In this case, the TDC mark on the crankshaft pulley should be opposite the indicator on the lower cover of the valve timing mechanism.
Insert the target into the guide shoe and place it on the crankshaft sprocket according to the timing mark applied to the chain during removal.
Install the chain guide shoe.
Connect both chain strands together at the top of the guide shoe with wire.
Install the lower timing cover gasket and apply Atmosit type sealing paste to the lower mating surface of the cover.
Remove the crankshaft pulley without turning the shaft, then install the lower timing cover.
After assembling the cylinder head, install the camshaft flange so that the locating pin points downwards. The mark on the flange should align with the locating boss on the cylinder head.
Place the gasket on the cylinder head studs. Install the cylinder head.
Tighten the cylinder head mounting bolts (see "Cylinder head assembly").
Disconnect the chain branches and place it on the camshaft pulley, aligning the holes in the pulley and in the camshaft flange.
Tighten the camshaft pulley mounting bolts and lock them by bending the locking plates.
Fill the upper timing cover reservoir with engine oil to the level of the chain tensioner plunger. Bleed the chain tensioner as follows:
- install the plunger and tensioner spring; in this case it is necessary to insert the front groove of the plunger into the bracket of the tensioner shoe and direct the spring with the conical part towards the plug;
- partially tighten the tensioner plug;
- press the tensioner shoe bracket several times with a screwdriver until oil starts to flow out of the plug;
- wipe the cork and screw it on tightly.
Note: Causes of camshaft drive chain noise may include air in the plunger, plunger sticking, clogged plunger ventilation slots, faulty ball valve, excessively stiff or weak plunger spring, or sticking of the tensioner shoe bracket on the axle.
Install the upper cover of the valve timing mechanism, having first applied a sealant such as Atmosit to its lower part.
Install the ignition distributor bracket. Install the ignition distributor in such a position that the rotor is opposite the mark on the distributor housing, and the piston of the 1st cylinder is at TDC of the end of the compression stroke.
Insert the woodruff keys into the slots on the front end of the crankshaft, press in the new front crankshaft oil seal. Install the crankshaft pulley and secure it with the nut and washer.
Install the clutch with the driven disc positioned with the protruding part towards the pressure plate, and center the disc relative to the flywheel with a drift.
Adjust the valve drive clearances. Install the removed components and assemblies on the engine.
Start the engine and install it on the car.
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