User manual AUTOTECH 10.109.418K

[. . . ] Remove the camshaft drive belt cover on the front ( 6 Nm/53 in. Rotate the crankshaft clockwise with a 19mm wrench until the No. 1 cylinder is at TDC (Top Dead Center), indicated by the marks on the camshaft sprocket and valve cover (see Fig 1) Fig 1 32240-E Paseo Adelanto, San Juan Capistrano, CA 92675 Phone 949. 240. 4000 Fax 949. 240. 0450 2 2. (cont) Note: because the timing mark on the vibration damper and the "0" on the flywheel can indicate TDC for either cylinder No 1 or No 4, don't use these marks for double-checking here. [. . . ] IF THESE CAPS ARE INSTALLED INCORRECTLY, IT CAN PREVENT THE CAMSHAFTS FROM TURNING AND WILL CAUSE UNREPAIRABLE CAMSHAFT AND BEARING WEAR!Lift the camshafts from the head TOGETHER, then remove the drive chain. Make sure you have marked the chain and chainwheels, as in Figure 2, before separating them!(cont) 32240-E Paseo Adelanto, San Juan Capistrano, CA 92675 Phone 949. 240. 4000 Fax 949. 240. 0450 12. Now use a 17mm wrench to remove the bolt that holds the timing belt sprocket to the 3 exhaust cam ( 65 Nm/48 ft lb). We recommend holding the cam in a vise using soft jaws to do this easily. Gently tap the sprocket to remove from the camshaft. Be careful not to damage the keyway integral on the sprocket!Removing the chainwheels for transfer to the new cams. BEFORE REMOVING, NOTE WHICH WAY THE CHAINWHEELS ARE FACING. THEY MUST BE PLACED THE SAME WAY ON THE NEW CAMS, OR YOU WILL NOT BE ABLE TO PROPERLY TIME THEM!The chainwheels have a front and back, distinguished by the chamfer or radius of the wheel's face near the center hole (Fig 3) inner radius outer chamfer Fig 3 The chainwheels must be locally heated to be removed or installed. It is best to have them pressed on or off the cams using a hydraulic press with steady force after heating. If this is not possible, you will have to heat, then gently drive the chainwheels off or on with a soft faced mallet. This is best accomplished by driving the cam off of or onto the chainwheel, while supporting the chainwheel on at least two places over an open vise. Make sure to keep the woodruff keys for re-use. Install the chainwheels on the new cams facing the same direction as on the originals. Once the chainwheels are installed on the new cams, apply a small amount of cam lube or oil to the inside of a new camshaft oil seal (OE no 068. 103. 085A) and place it on the exhaust cam. On a table or flat surface, place the drive chain onto the new cams, and make sure the marks you made (in Step 9) on the chainwheels and chain align. Now place the cams in the head TOGETHER, making sure that the chain does not skip or move a tooth while doing so. Install bearing caps 2, 4, 6, and 8, tightening them down gradually and evenly. Make sure the caps are on the correct journals and that the caps' beveled corners face the intake (forward) side of the engine. [. . . ] The hydraulic lifters will need at least that time to bleed down to normal level. If you start the engine, and the lifters have not yet bled down, you could possibly damage the engine due to valve-to-piston interference. When you're ready to start the car, be ready to shut it down if the engine runs rough. If it does not start or runs rough, DON'T PANIC! [. . . ]