Despite the PO believing the cam belt had been changed late in 2008 -
a) The Disco the engine came from had been through a lot of mud (sans plug)
b) Had the idlers etc. been changed?
Opening up the cam belt cover it was actually pretty clean internally and the belt did appear to be recent. But the idler was rusty so prob original and old as did the tensioner. Also someone had mullered the injection timing cover bolts.
So this weekends plan was to get the cam belt swapped and the front and rear crank oil seals. The first issue was despite the various searches on the 'net and the Haynes book 'O' lies my timing case markers are not as per any of those - plus the timing tool will never fit in the notch in the flywheel when the engine is at TDC - it is about 60 degrees out!
See flywheel pic below. Arrow on flywheel is on the notch and arrow at the bottom is the drain/tool entry point.
Sussed it in the end and used the crank woodruff key at the vertical position as TDC and ignored the flywheel (and marked it in red for next time). From now on I won't be able to access the drain anyway so this works for me and I will prob drill and tapo another in the gearbox bellhousing.
Pic below with everything lined up after the new idler, front crank oil seal and tensioner where fitted with the new Dayco belt.
Now ready for next weekend and maybe I can get the flywheel housing modified ready for the S2 gearbox to mate up...and fit the rear crank seal. The only reason I didn't do the seal this weekend was the 'OEM' seal that arrived was a rubber Br1tpart affair. There was no way that was going in with all the hassle that would be entailed in replacing it if it failed. A genuine one is now on order at the cost of £25!
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