How do I align the camshaft/flywheel when reassembling? And the small plastic "banjo looking piece" on the bottom of the camshaft,which I assume is the oil pump for it,is tapered on one side,does that side face the bottom or up towards the camshaft?
The crank gear has a marked tooth and the cam has a mark between two of the teeth - the other piece is the govener gear which meshes on the cam - it must be aligned so it contacts the gov arm - without a mod # im not sure which style gov gear you have . there is no oil pump in an engine of that size
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take the plastic piece off the end,get some 3 in 1 oil and put some on the top of the shaft,manually try to pull up on the gear,if it doesnt move,then it is rusted on,if it loosens up keep doing that till it moves freely,then try to start it,if it still doesnt work,your starter is bad
remove the top cover from the engine and then the nut on the top of the flywheel look down at the space between the shaft and flywheel the key between the two might have sheared happens more if you hit a rock
really need to know what engine is fitted, but assuming its a 2.0ltr turbo with engine B5204T3. Looking at the cam pulley's with crankshaft markings aligned ( 12'o'clock position ) with No1 cylinder on TDC, on the outer circumference of both cam pulleys you should find a small groove these should be at 12 o'clock and align with a small cut out on the plastic cowling behind pulleys, hope that's clear enough, cheers
If you need to remove the cylinder head, here's how. To remove the cam chain, you've got to also remove the left crankcase cover and flywheel.
First, you need to turn the engine over until the piston is at top dead center (TDC) of the compression stroke. Begin by removing the two round covers from the left side of the crankcase cover. Also remove the four tappet hole covers from the cylinder head cover. Turn the engine (in the normal direction of rotation) and watch the intake valves open - and close, then see that the exhaust valves open, then close. Now align the 'T' on the flywheel with the notch in the inspection hole. With all of the valves closed, the engine is at TDC of the compression stroke. Do not begin removal of the cylinder head cover until this is done - to avoid damage to the cover.
With the cylinder head cover removed, you will find two bolts attaching the cam chain sprocket to the camshaft. Turn the engine until you can get a 10mm socet onto the heads of the bolts and remove them. The sprocket will come loose and slide down onto the camshaft, enabling you to remove it an the camshaft.
Upon reassembly, set the cam timing by first setting the engine at TDC. Then, align the two marks on the cam sprocket with the gasket surface on the cylinder head. With the engine at TDC and the marks lined up, the cam timing is properly set.
To identify the engine, look on the blower housing (the half round - half rectangular piece covering the flywheel), the numbers should be stamped into the metal somewhere.
As for the magnets inside the flywheel, if you are talking about the ones that go against the inner circumference, you cannot replace them. They have to be in an EXACT location to retain the balance of the flywheel and if they are for the magneto they have to be located so that they trigger your spark at the exact right timing of the engine. Best solution is to purchase a new flywheel.
for somoeone you can help you with that motor you can contact KCK motors at 541-479-7815 and ask for ken he can tell you where to look for the number to identify the engine he has the dorce for the books and can ship it to you so you will have everything you need for this engine and will only have to pay a shipping charge from his shop to your home. Tell him Bruce from B & B service sent you and he will treat you right. top notch small engine repari shop, his advise is free and is quite knoledgeable. I could look it up but this guy is a mountian of resores for engine repair.
If you are talking of the rubber timing belt setting then rotate the cam gear till the timing mark (small hole) on the camshaft gear aligns with the mark on the plastic cover behind it. Mark is on top of plastic cover (12 'o' clock). Rotate the crank till the timing mark (groove, not the one for the crankshaft woodruff key) on crankshaft gear is aligned with the mark on the bottom of the plastic cover behind it. (6 'o' clock). Tighten tensioner against timing belt rotate engine a few times make sure alignment of timing marks remain.
the banjo part is the pump - this should be a two piece unit - you will see a cutout in the base plate where the ball end fits into - by tipping the engine upside down while installing base plate you can manuver the ball into place - as far as the crank gear mark one tooth may look different then the rest or have a line on it . it has to be there also as far as the tapered banjo part it realy doesnt matter which way the taper faces
If your caddy is the 1.9 diesel
The mark you are looking for is on the flywheel. Remove the plastic
plug in top of the bell housing to reveal a small arrow. Rotate engine
until the flywheel TDC mark lines up with this arrow