Camshaft

Removal and refit

Remove the camshaft drive belt cover. Turn the crankshaft unit the following conditions are achieved to assist assembly:

1) The mark on the crankshaft pulley is in line with the "0" on the timing scale. (4a and 4b)
2) The groove in the camshaft drive gear coincides with the carrier.
3) The distributor rotor arm points to nr 6 spark plug cap.

Remove the hot air hose for better clearance. Disconnect the vacuum pipe and LT leads from the distributor. Slacken the camshaft drive belt, adjust the bolts and slip the belt from the camshaft gear. Remove the seventeen camshaft carrier retaining bolts.

To prevent the exhaust valve pallets falling from their location when the carrier is lifted, carefully lift the carrier squarly off the cylinderhead approx. 50 mm and place a piece of wood at both ends. To prevent the pallets to fall into the engine you can close the two large gaps at both front and rear of the engine, exhaust side with some cloth.
Push the exhaust valve tappets down onto the valves and lift of the camshaft carrier clear of the cylinderhead leaving the tappets on the valves.

Camshaft removing.

When the carrier is removed, remove the camshaft keeper plate. It can be found on the second bearing journal from the front. Hold the rockers aside whilst withdrawing the camshaft from the carrier.

Removing the rockershafts and rockers.

1) Remove the front rocker shaft blanking plug(4) with the "o" ring (9).
2) Remove the front rocker shaft locating screw. (5)
3) Withdraw the front rocker shaft (6). Remove the rockers while removing the shaft.
4) Repeat this with the second rocker shaft on the rear end of the cylinderhead.

Inspection

1) Check the rocker shaft for wear, scoring and pitting.
2) Examine the rocker pads for wear and pitting. Rockers with worn pads must be renewed. Grinding the pads it not permissible.
3) Check the rocker bores for wear.
4) Examine the camshaft cams for wear, scores, cracks or pitting.
5) Check the bearing journals for wear, pitting and scoring.
6) Examine the tappets for wear and pitting.
7) Examine the camshaft bearing surfaces in the carrier for scores, wear and ‘picking up’.
8) Systematically check that all oilways in the carrier are clear, firstly with compressed air, secondly pumping oil trough the passages, and ensure oil is supplied to all bearings.

Reassembling

When everything is inspected, cleaned and fault parts are replaced you can start re-assembling the camshaft carrier.
First check the camshaft end-float, and adjust if necessary. Remove the old camshaft oil seal and refit a new one. Lubricate all the journals to fit the carrier.
Refit the camshaft, and secure it with the camshaft keeper plate. Refit the camshaft drive wheel and secure with the bolt and washer.

Refit the rocker shafts, fit the front rocker first in position. Fit the blanking plug and secure the rocker shaft with the rocker shaft locating screw.

Refitting the camshaft carrier.

1) Turn the crankshaft 45 degrees from T.D.C. to prevent damage to valves and pistons.
2) Fit the tappets onto their locations in the camshaft carrier (13).
3) Carefully lower the camshaft carrier onto the cylinderhead whilst ensuring that the pallets are not disturbed.
4) Tighten the 17 carrier retaining bolts to 40 to 54 Nm.
5) Check the valve clearance and adjust if necessary. If all adjustments are correct, remove the carrier once again.
6) Clean the carrier and cylinderhead mating faces.

7) Apply to the camshaft carrier mating face a continuous bead of Silcoset sealant (19).
8) Fit the carrier back on to the cylinderhead and evenly tighten all the retaining bolts to 40 to 54 Nm.
9) Turn the camshaft to T.D.C., see marker on the belt pulley.
10) Mount the complete cylindehead back on the engine block.
11) Turn the crankshaft back in T.D.C. position and refit the camshaft drive belt.
12) With a spanner, turn one the engine by hand to check the clearance of the valves. (just a security procedure)
13) Refit the distributor, the HT leads, and the air hose.