt teeth are seated centrally in the sprockets.
39. Loosen the tensioner pulley retaining nut. Rotate the pulley anti-clockwise to remove all free play from the timing belt, then retighten the nut.
40. Tension the belt as described under the relevant sub-heading of Section 6.
41. Refit the timing belt covers as described in Section 5.
Crankshaft sprocket
42. Where removed, locate the Woodruff key in the crankshaft end, then slide on the flanged spacer, aligning its slot with the Woodruff key.
43. Align the crankshaft sprocket slot with the Woodruff key, and slide it onto the end of the crankshaft.
44. Temporarily remove the locking pin from the rear of the flywheel, then refit the crankshaft sprocket retaining bolt and washer. Tighten the bolt to the specified torque, whilst preventing crankshaft rotation using the method employed on removal. Refit the locking pin to the rear of the flywheel.
45. Relocate the timing belt on the crankshaft sprocket. Ensure that the "front run" of the belt is taut - ie, ensure that any slack is on the tensioner pulley side of the belt Do not twist the belt sharply while refitting it, and ensure that the belt teeth are seated centrally in the sprockets.
46. Loosen the tensioner pulley retaining nut. Rotate the pulley anti-clockwise to remove all free play from the timing belt, then retighten the nut.
47. Tension the belt as described under the relevant sub-heading of Section 6.
48. Refit the timing belt covers as described in Section 5.
Tensioner pulley
49. Refit the tensioner pulley to its mounting stud, and fit the retaining nut.
50. Ensure that the "front run" of the belt is taut - ie, ensure that any slack is on the tensioner pulley side of the belt. Check that the belt is centrally located on all its sprockets. Rotate the tensioner pulley anticlockwise to remove all free play from the timing belt, then tighten the pulley retaining nut securely.
51. Tension the belt as described under the relevant sub-heading of Section 6.
52. Refit the timing belt covers as described in Section 5.
Refitting - 16-valve engines
Camshaft sprockets
53. Engage the sprocket hub with the camshaft, ensure that the correct sprocket is fitted to the relevant camshaft if both were removed.
54. Refit the sprocket retaining bolt and washer, and tighten it to the specified torque. Prevent rotation of the camshaft as the bolt is tightened using the spanner on the camshaft square section provided.
55. Turn the sprocket so that the locking pin can be engaged.
56. Relocate and tension the timing belt as described in Section 6.
Crankshaft sprocket
57. Refit the Woodruff key to its slot in the crankshaft end.
58. Slide on the crankshaft sprocket, aligning its slot with the Woodruff key.
59. Relocate and tension the timing belt as described in Section 6.
Tensioner and idler pulleys
60. Refit the tensioner and idler pulleys and secure with the retaining bolts.
61. Relocate and tension the timing belt as described in Section 6.