### Timing Chain Cover

#### REMOVAL & INSTALLATION

##### 200SX (Z Series Engine)

Fig. 1: Timing chain front cover — Z series engine

NOTE: It may be necessary to remove additional components to perform this operation if you cannot cut the gasket cleanly as described in Step 10. The CA20E, CA18ET and VG30E are belt driven engines.

1. Disconnect the negative battery cable from the battery, drain the cooling system, and remove the radiator together with the upper and lower radiator hoses.
2. Loosen the alternator drive belt adjusting screw and remove the drive belt. Remove the bolts, which attach the alternator bracket to the engine and set the alternator aside out of the way.
3. Mark and remove the distributor. Refer to Distributor Removal And Installation if necessary.
4. Remove the oil pump attaching screws, and take out the pump and its drive spindle.
5. Remove the cooling fan and the fan pulley together with the drive belt.
6. Remove the water pump.
7. Remove the crankshaft pulley bolt and remove the crankshaft pulley.
8. Remove the bolts holding the front cover to the front of the cylinder block, the four bolts which retain the front of the oil pan to the bottom of the front cover, and the two bolts which are screwed down through the front of the cylinder head and into the top of the front cover.
9. Carefully pry the front cover off the front of the engine.

   To install:

10. Cut the exposed front section of the oil pan gasket away from the oil pan. Do the same to the gasket at the top of the front cover. Remove the two side gaskets and clean all of the mating surfaces.
11. Cut the portions needed from a new oil pan gasket and top front cover gasket.
12. Apply sealer to all of the gaskets and position them on the engine in their proper places.
13. Apply a light coating of grease to the crankshaft oil seal and carefully mount the front cover to the front of the engine and install all of the mounting bolts.

    Tighten the 8mm bolts to 7–12 ft. lbs. and the 6mm bolts to 36–72 inch lbs. Tighten the oil pan attaching bolts to 48–84 inch lbs.

14. Before installing the oil pump, place the gasket over the shaft and make sure that the mark on the drive spindle faces (aligned) with the oil pump hole.
15. Install the oil pump after priming it with oil. For oil pump installation procedures, see Oil Pump Removal and Installation in this section.
16. Install the crankshaft pulley and bolt.
17. Install the water pump with a new gasket. Install the fan pulley and cooling fan. Install the drive belt and adjust the belt to the correct tension.
18. Install the distributor in the correct position. Reconnect the alternator bracket and alternator if it was removed. Install the drive belt and adjust the belt to the correct tension.
19. Reconnect the upper and lower radiator hoses and refill the cooling system.
20. Reconnect the negative battery cable. Start the engine, check ignition timing and check for leaks.

##### 240SX (KA24DE Engine)

1. Remove the negative battery cable.
2. Drain the engine oil and coolant.
3. Remove the cylinder head assembly.
4. Raise and support the vehicle safely. Remove the oil pan, oil strainer and baffle plate.
5. Remove the crankshaft pulley using a suitable puller. Removal of the radiator may be necessary to gain clearance.
6. Support the engine and remove the front engine mount.
7. Loosen the front cover bolts in two or three steps and remove the front cover.

   To install:

8. Clean all mating surfaces of liquid gasket material.
9. Apply a continuos bead of liquid gasket to the mating surface of the timing cover. Install the oil pump drive spacer and front cover. Tighten front cover bolts (in steps) to 56 ft. lbs. (68 Nm). Wipe excess liquid gasket material.
10. Install front engine mount.
11. Install crankshaft pulley and tighten bolt to specifications. Set No. 1 piston at TDC on the compression stroke.
12. Install the oil strainer and baffle. Install the oil pan.
13. Install the cylinder head assembly.
14. Lower the vehicle, connect the negative battery cable, Refill fluid levels, start the engine and check for leaks. Road test the vehicle for proper operation.

##### 240SX (KA24E Engine)

1. Disconnect the negative battery cable.
2. Drain the cooling system and oil pan. To drain the cooling system, open the radiator drain cock and remove the engine block drain plug. The block plug is located on the left side of the block near the engine freeze plugs.
3. Remove the radiator shroud and the cooling fan.
4. Loosen the alternator drive belt adjusting screw and remove the drive belt.
5. Remove the power steering and air conditioning drive belts.
6. Remove the spark plugs and the distributor cap. Set the No. 1 piston to TDC of the compression stroke. Carefully remove the distributor. Before removal, scribe alignment marks in the timing cover and flat portion of the oil pump/distributor drive spindle. This alignment is critical and if not done properly, it could cause difficulty is aligning the distributor and setting the timing.
7. Remove the power steering pump, idler pulley and the power steering brackets.
8. Remove the air conditioning compressor idler pulley.
9. Remove the crankshaft pulley bolt and remove the crankshaft pulley with a 2 jawed puller.
10. Remove the oil pump attaching screws, and withdraw the pump and its drive spindle.
11. Remove the rocker arm cover.
12. Remove the oil pan.
13. Remove the bolts holding the front cover to the front of the cylinder block, the 4 bolts which retain the front of the oil pan to the bottom of the front cover, and the 4 bolts which are screwed down through the front of the cylinder head and into the top of the front cover. Carefully pry the front cover off the front of the engine. Clean all the old sealant from the surface of the front cover and the cylinder block.
14. Replace the crankshaft oil seal and the 2 timing chain cover oil seals in the block. These two seals should be installed in the block and not in the timing cover.

    To install:

15. Verify the No. 1 piston is at TDC of the compression stroke. Apply a very thin bead of high temperature liquid gasket to both sides of the front cover and to where the cover mates with the cylinder head. Apply a light coating of grease to the crankshaft and timing cover oil seals and carefully bolt the front cover to the front of the engine.

    NOTE: When installing the front cover, be careful not to damage the cylinder head gasket or to disturb the position of the oil seals in the block. Make sure the tab on the larger block oil seal is pointing to the exterior of the block.

16. Install new rubber plugs in the cylinder head.
17. Install the oil pan.
18. Install the rocker arm cover.
19. Before installing the oil pump, place the gasket over the shaft and make sure the mark on the drive spindle faces (aligned) with the oil pump hole. Install the oil pump and distributor driving spindle into the front cover with a new gasket.
20. Install the crankshaft pulley and bolt. Torque the pulley bolt to 87–116 ft. lbs. (118–157 Nm).
21. Install the distributor and the spark plugs.
22. Install the compressor idler pulley. Install power steering pump brackets, idler pulley and power steering pump. Install the drive belts and adjust the tension.
23. Install the radiator shroud and the cooling fan.
24. Refill the cooling system and crankcase to the proper levels.
25. Connect the negative battery cable.
26. Start the engine, check/set the ignition timing and check for engine leaks. Road test the vehicle for proper operation.

    Fig. 2: Timing chain cover — 240SX KA24E engine

    Fig. 3: Aligning the timing cover and distributor/oil pump drive — 240SX KA24E engine

    Fig. 4: Cylinder block timing chain cover seals — make sure tab on larger seal is positioned as shown — 240SX KA24E engine

    Fig. 5: Applying sealant to front cover — 240SX KA24E engine

##### Stanza (KA24E Engine)

1. Disconnect the negative battery cable.
2. Raise the front of the vehicle and support safely.
3. Remove the right front wheel.
4. Remove the dust cover and undercover.
5. Drain the oil pan.
6. Set the No. 1 piston at TDC of the compression stroke.
7. Remove the alternator and air conditioning compressor drive belts.
8. Remove the alternator and adjusting bar.
9. Remove the oil separator.
10. Remove the power steering pump pulley, pump stay and mounting bracket.
11. Discharge the air conditioning system and remove the compressor and mounting bracket.
12. Remove the crankshaft pulley and oil pump drive boss.
13. Remove the oil pan.
14. Remove the oil strainer mounting bolt.
15. Remove the bolts that attach the front cover to the head and the block.
16. Remove the rocker cover.
17. Support the engine with a suitable lifting device.
18. Unbolt the right side engine mount bracket from the block and lower the engine.
19. Remove the front cover.
20. Clean all the old sealant from the surface of the front cover and the cylinder block.
21. Replace the crankshaft oil seal and the 2 timing chain cover oil seals in the block. These two seals should be installed in the block and not in the timing cover.

    To install:

22. Verify the No. 1 piston is at TDC. Apply a very thin bead of high temperature liquid gasket to both sides of the front cover and to where the cover mates with the cylinder head. Apply a light coating of grease to the crankshaft and timing cover oil seals and carefully mount the front cover to the front of the engine.

    NOTE: When installing the front cover, be careful not to damage the cylinder head gasket or to disturb the position of the oil seals in the block. Make sure the tab on the larger block oil seal is pointing to the exterior of the block.

23. Install new rubber plugs in the cylinder head.
24. Raise the engine and install the right engine mount bracket bolts. Torque the bolts to 58–65 ft. lbs. (78–88 Nm).
25. Install the rocker arm cover.
26. Install the front cover bolts.
27. Install the oil strainer mounting bolt.
28. Install the oil pan.
29. Install the oil pump drive boss and the crankshaft pulley. Torque the pulley bolt to 87–116 ft. lbs. (118–157 Nm).
30. Install the air conditioning compressor bracket and mount the compressor.
31. Install the power steering bracket, pump stay and power steering pump.
32. Install the oil separator.
33. Install the dust cover and undercover.
34. Mount the right front wheel and lower the vehicle.
35. Fill the crankcase to the proper level and charge the air conditioning system.
36. Make all the necessary engine adjustments.