65. Clean camshaft bearings.

66. Clean camshaft gear, thrust plate and mating surface on cylinder block.

67. Position thrust plate on camshaft.

68. Fit Woodruff key to slot in camshaft.

69. Press gear on to camshaft.

70. Lubricate camshaft lobes and bearings with clean engine oil.

71. Fit camshaft and align timing marks on camshaft gear with timing mark on injection pump gear.

72. Align thrust plate, fit Allen screws and tighten to 24 Nm.

73. Clean oil pick-up strainer and pick-up pipe.

74. Lubricate NEW ’O’ rings with clean engine oil and fit to pipe.

75. Fit strainer, fit bolts and tighten to 25 Nm.

76. Clean sealing surfaces on sump and cylinder block.

77. Clean inside of sump.

78. Apply a bead of RTV sealant to the sump flange.

79. Position sump and fit Allen screws finger tight.

80. Fit reinforcing plate and fit remaining Allen screws. Finally tighten Allen screws to 8 Nm.

81. Roll engine upright.

82. Clean brake servo vacuum pump and cylinder block mating faces.

83. Lubricate NEW ’O’ ring with clean engine oil.

84. Fit ’O’ ring to vacuum pump

85. Fit vacuum pump ensuring timing marks on camshaft, crankshaft, vacuum pump and fuel injection pump are aligned.

86. Fit Allen screws and tighten to 27 Nm.

87. Remove sealant from timing cover and cylinder block mating faces.

88. Clean cover.

89. Apply a 3 to 6 mm bead of RTV to timing cover.

90. Fit cover, position timing pointer and fit bolts securing cover.

91. Tighten bolts progressively in a diagonal sequence to: 6 mm bolts 10 Nm. 8 mm bolt 25 Nm.

92. Position brake servo vacuum pipe union to cylinder block, fit banjo bolt using NEW sealing washers, tighten banjo bolt to 40 Nm.

93. Position engine mounting plate, fit 2 bolts and Allen screw and tighten to 45 Nm.

94. Position coolant pump drive pulley, fit Allen screw and tighten to 68 Nm.

95. Position coolant pump drive belt jockey arm and fit bolts finger tight.

96. Clean coolant pump, tensioner and drive pulleys.

97. Fit drive belt.

98. Using a suitable dial gauge torque wrench,

raise jockey arm until gauge reads 5.5 Nm and tighten jockey arm bottom bolt.

99. Remove torque wrench and tighten top bolt.

100. Clean ancillary drive belt tensioner pivot and fit tensioner assembly.

101. Fit washer and circlip.

102. Align tensioner and fit and tighten top bolt.

103. Clean jockey pulleys and centre bolts, position pulleys and fit and tighten centre bolts to 45 Nm.

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Index