PART A - Engine, Engine Management and Turbocharger

1.2 Repair Informations

Further important Repair Notes

The crankshaft V-belt pulley, the thrust washer and the sprocket gear can be pulled off the crankshaft by hand. If the sprocket gear has a tight fit then special tool 21-028 A should be used.

When fitting the sprocket gear the tapered side of the gear should face the camshaft. The V-belt pul*ley should be fitted with its teeth closest to the engine.

The thread of the fastening bolt for the auxiliary shaft gear is plastic coated. When reinstalling always use a new bolt.

The flywheel is balanced together with the crankshaft.

The position of the flywheel to the crankshaft is fixed through unequal spacings between bolt holes i.e. the space "A" between two holes is smaller than between the others .

The installer for the crankshaft rear oil seal is from the tool set for the standard OHC engine. However, the tool has two additional fastening holes to suit the revised bolt hole circle.

1 = V-belt pulley with teeth
2 = Thrust washer
3 = Crankshaft sprocket gear
4 = Fastening bolt-auxiliary shaft gear.
Bolt thread is plastic coated.

Flywheel fastening to crankshaft
A = Reduced spacing
1 = Special tool with two additional fastening holes

Crankshaft bearing clearance should be measured using "Plastigage" as on the standard OHC engine.
• The main bearing caps are marked with an arrow which should point to the front of the engine.

• The rear main bearing cap is cham*fered on both sides to ensure cor*rect seating on the cylinder block. When installing the bearing cap, the chamfered edge should be coated with sealer (Loctite 518). Make sure the sealer is not applied to the flat contact area.

Rear main bearing cap

Sealer to be applied only to the chamfered edge.

Crankshaft endfloat is controlled by thrust half washers. Their respective position must be marked when removing.

The connecting rod big ends and bearing caps are numbered. These numbers should be noted before removing the bearing caps and the caps should always be installed in their original posi*tion.

When installing the pistons to the connecting rods the arrow on the piston crown must point to the front of the engine. The bearing retainer groove in the connecting rod should point to the auxiliary shaft.

Before installing the oil pump, fit the oil pump driveshaft. The longer end of the shaft should point to the distributor (see illustration).

Fit oil pan gasket as follows:

Coat sealing wedges with sealer (Loctite 518, see illustration). Insert them into the groove of the rear main bearing cap and press them fully home.

Apply sealer to the ends of the front rubber seal and the cork gasket and install. Slide the ends of the cork gasket under the ends of the rubber gasket.

Coat the threads of the oil pan fastening bolts with Loctite 270 and tighten them in three stages to the specified torque (see technical data).

If the distributor was removed, installation should proceed as follows:

- Hold distributor so that the spring clip points to the engine and that the distributor rotor points away from the engine (see illustration).

- When inserting the distributor the rotor will turn to its correct position and point to the marking for cylinder No.1
Note: When installing the distribu*tor, the crankshaft, the camshafts and the auxiliary shaft must all be in TDC position.

Oil pump driveshaft

Coat sealing wedges with sealer

Position of the distributor rotor when installing the distributor
1 = Marking cylinder No.1