![]() although I am sure oil leaks are inevitable eventually Again I can't recommend that approach, but for now it seems to be working as I now have about 700 ish miles on my fresh 1296 engine build, no oil leaks as yet. I was also worried about the small groove in the pulley affecting the oil seal, but as there does not appear to be any obvious way to adjust where the groove in the pulley sits in relation to the oil seal lips, and no apparent way to adjust the location of the oil seal in the timing cover, again like any great "DPO" I moved the entire timing cover outwards just a bit by using doubled timing cover gaskets, glued together with Permatex "The Right Stuff". I have it on my long term list to keep a look out for a less beat up timing cover to acquire, but this one seems to be working for now. ![]() I can't recommend that approach, and there is not much movement available, but it worked for me with that particular slightly bent timing cover. My particular timing cover looked like it had been through a war, so I wasn't shy about taking a hammer to it, and then I became one of those "Dreaded Previous Owners" everyone complains about when I drilled the holes that the fixed pins sit into in the timing cover just a bit bigger so that I could shift the fit and location of the timing cover just a tiny bit to get a hopefully slightly more concentric fit of the seal to the pulley shaft. I did the things suggested in the earlier responses in this thread, especially clean bare metal mating surfaces, flat mating surfaces (pounding the dimpled bolt holes flat), and then when I fitted the pulley, the oil seal fit to the pulley shaft looked kind of "off" to me. Maybe the "young" seal in your cover right now may be easier to remove for you, hopefully! If there is a trick to more easily removing that oil seal, I wish I knew what it is! For some reason that was one of the most frustrating jobs in my entire engine rebuild, at least with the heavily rusted timing cover and ancient petrified seal I was working with. I don't envy you the task of getting the leaking oil seal out of that timing cover.
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