Timing belt sprockets - removal and refitting

Engine in-car repair procedures / Timing belt sprockets - removal and refitting

Camshaft sprocket
Removal
1 With reference to Section 2 remove the timing belt cover, set the engine to TDC on cylinder No1 and remove the timing belt.

2 The camshaft sprocket must be held stationary whilst its retaining bolt is slackened; if access to the correct WV special tool is not possible, a simple home-made tool using basic materials may be fabricated (see Tool Tip).

3 Using the home made tool, brace the camshaft sprocket and slacken and remove the retaining bolt; recover the washer where fitted.

4 Slide the camshaft sprocket from the end of the camshaft. Where applicable, recover the Woodruff key from the keyway.

5 With the sprocket removed, examine the camshaft oil seal for signs of leaking. If necessary, refer to Section 8 and renew it.

6 Wipe the sprocket and camshaft mating surfaces clean.

Refitting
7 Where applicable, fit the Woodruff key into the keyway with the plain surface facing upwards. Offer up the sprocket to the camshaft, engaging the slot in the sprocket with the Woodruff key. On engines where a key is not used, ensure that the lug in the sprocket hub engages with the recess in the end of the camshaft.

8 Insert the camshaft sprocket bolt and tighten it to the specified torque - hold the sprocket still using the method described in the Removal Section.

9 Working from Section 2, check that the engine is still set to TDC on cylinder No 1, then refit and tension the timing belt, as described in Section 4. Refit the timing belt cover and fasten the retaining clips securely.

Crankshaft sprocket
Removal
10 With reference to Section 2, remove the timing belt cover, set the engine to TDC on cylinder No1 and remove the timing belt.

11 Refer to Chapter 5A and remove the starter motor. Hold the crankshaft stationary using a lever inserted between the teeth of the starter ring gear.

12 Slacken the bolt and remove the sprocket, recovering the Woodruff key, where applicable. If the sprocket is tight, carefully lever it from the end of the crankshaft using a prybar. Note: Discard the sprocket retaining bolt - a new one must be used on reassembly.

Refitting
13 Fit the Woodruff key in the crankshaft and tap the sprocket into position. On engines where a Woodruff key is not used, offer up the sprocket to the crankshaft, engaging the lug on the inside of the sprocket with the recess in the end of the crankshaft.

14 Insert a new sprocket retaining bolt and tighten it to the specified torque - hold the crankshaft stationary using a lever in the starter ring gear, as described in the Removal sub-Section.

15 Working from Section 2, check that the engine is still set to TDC on cylinder No 1, then refit and tension the timing belt, as described in Section 4. Refit the timing belt cover and fasten the retaining clips securely.

Coolant pump timing belt sprocket
16 The coolant pump sprocket is an integral part of the coolant pump assembly and cannot be renewed as a separate item.