Engine Front Cover Installation

Special Tools

• EN-48853  Front Cover Alignment Tool. See Special Tools .
• J 41480  Front and Rear Cover Alignment

Fig 1: Identifying Alignment Tab Distance On Front Cover
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
• Do not use the crankshaft oil seal or the engine front cover gasket again.
• Do not apply any type of sealant to the front cover gasket, unless specified.
• The special tools in this procedure are used to properly align the engine front cover at the oil pan surface and to center the crankshaft front oil seal.
  • All gasket surfaces should be free of oil or other foreign material during assembly.
  • The crankshaft front oil seal MUST be centered in relation to the crankshaft.
  • The oil pan sealing surface at the front cover and engine block MUST be aligned within specifications.
  • An improperly aligned front cover may cause premature front oil seal wear and/or engine assembly oil leaks.
  • First design covers are to be replaced and not reinstalled during assembly.
1. Measure the alignment tab distance on the front cover.

   A very limited number of first design front covers with the 162 mm (6.38 in) alignment tab dimension (a) have been produced. In situations where the engine has a front cover with the 162 mm (6.38 in) dimension (a), the cover is to be replaced. Front cover alignment tool EN-48853  is designed to properly align the second design 159 mm (6. See Special Tools .26 in) front cover (b).

Fig 2: Engine Front Cover Components
Courtesy of GENERAL MOTORS CORP.
2. Install the front cover gasket (503), front cover (502), and bolts (501).
3. Tighten the cover bolts finger tight. Do not overtighten.
Fig 3: View Of Front & Rear Cover Alignment Tool J 41480
Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Fastener Notice .
IMPORTANT: Start the tool-to-front cover bolts. Do not tighten the bolts at this time.
4. Install the J 41480  .

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

Fig 4: Identifying Front Cover Alignment Tool EN-48853
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Align the tapered legs of the tool with the machined alignment surfaces on the front cover.
5. Install the EN-48853  (1). See Special Tools .
6. Install the crankshaft balancer bolt.

   Tighten: 

   1. Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten.
   2. Tighten the J 41480  (2).
   3. Tighten the engine front cover bolts to 25 N.m (18 lb ft).

7. Remove the tools.
Fig 5: Measuring Oil Pan Surface Flatness & Front Cover-To-Engine Block
Courtesy of GENERAL MOTORS CORP.
8. Measure the oil pan surface flatness, front cover-to-engine block.
   1. Place a straight edge across the engine block and front cover oil pan sealing surfaces.

      Avoid contact with the portion of the gasket that protrudes into the oil pan surface.

   2. Insert a feeler gage between the front cover and the straight edge tool. The cover must be flush with the oil pan surface or no greater than 0.5 mm (0.02 in) (a) below flush.
9. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure.
10. If the correct front cover-to-engine block alignment cannot be obtained, replace the front cover.
Fig 6: View Of CMP Actuator Magnet, Bolts, Gasket & Oil Seal
Courtesy of GENERAL MOTORS CORP.
11. Install the camshaft position (CMP) actuator magnet (752), gasket (753), and bolts (751).

    Tighten:  Tighten the bolts to 12 N.m (106 lb in).

Fig 7: View Of CMP Sensor & O-Ring
Courtesy of GENERAL MOTORS CORP.
12. Install the CMP sensor (703) and O-ring (704).
Fig 8: View Of CMP Sensor Wire Harness & Bolts
Courtesy of GENERAL MOTORS CORP.
13. Install the CMP sensor wire harness (737) and bolts (738).

    Tighten:  Tighten the bolts to 12 N.m (106 lb in).