Engine Front Cover Installation

Special Tools

• EN-48853  Front Cover Alignment Tool
• J 41480  Front and Rear Cover Alignment

For equivalent regional tools, refer to Special Tools

Fig 1: Identifying Engine Front Cover Alignment Tab Distance
Courtesy of GENERAL MOTORS COMPANY
1. The engine front cover alignment tab distance is 141 mm (5.55 in), see dimension (a). The EN-48853-2  adapters must be used with the EN-48853  alignment tool to properly align the front covers.
Fig 2: Engine Front Cover Components
Courtesy of GENERAL MOTORS COMPANY
CAUTION:

Refer to Fastener Caution .

NOTE:
• 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.
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: Aligning Front Cover Using Special Tool J 41480
Courtesy of GENERAL MOTORS COMPANY
NOTE:

Start the tool-to-front cover bolts. Do not tighten the bolts at this time.

4. Install the J 41480  alignment and tighten to 25 N.m (18 lb ft).
Fig 4: Installing EN 48853-2 Adapters
Courtesy of GENERAL MOTORS COMPANY
5. Install the EN 48853-2 adapters as required for usage on the 141 mm (5.55 in) dimension (a) front cover. Position the adapters against the legs of the EN-48853  tool with the words "cover side" (1) facing away from the tool.
Fig 5: View Of Special Tool EN-48853
Courtesy of GENERAL MOTORS COMPANY
NOTE:

Align the tapered legs of the tool with the machined alignment surfaces on the front cover.

6. Install the EN-48853  tool (1).
7. Install the crankshaft balancer bolt.
   1. Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten.
   2. Tighten the J 41480  alignment (2).
   3. Tighten the engine front cover bolts to 25 N.m (18 lb ft).
8. Remove the tools.
Fig 6: Measuring Oil Pan Surface Flatness & Front Cover-To-Engine Block
Courtesy of GENERAL MOTORS COMPANY
9. 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 gauge between the front cover and the straight edge tool. The cover must be flush with the oil pan surface or no greater than 0.3 mm (0.0118 in) (a) below flush.
10. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure.
11. If the correct front cover-to-engine block alignment cannot be obtained, replace the front cover.
Fig 7: View Of CMP Actuator Magnet, Bolts, Gasket & Oil Seal
Courtesy of GENERAL MOTORS COMPANY
12. Install the camshaft position (CMP) actuator magnet (752), gasket (753), and bolts (751). Tighten the bolts to 10 N.m (89 lb in).
Fig 8: View Of CMP Sensor & O-Ring
Courtesy of GENERAL MOTORS COMPANY
13. Install the CMP sensor (703) and O-ring (704).
Fig 9: View Of CMP Sensor Wire Harness & Bolts
Courtesy of GENERAL MOTORS COMPANY
14. Install the CMP sensor wire harness (737) and bolts (738). Tighten the bolts to 10 N.m (89 lb in).