REMOVAL & INSTALLATION
1597cc Engine W/O Silent Shaft 1597cc Engine W/Silent Shaft
- Disconnect the negative battery cable. On rear wheel drive cars, drain the coolant, disconnect the radiator hoses, remove the radiator.
- Remove the alternator and accessory belts. Remove the belt cover.
- Rotate the crankshaft to bring No. 1 piston to TDC on the compression stroke. Align the notch on the crankshaft pulley with the T mark on the timing indicator scale and the timing mark on the upper under cover of the timing belt with the mark on the camshaft sprocket.
- Remove the crankshaft pulley and bolt.
- On rear wheel drive cars, remove the fan blades.
- Remove the timing belt covers, upper front and lower front.
- Remove the crankshaft sprocket bolt.
- Loosen the tensioner mounting nut and bolt. Move the tensioner away from the belt and retighten the nut to keep the tensioner in the off position. Remove the tensioner.
If the belt is all that needs servicing, proceed to the Installation information.
- Remove the camshaft sprocket, crankshaft sprocket, flange, and tensioner.
- Silent shaft engines:
- Loosen the counterbalance shaft sprocket mounting bolt.
- Remove the belt tensioner and remove the timing belt.
- Remove the crankshaft sprocket (inner) and counterbalance shaft sprocket.
- Remove the upper and lower under timing belt covers.
- The water pump or cylinder head may be removed at this point, depending upon the type of repairs needed.
- Raise the front of the car and support it safely. Remove any interfering splash pans.
- Drain the oil pan and remove the pan from the block.
- Remove the oil pump sprocket and cover.
On the silent shaft engines, remove the plug at the bottom of the left side of the cylinder block and insert a screwdriver to keep the left counter balance shaft in position while removing the sprocket nut.
- Remove the front cover and oil pump as a unit, with the left counter shaft attached, if equipped.
- Remove the oil pump gear and left counterbalance shaft.
To aid in removal of the front cover, a driver groove is provided on the cover, above the oil pump housing. Avoid prying on the thinner parts of the housing flange or hammering on it to remove the case.
- Remove the right counterbalance shaft from the engine block.
- On the STANDARD ENGINE: Install a new front seal in the cover. Install a new gasket on the front of the cylinder block, and using a seal protector on the front of the crankshaft, install the front cover on the engine block.
- Tighten the front case mounting bolts to 11-13 ft. lbs.
- Install the oil screen, and using a new gasket, install the oil pan. Tighten bolts to 5-6 ft. lbs.
- If the cylinder head and/or water pump had been removed reinstall them using new gaskets.
- Install the upper and lower under covers.
- Install the spacer, flange and crankshaft sprocket and tighten the bolt.
- Align the timing mark on the crankshaft sprocket with the timing mark on the front case.
- Align the camshaft sprocket timing mark with the upper under cover timing mark.
- Install the tensioner spring and tensioner. Temporarily tighten the nut. Install the front end of the tensioner spring (bent at right angles) on the projection of the tensioner and the other end (straight) on the water pump body.
- Loosen the nut and move the tensioner in the direction of the water pump. Lock it by tightening the nut.
- Ensure that the sprocket timing marks are aligned, and install the timing belt. The belt should be installed on the crankshaft sprocket, the oil pump sprocket, and then the camshaft sprocket, in that order, while keeping the belt tight.
- Loosen the tensioner mounting bolt and nut and allow the spring tension to move the tensioner against the belt.
Make sure the belt comes in complete mesh with the sprocket by lightly pushing the tensioner up by hand toward the mounting nut.
- Tighten the tensioner mounting nut and bolt.
Be sure to tighten the nut before tightening the bolt. Too much tension could result from tightening the bolt first.
- Recheck all sprocket alignments.
- Turn the crankshaft through a complete rotation in the normal direction. Do not turn in a reverse direction or shake or push the belt.
- Loosen the tensioner bolt and nut. Retighten the nut and then the bolt.
- Install the lower and upper front outer covers.
- Install the crankshaft pulley and tighten the bolts to 7-9 ft. lbs.
- Install the alternator and belt and adjust. Install the distributor.
- Install the radiator, fill the cooling system, and inspect for leaks.
- On SILENT SHAFT ENGINES: Install a new front seal in the cover. Install the oil pump drive and driven gears in the front case, aligning the timing marks on the pump gears.
- Install the left counterbalance shaft in the driven gear and temporarily tighten the bolt.
- Install the right counterbalance shaft into the cylinder block.
- Install an oil seal guide on the end of the crankshaft, and install a new gasket on the front of the engine block for the front cover.
- Install a new front case packing. If equipped.
- Insert the left counterbalance shaft into the engine block and at the same time, guide the front cover into place on the front of the engine block.
- Insert a screwdriver at the bottom of the left side of the block and hold the left counterbalance shaft and tighten the bolt. Install the hole plug.
- Install an O-ring on the oil pump cover and install it on the front cover.
- Tighten the oil pump cover bolts and the front cover bolts to 11-13 ft. lbs.
- Install the oil screen, and using a new gasket, install the oil pan.
- Install the water pump and/or the cylinder head, if removed previously.
- Install the upper and lower under covers.
- Install the spacer on the end of the right counterbalance shaft, with the chambered edge toward the rear of the engine.
- Install the counterbalance shaft sprocket and temporarily tighten the bolt.
- Install the inner crankshaft sprocket and align the timing marks on the sprockets with those on the front case.
- Install the inner tensioner (B) with the center of the pulley on the left side of the mounting bolt and with the pulley flange toward the front of the engine.
- Lift the tensioner by hand, clockwise, to apply tension to the belt. Tighten the bolt to secure the tensioner.
- Check that all alignment marks are in their proper places and the belt deflection is approximately 1 / 4 - 1 / 2 " on the tension side.
When the tensioner bolt is tightened, make sure the shaft of the tensioner does not turn with the bolt. If the belt is too tight there will be noise, and if the belt is too lose, the belt and sprocket may come out of mesh.
- Tighten the counterbalance shaft sprocket bolt to 22-29 ft. lbs.
- Install the flange and crankshaft sprocket. Tighten the bolt to 43-50 ft. lbs.
- Install the camshaft spacer and sprocket. Tighten the bolt to 44-57 ft. lbs.
- Align the camshaft sprocket timing mark with the timing mark on the upper inner cover.
- Install the oil pump sprocket, tightening the nut to 25-28 ft. lbs. Align the timing mark on the sprocket with the mark on the case.
To be assured that the phasing of the oil pump sprocket and the left counterbalance shaft is correct, a screwdriver or a metal rod should be inserted in the plugged hole on the left side of the cylinder block. If it can be inserted more than 60mm, the phasing is correct. If the tool can only be inserted approximately 25mm, turn the oil pump sprocket through one turn and realign the timing marks. Keep the screwdriver or metal rod inserted until the installation of the timing belt is completed. Remove the tool from the hole and install the plug, before starting the engine.
- Refer to Step 9 of the belt installation for the standard engine.
- If the timing belt is correctly tensioned, there should be about 12mm clearance between the outside of the belt and the edge of the belt cover. This is measured about halfway down the side of the belt opposite the tensioner.
- Complete the assembly by installing the upper and lower front covers.
- Install the crankshaft pulley, alternator, and accessory belts, and adjust to specifications.
- Install the radiator, fill the cooling system, and start the engine.
- Turn the engine until No. 1 piston is on TDC with the timing marks aligned.
- Disconnect the negative battery cable.
- Remove the fan drive belt, the fan blades, spacer and water pump pulley.
- Remove the timing belt cover.
- Loosen the timing belt tensioner mounting bolt and move the tensioner toward the water pump. Temporarily secure the tensioner.
- Remove the crankshaft pulley and slide the belt off of the camshaft and crankshaft drive sprockets.
- Inspect the drive sprockets for abnormal wear, cracks or damage and replace as necessary. Remove and inspect the tensioner. Check for smooth pulley rotation, excessive play or noise. Replace tensioner if necessary.
- Reinstall the tensioner, if it was removed, and temporarily secure it close to the water pump.
- Make sure that the timing mark on the camshaft sprocket is aligned with the pointer on the cylinder head and that the crankshaft sprocket mark is aligned with the mark on the engine case.
- Install the timing belt on the crankshaft sprocket.
- Install the belt counterclockwise over the camshaft sprocket making sure there is no play on the tension side of the belt. Adjust the belt fore and aft so that it is centered on the sprockets.
- Loosen the tensioner from its temporary position so that the spring pressure will allow it to contact the timing belt.
- Rotate the crankshaft two complete turns in the normal rotation direction to remove any belt slack. Turn the crankshaft until the timing marks are lined up. If the timing has slipped, remove the belt and repeat the procedure.
- Tighten the tensioner mounting bolts, slotted side (right) first then the spring side.
- Once again rotate the engine two complete revolutions until the timing marks line up. Recheck the belt tension.
When the tension side of the timing bolt and the tensioner are pushed in horizontally with a moderate force (about 11 lbs.) and the cogged side of the helt covers about 6mm of the tensioner right side mounting bolt head, (across flats) the tension is correct.
- Install the timing belt cover, the water pump pulley, spacer, fan blades and drive belt.
- Connect the negative battery cable.
An 8mm diameter metal bar is needed for this procedure.
- Remove the water pump drive belt and pulley.
- Remove the crank adapter and crankshaft pulley.
- Remove the upper and lower timing belt covers.
- Move the tensioner fully in the direction of the water pump and temporarily secure it there.
- If you are going to reuse the timing belt, make a paint mark on the belt to indicate the direction of rotation. Slip the belt from the sprockets.
Place the belt in an area where it will not be contacted by oil or other petroleum distillates.
- Remove the camshaft sprocket bolt and pull the sprocket from the camshaft.
- Remove the crankshaft sprocket bolt and pull the crankshaft sprocket and flange from the crankshaft.
- Remove the plug on the left side the block and insert an 8mm diameter metal bar in the opening to keep the silent shaft in position.
- Remove the oil pump sprocket retaining nut and remove the oil pump sprocket.
- Loosen the right silent shaft sprocket mounting bolt until it can be turned by hand.
- Remove the silent shaft belt tensioner, and slip the silent shaft belt off its sprockets.
Do not attempt to turn the silent shaft sprocket or loosen its bolt while the belt is off.
- Remove the silent shaft belt sprocket from the crankshaft.
- Check the belt for wear, damage or glossing. Replace it if any cracks, damage, brittleness or excessive wear are found.
- Check the tensioners for a smooth rate of movement.
- Replace any tensioner that shows grease leakage through the seal.
- Install the silent shaft belt sprocket on the crankshaft, with the flat face toward the engine.
- Apply light engine oil on the outer face of the spacer and install the spacer on the right silent shaft. The side with the rounded shoulder faces the engine.
- Install the sprocket on the right silent shaft and install the bolt finger-tight.
- Install the silent shaft belt and adjust the tension, by moving the tensioner into contact with the belt, tight enough to remove all slack. Tighten the tensioner bolt to 21 ft. lbs.
- Tighten the silent shaft sprocket bolt to 28 ft. lbs.
- Install the flange and crankshaft sprocket on the crankshaft. The flange conforms to the front of the silent shaft sprocket and the timing belt sprocket is installed with the flat face toward the engine.
The flange must be installed correctly or a broken belt will be the result.
- Install the washer and bolt in the crankshaft and tighten it to 94 ft. lbs.
- Install the camshaft sprocket and bolt and tighten the bolt to 72 ft. lbs.
- Install the timing belt tensioner, spacer and spring.
- Align the timing mark on each sprocket with the corresponding mark on the front case.
- Install the timing belt on the sprockets and move the tensioner against the belt with sufficient force to allow a deflection of 5-7mm along its longest straight run.
- Tighten the tensioner bolt to 21 ft. lbs.
- Install the upper and lower covers, the crankshaft pulley and the crank adapter. Tighten the bolts to 21 ft. lbs.
- Remove the 8mm bar and install the plug.