Note: Do not attempt to rotate the engine whilst the crankshaft/camshaft are locked in position. If the engine is to be left in this state for a long period of time, it is a good idea to place warning notices inside the vehicle, and in the engine compartment. This will reduce the possibility of the engine being accidentally cranked on the starter motor, which is likely to cause damage with the locking pins in place.

1 On all models, timing holes are drilled in the camshaft sprocket and in the rear of the flywheel. The holes are used to ensure that the crankshaft and camshaft are correctly positioned when assembling the engine (to prevent the valves contacting the pistons when refitting the cylinder head), or refitting the timing belt. When the timing holes are aligned with access holes in the cylinder head and the front of the cylinder block, suitable diameter pins can be inserted to lock both the camshaft and crankshaft in position, preventing them from rotating. Proceed as follows.

2 Remove the timing belt upper cover as described in Section 6.

3 The crankshaft must now be turned until the timing hole in the camshaft sprocket is aligned with the corresponding hole in the cylinder head. The holes are aligned when the camshaft sprocket hole is in the 2 o’clock position, when viewed from the right-hand end of the engine. The crankshaft can be turned by using a spanner on the crankshaft sprocket bolt, noting that it should always be rotated in a clockwise direction (viewed from the right-hand end of the engine).

4 With the camshaft sprocket hole correctly positioned, insert a 6 mm diameter bolt or drill through the hole in the front, left-hand flange of the cylinder block, and locate it in the timing hole in the rear of the flywheel (see illustration).

3.4 Insert a 6 mm bolt (arrowed) through hole in cylinder block flange and into timing hole in flywheel . . .

Note that it may be necessary to rotate the crankshaft slightly, to get the holes to align.

5 With the flywheel correctly positioned, insert a 10 mm diameter bolt or a drill through the timing hole in the camshaft sprocket, and locate it in the hole in the cylinder head (see illustration).

3.5 . . . then insert a 10 mm bolt through the camshaft sprocket timing hole, and locate it in the cylinder head

6 The crankshaft and camshaft are now locked in position, preventing unnecessary rotation.