Engine Rear Cover Installation

WARNING: This page is about a different car, the 2003 GMC Envoy XL and 2003 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

J 41480 Front/Rear Cover Alignment - Oil Pan Surface
J 41476 Front/Rear Cover Alignment - Crankshaft Oil Seal Area

IMPORTANT:

Do not use the crankshaft rear oil seal or the engine rear cover gasket again.
Do not apply any type sealant to the rear cover gasket, unless specified.
The special tools in this procedure are used to properly align the engine rear cover at the oil pan surface and to center the crankshaft rear oil seal.
The crankshaft rear oil seal will be installed after the rear cover has been installed and aligned. Install the rear cover without the crankshaft oil seal.
- The crankshaft rear oil seal MUST be centered in relation to the crankshaft.
- The oil pan sealing surface at the rear cover and engine block MUST be aligned within specifications.
- An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly oil leaks.
  
  Fig 1: Identifying Oil Pan Sealing Surface At Rear Cover Specifications
  Courtesy of GENERAL MOTORS CORP.

Inspect the rear oil gallery plug for proper installation.
Install the rear cover gasket, rear cover and bolts.
Tighten the bolts finger tight. Do not overtighten.

Fig 2: Installing Rear Cover Gasket, Rear Cover And Bolts
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

IMPORTANT: Start the J 41480 tool-to-rear cover bolts. Do not tighten the bolts at this time.
Install the J 41480 and bolts.
Tighten

Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft).

Fig 3: Installing J 41480 Tool And Bolts
Courtesy of GENERAL MOTORS CORP.

IMPORTANT: To properly align the rear cover, the J 41476 must be installed onto the rear of the crankshaft with the tool mounting bolts parallel to the oil pan surface.
Rotate the crankshaft until 2 opposing flywheel bolt holes are parallel to the oil pan surface.

Fig 4: Identifying Flywheel Bolt Holes Parallel To Oil Pan Surface Position
Courtesy of GENERAL MOTORS CORP.

IMPORTANT: The tapered legs of the alignment tool must enter the rear cover oil seal bore.
Install the J 41476 and bolts onto the rear of the crankshaft.
Tighten
1. 6.1. Tighten the tool mounting bolts until snug. Do not overtighten.
2. 6.2. Tighten the J 41480 tool-to-rear cover bolts evenly to 12 N.m (106 lb in).
3. 6.3. Tighten the rear cover bolts to 25 N.m (18 lb ft).
Remove the tools.

Fig 5: Installing J 41476 Tool And Bolts Onto Rear Of Crankshaft
Courtesy of GENERAL MOTORS CORP.
Measure the rear cover-to-engine block oil pan surface for flatness.
1. 8.1. Place a straight edge onto the engine block and rear cover oil pan sealing surfaces.
  Avoid contact with the portion of the gasket that protrudes into the oil pan surface.
2. 8.2. Insert a feeler gage between the rear cover and the straight edge. The cover must be flush with the oil pan or no more than 0.5 mm (0.02 in) below flush.
If the rear cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure.
If the correct rear cover-to-engine block alignment at the oil pan surface cannot be obtained, replace the rear cover.

Fig 6: Measuring Rear Cover-To-Engine Block Oil Pan Surface
Courtesy of GENERAL MOTORS CORP.