Engine teardown and inspection

[Bryanj]

I was delivering car perts when the Astra/Cavalier had the cam troubles and every dealer was waiting for camshaft/follower sets.
There used to be a proceedure for first start up, something like 3 minutes at 4000 rpm followed by 2 minutes at 2000 rpm before you let it tick over. Something to do with oil flow quantity

[cantarauk]

Any comments to the post on 22nd about washer an o-ring question

[Bryanj]

Would it be part 27

[cantarauk]

Bryan,

Thinking about again it must be as the spacer is the bearing looking think attached to the shaft itself. Now I never removed all the gears on that shaft as I could not figure out how to get No 7 off. Would it be best to try again and replace the o-ring or would I be good with that one.

Also any view on the extra washer that was on mainshaft ?

[Bryanj]

Never changed one so dont know

[cantarauk]

Thanks both.

For now I have assembled as per the photos with the flat washer first toward the sprocket end against No7 and then the ear-washer after with the ears towards No 9. So from your understanding could be wrong. Oddjob, If you could please check the part numbers it would be appreciated.

[Trigger]

Had a little time today so, split this gear box so, you can see how it split as you can't go off a manual 

The circlips must be wround the correct way as, there is a flat side. The washer with the tags fits inside the washer once that washer is turned and acts as a lock.


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[cantarauk]

That is brilliant thank you very much.

Was going to ask second gear No7 in parts image did that come off easy enough as mine seems stuck.

Then for circlips any reason why not to use similar to below.



Washer with the tags that I have the wrong way round so thank you very much I will have to go and rectify that.

[Bryanj]

 Dont think you can use that type of circlip as the ears are too big

[cantarauk]

Hi Bryan,

I had a few of the circlips I order a while back and did a quick assemble using them.





The ears are a bit big but do pretty much align with the end of the washer. Any good ?

[Trigger]

You CAN NOT use that type as, it does not have a running surface. you need the type like the Honda ones that have flat one side and a bevel sided 
What happened to the ones you took off ?

[cantarauk]

Roger that Tigger.

The one I took off has a kink in the middle like it was bent and then straightened. From the initial inspection of the engine I made a decision to strip down completely as I was very unsure about how well it had been assembled in the past. If recall at the start of this post I found a primary chain link in the oil pan and also terrible wear on cam, and cam head surface bearings.

I have 550 engine so will steal one of there and replace that one when I get around to the 550.

[Trigger]

Set rings (Honda circlips)are ready available for a couple of quid, 90602259010 

[cantarauk]

Cheers

Placed a David silver order straight after I sent that post as I realised I did not fancy all the work to get them from the other engine. I can wait a few days

[cantarauk]

On closer inspection of the pictures you sent over Trigger I was still wondering why the second gear (No 7 in parts list) was stuck. I gave it quite a few taps and got it off the shaft but guess what I found is not what I wanted to.

Image of the shaft where the second gear came off. Am I right in assuming this means it needs replacing ?





Then the gear itself -




I can only assume something has gone in and around here or am I off the mark ?