Installing the gear and timing cover

1. Install a new O-ring in the drive cover.

2. Check the keyways at the end of the crankshaft, they should be clean and there should be no burrs on the keys. Install the keys in the keyways.



3. If the crankshaft gear was removed, reinstall it so that the gear is fully seated on the crankshaft, using a pipe of a suitable diameter. You can also temporarily use a pulley and bolt to press it.



4. Install the camshaft gear onto the shaft so that the punch mark is aligned with the mark on the crankshaft gear. Please note that there are two marks made with a core on the crankshaft gear, it is necessary to match the desired mark. In this case, the keyways face each other. Later 2.4 and 2.8 in³ engines have a nylon camshaft gear.


5. Install the washer and camshaft gear bolt. Tighten the bolt according to the tightening torque.

6. Clean the front surface of the intermediate plate and the mating surface of the drive cover, then apply sealant to both mating surfaces.

7. Install a new gasket on the intermediate plate and install the timing cover to the cylinder block.

8. Install the drive cover mounting bolts and tighten them to the correct torque.



9. Check camshaft end play.



10. Determine the position of the O-ring in the timing cover, then press out the old seal.

11. Clean the front plane of the adapter plate and the plane of the timing cover, then coat both surfaces with sealant.

12. Place a new gasket on the adapter plate and install the timing cover on the cylinder block. Tighten the screws by hand.




13. Using a vernier caliper, center the timing cover on the camshaft, fully tighten the bolts.



14. Install the O-ring on the timing cover, and push it into place using the bushing and bolt.



15. Remove the gasket protrusions from the mating surfaces of the oil pan.