I was reading up on the KDP problem, and the possible fixes. Is this a major job to secure that dowel pin, as a preventive to it coming out.

 

I probably spent 4 hours removing the timing cover, securing the pin, loctiting the additional timing housing bolts, replacing the crank seal, cleaning the cover and gasket area, and replacing the cover. Technically it's not hard. Just takes some time. The hardest is the grunt work of getting the fan off. It sure is a lot better than spending the clams on a new timing housing though!

 

i'm gona do mine here. How many bolts are there in the timing case that need to be secured and loctite applied?

Jeff

 

I was told that with the 1st gens there's MORE of an issue with the 5 bolts that hold the housing to the block. They loosen and fall out just like the KDP. Mine were all very UN-tight! That's a good reason to me not to drill the housing with the jig setup. You can remove 4 of the bolts and reassemble with loktite, then torque to 18 ft-lbs. One is the bolt that holds the tab for the KDP. The second is at the top of the housing between the cam gear and the oil pump idler gear. 3 and 4 are behind the cam gear at about 12:30 and 3:00 that you can reach through the voids in the cam gear. The 5th you just have to check for tightness as it's behind the cam gear at about 2:00 and behind the toothed portion of the gear. A 10mm end wrench with a 45* bend can reach it from inside the voided area.

My housing was stepped. I made a tab out of some 1/8" stock. I used these dimensions: KDP Tab . Then I bent a step into it to match the step on the housing. I first bent the tab, close to the drilled hole for the bolt, at a 90* angle. Then I took a piece of angle iron, drilled a hole in it to match the one in the tab, so that the 90* tab fit snuggly into the 90* of the angle iron. I then measured the step in the housing. I believe it was right around 1/4". I then cut off the vertial portion of the angle iron so that it was the same height as the step. Then I bolted the the 90* tab to the angle and bent it down, resulting in a 1/4" stepped tab. I should have taken photos!! I still have the little angle jig I made. I'd be happy to post some pictures of that if interested.

 

none of my bolts were loose but my pin was way out and almost fell in to the gears ...just take a ball peen hammer and make the open end of the hole smaller by hitting the edge it will never come out and it doesnt hurt anything and just takes a few hits to doit