Engine Front Cover Installation

Special Tools

• EN-48853  Front Cover Alignment Tool
• J-41478  Crankshaft Front Oil Seal Installer
• J-41480  Front and Rear Cover Alignment

For equivalent regional tools, refer to Special Tools .

Fig 1: Alignment Tab Distance On Front Cover
Courtesy of GENERAL MOTORS COMPANY
1. Measure the alignment tab distance on the front cover.

   For 2009 model year, the engine front cover may have either a 141 mm (5.55 in) dimension (a) or 159 mm (6.26 in) dimension (b) alignment tab distance. The EN-48853  front cover alignment tool is designed to properly align both design front covers. For the 141 mm (5.55 in) cover, the EN 48853-2  adapters must be used.

Fig 2: Front Cover & Gasket
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 (3), front cover (2), and bolts (1).
3. Tighten the cover bolts finger tight. Do not overtighten.
Fig 3: Front & Rear Cover Alignment Tool
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 tool. Tighten the tool-to-engine block bolts to 25 N.m (18 lb ft).
Fig 4: Installing Special Tool 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  alignment tool with the words "cover side" (1) facing away from the tool.
Fig 5: Front & Rear Cover Alignment Tools
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  alignment tool (1).
7. Install the threaded rod, washer and nut from J-41478  crankshaft front oil seal installer.
8. Tighten the nut until snug, holding EN-48853  alignment tool firmly in place. Do not overtighten.
9. Tighten the engine front cover bolts to 25 N.m (18 lb ft).
10. Remove the tools.
Fig 6: Measuring Oil Pan Surface Flatness & Front Cover-To-Engine Block
Courtesy of GENERAL MOTORS COMPANY
11. 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 0.5 mm (0.02 in) (a) below flush.
12. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure.
13. If the correct front cover-to-engine block alignment cannot be obtained, replace the front cover.
Fig 7: Front Cover, Oil Seal, Camshaft Position Sensor, Bracket & O Ring
Courtesy of GENERAL MOTORS COMPANY
14. Inspect the camshaft position (CMP) sensor O-ring seal (3) for cuts or damage. If the seal is not cut or damaged, it may be used again.
15. Lubricate the O-ring seal with clean engine oil.
16. Install the O-ring seal onto the sensor (2).
17. Install the sensor to the cover.
18. Install the CMP sensor wire harness (5) and bolts (1, 6). Tighten the bolts to 12 N.m (106 lb in).