Front Crankshaft Cover Replacement

[AlSmith]

One of the previous owners of my MY89 Excel decided it would be much easier to change the cam belt by modifying the front crankshaft cover and cutting of the timing mark stub so the triple pulley didn't need removing to do a cam belt change. However, this has made setting up the timing rather difficult!

Therefore I've managed to source an unmolested cover and used this as a guide to paint on some timing lines on the modified crankshaft cover as a stop gap. But what I really want to do is make it right and fit the replacement cover.

So my question is:

1. Can this be done with the engine in the car (after removing all the normal bits, bonnet, oil cooler out the way, possibly the fans again so I can get the triple pull off, skin of the knuckles ).
2. Will the Engine Oil need draining or will the resting oil level be enough not to spill out on the drive?

Not quite the worst bodge job Ive found so far, but close (a modified fan wiring loom connector gets that award)

Al

[bash]

You dont need to take it off. Find number one spark plug lead at the distributor and make sure that the rotor arm is pointing vaguely at it. It only needs to the approximately because of the next bit. I made a piston stop for the next bit by knocking the centre out of a spark plug and putting a screwed rod down the centre and then fitting it into the plug hole. Turn the engine over with a socket ( its easier with all the plugs out. When the piston stops mark the bottom pulley then turn the engine in the opposite direction until it stops again and mark the pulley again. Tdc is exactly between the two marks. You can also do it with a screw driver or similar down the plughole in line with the cylinder and observing a mark on it, when you see the mark in the same place twice thats your two marks on the pulley. Heres where you need someone elses help, I havnt got a Lotus engine in my excel, if someone could measure the distance you could then get the accurate distance, or you could calculate it with some simple maths.
Rover v8s are notorious for having incorrect marks so had to this to get it accurate.

Bash

[Marten]

1. Can this be done with the engine in the car (after removing all the normal bits, bonnet, oil cooler out the way, possibly the fans again so I can get the triple pull off, skin of the knuckles ).
2. Will the Engine Oil need draining or will the resting oil level be enough not to spill out on the drive?

1) don't see why not, all pulleys etc come off with the engine on the engine mounts
2) if the oil level would be so high that the crank could hit it you've got other problems . It's way down in the sump

[AlSmith]

Thanks Bash, I’ll try that idea for now, I can take the measurements from the replacement cover.

and thanks Martin for confirming the oil shouldn’t spill out. Will give it a go at changing the cover in situ, just need the spare time now

Al