Installing the Cam Drive/Driven Gears

Put on the front cam retaining washer using two little, 5mm bolts. See photo above. Use blue thread-lock to bolt and torque the bolts.

Note: The service manual doesn’t specify the torque (at least, not my manual). Since the cams are hardened steel, I used 7.2 ft-lbs, which is 86.4 In-lbs.

Rotate the cam driveshaft (aka crankshaft) counter-clockwise so that its keyway is pointed toward the rear camshaft (at about the 11 'O-clock position). This makes it easier to install the key, and also to line up more timing dots. You can perform this rotation in either of two ways:

• By using a socket wrench on the left side of the crank (via the timing cover access, if the clutch cover is on)--turning it clockwise
• By temporarily screwing in the cam drive-gear bolt, and using a wrench on this bolt to turn the crankshaft counter-clockwise

Next, rotate the cams so that the keyway of the rear camshaft is pointed toward the crankshaft (aka cam driveshaft).

Tip: To do this, just use your fingers (or other tool) on the front-cam's, two, little, retaining-washer bolts, and rotate both cams. Alternatively, you can temporarily screw on the cam driven-gear nut, and using a wrench on this nut, turn the cams in either direction.

Now install the cam drive gear--the smaller gear shown in the photo above--using the shorter of the two keys. To do this, apply a little assembly-lube on the key (to make it sticky), then place it in the gear's keyway. Be sure to install the key, with the wide side down. See the photo above.

Next, slide the gear onto the cam drive shaft (aka crankshaft), aligning the key in the gear to the keyway of the shaft.

Tip: Use your finger to prevent the key from sliding too far out.

Once you check that the key is in position, insert and hand-tighten the cam drive gear bolt (and washer).

Slip the cam driven gear--the larger gear--part way on to the rear camshaft using the same key alignment technique as for the cam drive gear.

As you slide the gear part way on to the rear camshaft (aligning the keyways), do not go on so far as to engage the cam drive gear--the little gear. Now rotate the big gear--and its shaft--so that the timing marks on both gears align. Then, push the big gear in, to begin meshing the teeth of both gears.

Tip: As you align the gear timing dots described above, be sure to use a finger to prevent the key from sliding out of the keyway.

Now insert a cross-headed (phillips) screwdriver or a punch into a hole on the larger gear, and lever its spring-loaded, twin-gears so that you can slide it (the driven gear) the remaining way on to its shaft. See photo below.

Note: I had to try all three holes before I found one that would align the twin-gears just right.

Bolt and torque both cam gears on, with their washers. Use 37 Ft-lbs for the nut, and 22 Ft-lbs for the bolt.

Next, slide in the decompression pins. The long one goes to the rear cam.

Take picts.

Recommendation: Do not bolt on the outer, chrome, cam cover or the solenoid cover until you finish with valve and pushrod adjustment.