1.4.3.5. Flywheel

• Remove the crankshaft pulley. A tight pulley can be removed by inserting two tyre levers underneath the pulley.
• Unscrew the timing cover and remove the oil seal in conventional manner or use the two self-tapping screws as mentioned above to remove the seal without unscrewing the cover. The Woodruff key must be removed from the crankshaft (side cutter).

The ignition timing plate must not be removed from the timing cover. Do not slacken the timing plate securing screws.

• Coat the outside of the oil seal with engine oil and knock the oil seal into the timing cover or into the timing cover and over the crankshaft end. If the cover has been removed, re-attach it loosely (with a new gasket) and drive the oil seal in position, at the same time centering the cover. A piece of tube, a large washer and the pulley nut can also be used to draw the seal in position. Tighten the timing cover when the seal is fitted.
• Fit the Woodruff key and slide the pulley in position. Place the drive belt behind the pulley to facilitate its installation.
• Raise or lower the engine to refit the engine mounting. Tighten the bolts t 5.0 kgm (36 ft.lb.) and the nut in the centre to 5.5 kgm (40 ft.lb.).
• Block the crankshaft against rotation and tighten the nut to 17.0 kgm (122.5 ft.lb.).
• Refit the water pump drive belt in a similar manner as during removal. Fit and tension the alternator drive belt.

1.4.3.5. Flywheel

If the flywheel teeth are damaged, check the teeth of the starter motor pinion. Both may have to be replaced.

The flywheel bolts are offset, i.e. the flywheel can only be fitted in one position. Coat the flywheel bolts with “Loctite”. Always use new bolts. Tighten he bolts evenly to 6.8 kgm (49 ft.lb.). The flywheel must be blocked against rotation.

1.4.4. TIMING MECHANISM

A timing chain is used to drive the camshaft. The chain is held under its correct tension by means of a chain tensioner. The timing chain and the two timing gears can be replaced with the engine fitted. Remove and/or replace the parts as follows:

• Remove the timing cover as described in the last section.
• Drain the engine oil and remove the oil sump.
• Remove the chain tensioner, observing the different operations for the type fitted:

Sedis Chain Tensioner

• Insert a screwdriver as shown in Fig. 1.20 into the chain tensioner bore and press against the chain tensioner pad to release it from the chain. Lock the chain tensioner by turning the screwdriver in the direction of the arrow. The ratchet inside the tensioner will lock the pad in position. The tensioner is now free to remove (see next page).