Part Three
Fit The Timing Cover And Crankshaft Pulley
Timing Cover Gasket & Bolts:
1. Place a new timing cover joint washer in position and fit the timing cover locating it on the two dowels,
2. Clean the threads of the timing cover securing bolts, then coat them with Thread Lubricant-Sealant Loctite(r) 572.
3. Fit and evenly tighten the timing cover bolts to 24-30 Nm (18-22 ft lb).
4. Fit the crankshaft pulley and tighten the retaining bolt to 257-285 Nm (190-210 ft lb).
5. Fit timing pointer.
Fit The Water Pump
Water Pump:
1. Lightly grease a new joint washer and place it in position on the timing cover.
2. Clean the threads of the four long bolts and coat them with Loctite(r) 572 thread lubricant sealant. Locate the water pump in position.
3. Locate the alternator adjusting link on the water pump.
4. Leave the alternator adjusting link loose and tighten the remaining water pump housing bolts evenly to 24-30 Nm (18-22 ft lb).
Fit The Oil pan
1. Remove any traces of previous sealant from the oil pan and cylinder block joint faces.
Oil Pan Sealing:
2. Apply a 2 mm (0.08 in) wide bead of Hylosil 102 (Locktite 598 Black) to the joint face of the oil pan as shown.
3. Place the oil pan in position, fit the oil pan bolts and evenly tighten the bolts to:
Pan bolts except rear 7-11 Nm (5-8 ft lb)
Rear pan bolts 17-20 Nm (13-15 ft lb)
4. Allow the vehicle to stand for a period of 30 minutes to ensure that the Hylosil is cured. Failure to do so could possibly result in repeating the oil pan fitting operation.
Engine Thermostat & Components:
Fit The Thermostat
1. Fit the thermostat with the jiggle pin at the twelve o'clock position.
2. Position the gasket and fit the water outlet.
3. Fit the bolts and tighten to 24-30 Nm (18-22 ft lb).
Fit The Distributor
1. Turn the crankshaft to bring number one piston to 6° BTDC on the compression stroke (both valves closed number one cylinder).
2. Turn distributor drive until rotor arm is approximately 30° counter-clockwise from number one spark plug lead position on cap.
Distributor/Oil Pump Common Shaft:
3. Turn the oil pump and distributor common drive shaft so that the tongue is in the approximate position as illustrated.
Distributor:
4. Fit the distributor to the engine and check that the center line of the rotor arm is now in line with number one spark plug lead position in the distributor cap. Reposition distributor if necessary. The vacuum capsule should be at approximately 90° to the camshaft.
5. If distributor does not seat correctly in front cover, oil pump drive is not engaged. In this event, remove distributor, reset oil pump drive tongue as necessary, and repeat operation.
6. Fit the clamp and nut leaving both loose at this stage.
7. Rotate the distributor until the peak on the pick-up lines up with a peak on the reluctor ring. The rotor arm may be removed to afford a better view.
CAUTION: On no account must the engine be started before this operation is carried out.
8. Secure the distributor in this position by tightening the clamp nut.
Ignition Cable Sequence:
9. Fit the distributor cap and spark plugs and connect the H.T. leads.
NOTE: The above distributor setting is to enable the engine to he run so that the correct setting can be achieved once the engine is refitted to the vehicle.
Fit Rocker Covers
1. Remove all traces of old gasket and sealant from the covers and cylinder heads.
2. Clean and dry the gasket mounting surface, using Bostik cleaner 6001.
Valve Cover Gasket:
3. Apply Bostik 1775 impact adhesive to the seal face and the gasket, using a brush to ensure an even film. Allow the adhesive to become touch-dry, after approximately fifteen minutes.
NOTE: The gasket fits one way round only and must be fitted accurately first time; any subsequent movement would destroy the bond.
4. Place one end of the gasket into the cover recess with the edge firmly against the recess wall: at the same time hold the remainder of the gasket clear; then work around the cover, pressing the gasket into place ensuring that the outer edge firmly contacts the recess wall.
5. Allow the cover to stand for thirty minutes before fitting it to the cylinder heads.
6. Secure the rocker covers to the cylinder heads with the four screws. Short screws inboard, long screws outboard.
Fit Engine Oil Filter
Oil Filter:
1. Clean the oil pump/oil cooler adaptor mating face.
2. Coat the sealing ring of the new filter with clean engine oil.
3. Fill the filter with new oil as far as possible, noting the angle at which the filter is to be fitted.
4. Screw on the filter until the sealing ring touches the oil pump/oil cooler mating face, then tighten it a further half turn by hand only. Do not overtighten.
5. Refill the engine with the specified grade and quantity of oil.
Fit Exhaust Manifold
1. Ensure that the mating surfaces of the cylinder head and exhaust manifold are clean, fit new gaskets to the exhaust manifold and coat the threads of each bolt with anti-seize compound.
Exhaust Manifold Bolts:
2. Place the manifold in position on the cylinder head and fit new lockplates, securing bolts, and plain washers. The plain washers are fitted between the manifold and lockplates. Evenly tighten the manifold bolts to 19-22 Nm (14-16 ft lb) and bend over the lock tabs.