Firstly the the manual says that the engine must set to TDC, then before attempting to remove the bottom crankshaft pully to jam the starter ring gear on the fly wheel. This would be involve removing the starter motor ( a difficult job as bolts are hard to get to) and jamming something on the fly wheel to prevent rotation.
*(Automatic gears boxes would involve removing the transmission front cover plate and jamming something on the flywheel ring gear. I am provinding this tip for a manual gear box)
TIP #1. I found that by putting the vehicle in High gear and activating the Hi Difflock I was able to crack the crank shaft pulley nut. This saves considerable time. Reinstallation was just as easy.
To remove the timing case housing involves draining the sump of oil, to unbolt all the timing case housing and the bottom front sump screw nuts require removal. The next 4 sump screws require loosening also.
TIP # 2. I left the oil in the sump and unscrewed only the front 2 nuts that actually screw into the timing case housing, this will leave 2 studs from the timing case housing protruding the front 2 sump holes. Since the timing case housing is located on 2 dowells I did some thinking that it would be difficult to pull the housing foward and also litfing it clear of the sump.
I re installed the nut to the stud and then used the second nut to tighten it hard onto the first nut. Then it was simply a matter of unscrewing the top nut and the stud unscrewed out from the timing housing. Repeat for the second stud and it was just a matter of using a lump of wood to gently tap the housing to dislocate it from the dowells. After removing the housing you will see the front end of the sump lip, just apply RTV silicon onto it and at the corners then reinstall the housing.
Tip # 3. I installed a new crankshaft oil seal. I found that when I removed the old seal without damage that I was able to use the old seals' out face as 'Drift' to install the new seal. I placed the old seals outer face onto the outer face of the new seal and using a small hammer gently tapped old seal to drive the new one home, there is no chance of driving the old seal into the housing.
Hope info this might help
Rovernaut.
