Crankshaft Gear/Sprocket: Service and Repair

Remove
1. Drain crankcase and radiator.
2. Remove radiator. (If equipped with A/C, remove A/C condenser.)
3. Remove fan and water pump pulley.
4. Remove valve cover and gasket, loosen valve rocker and bolts and pivot rocker arms clear of push rods.
5. Remove oil pump drive shalt and gear assembly, and spark plugs.
6. Remove distributor and mark for installation.
7. Remove push rod cover and gasket. Remove push rods and valve lifters.
8. Remove hub and timing gear cover.





9. Remove the two camshaft thrust plate screws by working through holes in the camshaft gear.
10. Remove the camshaft and gear assembly by pulling it out through the front of the block. (Support shaft carefully when removing so as not to damage camshaft bearings.)

Disassemble
1. If the gear must be removed from the shaft, use press plate and adapter J-971 on press.





2. Place tools on table of a press. Place the camshaft through the opening in the tools. Press shaft out of gear using socket or other suitable tool. Thrust plate must be so positioned that woodruff key in shaft does not damage it when the shaft is pressed out of gear.

Assemble
To assemble camshaft gear, thrust plate and gear spacer ring to camshaft, proceed as follows.
1. Firmly support shaft at back of front journal in an arbor press using press plate adapters.
2. Place gear spacer ring and thrust plate over end of shaft, and install woodruff key in shaft keyway.





3. Install camshaft gear and press it onto the shaft until it bottoms against the gear spacer ring. The end clearance of the thrust plate should be 0.0015" to 0.0050". If less than 0.0015", the spacer ring should be replaced. If more than 0.0050", the thrust plate should be replaced. End Clearance

Install
1. Thoroughly coat the camshaft journals with a high quality engine oil supplement.
2. Install the camshaft assembly in the engine block, being carefull not to damage bearings or cam.
3. Turn crankshaft and camshaft so that the valve timing marks on the gear teeth will line up. Engine is now in the number 4 cylinder firing position. Install camshaft thrust plate to block screws and tighten to 10 N.m (75 lb. in.).
4. Install timing gear cover and gasket.
5. Line up keyway in hub with key on crankshaft and slide hub onto shaft. Install center bolt and torque to 212 N.m (160 lb. ft).
6. Install as previously described valve lifters, push rods, push rod cover, oil pump shaft and gear assembly. Install distributor as follows:
^ Turn crankshaft 36O° to firing position of number one cylinder (number one exhaust and intake valve lifters both on base circle of camshaft and timing mark on harmonic balancer indexed with top dead center mark on timing pad). Install distributor in its original position and align shaft so that rotor arm points toward number one cylinder spark plug contact.

7. Pivot rocker arms over push rods. With lifters on base circle of camshaft, tighten rocker arm bolt to 27 N.m (20 lb. ft.). Do not over torque.
8. Install water pump pulley and fan assembly.
9. If equipped with A/C, install A/C condenser and recharge A/C system.
10. Install radiator.
11. Refill cooling system and crankcase.