2A•6 Engine in-car repair procedures
5.20a View of the bolts securing the timing
cover to the cylinder block
15 Unscrew the upper bolt for the alternator,
and the two securing bolts for the power
steering pump, then withdraw the bracket and
the steady bar.
16 Loosen the alternator lower mounting bolt,
and swivel the alternator to one side.
17 Unscrew the mounting bolts, and remove
the alternator and power steering pump
mounting bracket from the timing cover.
18 On B202 engines, place a suitable
container beneath the oil filter to catch spilt oil,
then wipe clean the oil cooler pipe unions on
the filter housing. Identify the pipes for
position. Unscrew the unions, and disconnect
the oil cooler pipes from the housing. Position
the pipes clear of the timing cover.
19 On B202 engines, unscrew the bolts and
remove the pulley from the water pump drive
flange. Lever the coolant pipe away from the
rear of the cylinder block, so that it is
disconnected from the water pump housing.
Position the pipe well clear of the timing cover,
and remove the sealing O-ring.
20 Unscrew and remove the bolts securing
the timing cover to the cylinder block, sump
and cylinder head. Note that the bolts are of
different lengths. Note the two upper bolts on
the cylinder head and the two lower bolts in
the sump (see illustrations).
21 Taking care not to damage the cylinder
head gasket, carefully withdraw the timing
cover complete with the oil pump from the
nose of the crankshaft. Where fitted, remove
the gaskets from the cylinder block.
5.20b Removing one of the bolts securing
the timing cover to the sump
22 Thoroughly clean all traces of gasket and
sealant from the contact faces of the timing
cover, sump, cylinder head and block. Make
sure that the groove in the sump is free of all
23 Remove the oil pump from the timing
cover, with reference to Section 11.
24 Apply a bead of suitable sealant to the
sump. Locate new gaskets on the cylinder
block - if necessary, hold the gaskets in
position using a little grease. Where there are
no gaskets fitted, apply a bead of suitable
sealant to the timing cover flanges (see
25 Carefully locate the timing cover on the
cylinder block, at the same time engaging the
oil supply pipe from the block with the hole
near the bottom of the timing cover, where
26 Insert and tighten the timing cover
retaining bolts to the specified torque. On
B202 engines, do not fit the oil cooler pipe clip
retaining bolts at this stage. Insert loosely the
upper and lower bolts securing the timing
cover to the cylinder head and sump. Check
the dimension from the end of the oil supply
pipe to the oil pump flange is 25 ± 1 mm
(see illustration). Use vernier calipers to make
27 On B202 engines, fit a new O-ring to the
end of the coolant pipe, then locate it in the
water pump housing.
5.20c Removing the upper bolts securing
the timing cover to the cylinder head
28 Refit the oil pump with reference to
29 Tighten the two upper and two lower
timing cover bolts to the specified torque.
30 On B202 engines, refit the pulley to the
water pump drive flange, and tighten the bolts.
Check that the O-rings on the oil cooler pipe
unions are in good condition, then reconnect
the pipes to the oil filter housing, and tighten
the unions to the specified torque.
31 Refit the alternator and power steering
pump mounting bracket, and tighten the bolts.
32 Swivel the alternator towards the engine,
then refit the alternator/power steering pump
bracket and the steady bar, and tighten all
bolts to the specified torque.
33 On B202 engines, locate the clips on the
oil cooler pipes, then insert the retaining bolts
and tighten securely. Insert and tighten the
bolt securing the coolant pipe to the top of the
34 Slide the crankshaft pulley onto the
crankshaft, then insert the pulley bolt. Tighten
the bolt to the specified torque, while an
assistant holds the crankshaft stationary using
a wide-bladed screwdriver inserted in the
starter ring gear.
35 On B202 engines, refit the idler pulley and
backplate. Insert the centre bolt, but leave it
finger-tight at this stage.
36 Refit the drivebelt tensioner assembly, and
tighten the bolts. Before locating the assembly
on the stub, apply a little grease to the bearing
surfaces (see illustration).
5.24 Sealant on the timing cover flanges
5.26 Oil supply pipe fitting dimension on
the B202 engine
5.36 Apply a little grease to the bearing