Engine rebuild pt3...

Replacement con rod cap bolts arrived Saturday morning - so I cleaned and oiled up all the bits and refitted pistons 1 and 4 with new bolts and torqued them up to
45 Ibs ft without any problems.

Fitting two of the cylinder head bolts into block as guilds, cleaned the surfaces and fitted the head gasket and head - tightening the nuts and bolts in the correct order.

After positioning the crank back to TDC on 1 and 4, I started fitting the timing chain and gear assembly. I will refit the original chain tensioner and check to see if it needs replacing.

3hrs

Timing chain assemble...

Dropped the timing chain assemble in to the cleaner for 10 minutes, oiled the chain and bagged for refit later.

30 mins

Engine breakdown... pt13

Timing chain assembly and cover – I started by removing the crankshaft pulley, wedging the crank with a block of wood and undoing the large bolt.

By removing the remaining bolts I lifted off the cover and started undoing all the bolts holding the gear assembly, chain guides and timing chain tensioner. Using a allen key to remove the jackshaft keep plate I then slipped out the jackshaft.

I dropped some the bits into the ultrasonic clean which does a good job given enough time.

1.5 hrs (I had very cold fingers!)

Engine breakdown... pt5

Off with it's HEAD!

Having read my TR7 repair manual a couple of times, I started by removing the camshaft cover and unbolting the timing chain top sprocket from the camshaft.

Then I started loosening the cylinder nuts and bolts in the order from the manual. After removing the nuts I used my large bladed screw driver and adjustable spanner to remove the studs, but the two outer studs wouldn't undone.

Using my hide hammer I hit around the flange to break the seal. With the two studs still in place this made it very difficult to lift and the timing chain was also rubbing on the casting. After some gently persuasion (not) the head lifted off.

I was pleased to see very little water corrosion to the aluminium head - after having a couple of conversations other TR7 owners who's cylinder heads had been badly damaged.

A quick visual inspection of the bores also looked good, the block and crank were replaced back in 1985 due to a thrust washers failure.

3.5 hrs