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Timing Cover and Seal

To remove front cover the crankshaft damper or pulley must be removed, this usually requires a puller. Before proceeding review the procedures for crankshaft damper and make sure there is enough clearance to install the puller. If there is not enough clearance for the puller, you need to remove the engine. Review engine removal steps before proceeding as necessary. REMOVAL & INSTALLATION
E-Series Engines

Fig. 1: Bolt location on the timing belt cover E-Series engine

NOTE: The front crankshaft oil seal can only be replaced when the crankshaft sprocket is removed. 1. Disconnect the battery. 2. Drain the cooling. CAUTION When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

3. Remove the radiator together with the upper and lower radiator hoses. 4. Loosen the air conditioning belt and remove. 5. Loosen the alternator adjusting bolt, and remove the alternator belt. Unbolt the alternator mounting bracket and remove the alternator. 6. Remove the power steering belt (if equipped) by loosening the steering pump adjusting bolt. 7. Remove the water pump pulley. 8. Remove crankshaft pulley. Support the engine and remove the right side engine mount bracket. 9. Loosen and remove the 8 Torx head bolts securing the timing covers and remove the upper and lower covers. To install: 10. Install the timing belt covers and torque the belt cover bolts to 3648 inch lbs. (45.5 Nm) and reconnect the engine mounting bracket. 11. Install the crankshaft pulley in place and tighten the crankshaft pulley bolt to the specified torque: o 1982 E15 108145 ft. lbs. (147197 Nm) o 198388 E15 and E16 83108 ft. lbs. (113147 Nm) 12. Install the water pump pulley. 13. Install the alternator and all the drive belts. 14. Install the radiator and all cooling hoses. Refill the cooling system. 15. Connect the battery cable and start engine.
CA16DE and CA18DE Engines

For removal and installation of the timing belt upper and lower covers, refer to the timing belt procedures later in this section.
GA16i Engine

Fig. 2: Replacing the front cover GA16i engine

1. Disconnect the negative (-) battery cable. 2. Drain the engine coolant. CAUTION When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old. 3. 4. 5. 6. Remove the oil pan as outlined in this section. Remove all drive belts and power steering pump bracket, if so equipped. Remove the air cleaner. Install an engine lifting device to the front side of the engine. Remove the engine mounting bracket. 7. Remove the water pump as outlined in this section. 8. Remove the timing chain tensioner from the front cover. 9. Remove the rocker arm cover and all spark plugs. 10. Set the No. 1 cylinder to TDC of the compression stroke and remove the crankshaft pulley. 11. Remove the front cover. To install: 12. Apply RTV sealer to the front cover and install within 5 minutes. Torque the bolts to 60 84 inch lbs. (710 Nm).

NOTE: When using RTV sealant instead of gaskets, make sure the surface you are working on is very clean before applying the sealant, then apply an even bead. Allow the RTV to dry slightly to form a thin skin. The component MUST be tightened before the RTV dries completely. The bolt torque should be checked again after RTV has completely dried. 13. Install the crankshaft pulley and torque the bolt to 6976 ft. lbs. (94103 Nm). 14. Install the rocker arm cover and all spark plugs. 15. Install the timing chain tensioner to the front cover. 16. Install the water pump as outlined in this section. 17. Install the engine mounting bracket. 18. Install the air cleaner. 19. Install all drive belts and power steering pump bracket, if so equipped. 20. Install the oil pan as outlined in this section. 21. Connect the negative (-) battery cable and refill the engine coolant.
GA16DE Engine

The front oil seal can be replaced by removing the crankshaft damper. Review Crankshaft Damper procedures earlier in this section. Some engines may prove to be difficult to remove the damper or oil seal with front cover and engine installed. It may be helpful to raise and support the car and remove the front wheels. In some cases, it may be necessary to remove the engine or front cover. Fig. 3: Removing the crankshaft pulley to gain access to the front cover oil seal GA16DE shown

Fig. 4: Removing the front oil seal with the cover on the engine GA16DE shown

Fig. 5: Installing the front cover oil seal with the cover installed GA16DE shown

Fig. 6: Removing the front cover bolts

Fig. 7: The front oil pan bolts attach to the front cover

Fig. 8: Removing the upper front cover bolts

Fig. 9: Make sure all bolts are removed and gently pry back the upper front cover

Fig. 10: Removing the front cover and exposing the timing chain

1. Relieve the fuel system pressure. 2. Disconnect the negative (-) battery cable. 3. Drain the engine coolant. CAUTION When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old. 4. Remove the upper radiator hoses and coolant fan connectors. 5. Remove the engine drive belts. 6. Remove the power steering pulley and remove the pump with bracket. 7. Remove the air duct from the intake manifold collector. 8. Disconnect the vacuum hoses, wiring, and harness connectors. 9. Remove the right front wheel and remove the inner wheel covers. 10. Remove the engine under covers. 11. Remove the cylinder head front mounting bracket. 12. Remove the valve cover from the engine. Be sure to loosen in reverse order of installation. 13. Remove the distributor cap and remove the spark plugs, if necessary. 14. Remove the intake manifold supports. 15. Position the No. 1 cylinder to TDC of compression stroke. 16. Matchmark the distributor rotor and the distributor housing. Remove the distributor from the vehicle, if necessary. 17. Remove the water pump pulley from water pump. 18. Remove the complete thermostat housing assembly from the engine.

19. Remove the lower timing chain tensioner. 20. Remove the upper timing chain tensioner and slack side timing chain guide. To install: 21. Confirm that No. 1 piston is set at TDC on compression stroke. 22. Install the crankshaft sprocket with the marks of the sprocket facing the front of the engine. 23. Install the oil pump drive spacer and install the chain guide. 24. Install the lower timing chain. Set the chain by aligning its mating mark with the one on the crankshaft sprocket. Make sure the sprocket's mating mark faces the front of the engine. NOTE: The number of links between the alignment marks are the same for the left and the right side. 25. Install the crankshaft sprocket and the lower timing chain. Set the timing chain by aligning its mating mark with the one on the crankshaft sprocket. Make sure sprocket's mating mark faces engine front. The number of links between the alignment marks are the same for the left and right side. 26. Using liquid gasket, install the front cover assembly. 27. Install engine front mounting bracket and install the engine mount. 28. Install the oil strainer, oil pan assembly, and the crankshaft pulley. 29. Install the center crossmember. 30. Set the idler sprocket by aligning the mating mark on the larger sprocket with the silver mating mark on the lower timing chain. 31. If necessary, install the upper timing chain and set it by aligning the mating mark on the smaller sprocket with the silver mating marks on the upper timing chain. Make sure sprocket marks face engine front. 32. Install the upper timing chain tensioner. Before installation of the tensioner, install a suitable pin to hold the tensioner in the relaxed position. After installing the chain tensioner, remove the pin. 33. Install the lower timing chain tensioner. Be sure the notch of the gasket is positioned down. 34. Apply liquid gasket to the thermostat housing and install the housing. Tighten the mounting bolts to 5573 inch lbs. (78 Nm). 35. Install the remaining components. Tighten the water pump mounting bolts to 5573 inch lbs. (78 Nm). 36. Using liquid gasket, install the cylinder head front cover. Tighten the mounting nuts or bolts to 3344 inch lbs. (45 Nm). NOTE: If any part of the valve assembly or camshafts have been replace, the valve lash clearance will have to be checked. 37. Tighten the valve cover bolts in sequence to 1835 inch lbs. (24 Nm). Be sure to install new gaskets for the spark plug tubes.

38. Tighten the spark plugs to 1422 ft. lbs. (2029 Nm). Connect the vacuum hoses, wiring and harness connectors. 39. Install the upper radiator hose and refill the system with coolant. 40. Connect the negative battery cable. Refill all fluid levels. Road test the vehicle for proper operation.
SR20DE Engine

The front oil seal can be replaced by removing the crankshaft damper. Review Crankshaft Damper procedures earlier in this section. Some engines may prove to be difficult to remove damper or oil with front cover and engine installed. It may be helpful to raise and support the car and remove the front wheels. In some cases it may be necessary to remove the engine or front cover. CAUTION Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve the fuel pressure, as outlined in Section 5 before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. 1. Relieve the fuel system pressure. 2. Disconnect the negative (-) battery cable. 3. Drain the engine coolant. CAUTION When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old. 4. Remove the radiator. 5. Remove the right front wheel and engine side cover. 6. Remove the spark plugs. 7. Rotate the engine and position the No. 1 cylinder to TDC. 8. Remove the air duct to the intake manifold. 9. Remove the drive belts and the water pump pulley. 10. Remove the alternator and the power steering pump from the engine. 11. Label and remove the vacuum hoses, fuel hoses, and the wire harness connectors. 12. Remove the intake manifold supports, if necessary. 13. Unbolt and remove the oil filter bracket and the power steering pump bracket. 14. Remove the timing chain tensioner, as needed. 15. Remove the timing chain guide. To install: 16. Clean all gasket mating surfaces.

17. If removed, install the crankshaft sprocket. Position the crankshaft so that No. 1 piston is set at TDC (keyway at 12 o'clock, mating mark at 4 o'clock) fit timing chain to crankshaft sprocket so the mating mark is in line with mating mark on crankshaft sprocket. The mating marks on timing chain for the camshaft sprockets should be silver. The mating mark on the timing chain for the crankshaft sprocket should be gold. 18. Install the timing chain to the crankshaft sprocket and install the timing chain guides. Tighten the timing chain guides to 914 ft. lbs. (1319 Nm). Drape the timing chain over the left chain guide. 19. Install the oil pump drive spacer to the crankshaft. 20. Apply a continuous bead of liquid sealant to the front timing cover and install the cover. Torque the front cover mounting bolts to 5766 inch lbs. (6.47.5 Nm). 21. Install right front engine mount. 22. Install the crankshaft pulley and tighten the mounting bolt to 105112 ft. lbs. (142152 Nm). Be sure the No. 1 piston is at TDC. 23. Install the oil strainer, baffle plate, and the oil pan assembly. 24. Be sure to apply a bead of sealant to the joint of the block and front timing cover. 25. Using new hose clamps, install the coolant hoses to the engine block. 26. Install the timing chain guide, if removed. 27. Install the chain tensioner. Press the cam stopper down and the press-in sleeve until the hook can be engaged on the pin. When tensioner is bolted in position the hook will release automatically. NOTE: Ensure the arrow on the outside of the tensioner faces the front of the engine. 28. Install the oil filter bracket and the power steering pump bracket. 29. Install the intake manifold supports. 30. Install a continuous bead of sealant to the rocker cover and install the cover. Torque the mounting bolts in sequence as follows: A. Tighten nuts No. 1, 10, 11, 13 and 8 (in that order) to 35 inch lbs. (4 Nm). B. Tighten nuts No. 1 through 13 in numerical order to 7086 inch lbs. (810 Nm). 31. Install the remaining components. Install the vacuum hoses, fuel hoses, and the wire harness connectors. Lower the vehicle, connect the negative battery cable, Refill fluid levels, start the engine, and bleed the cooling system. Check for leaks and road test the vehicle for proper operation.