For 1990-2009 cars

#### Tools Required

• | J 41480 Front and Rear Cover Alignment

• | J 41476 Front and Rear Cover Alignment Tool

### Installation Procedure

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 correctly align the engine front cover at the oil pan surface and to centre 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 centred in relation to the crankshaft.

- | The oil pan sealing surface at the front cover and engine block MUST be aligned within specifications.

- | An incorrectly aligned front cover may cause premature front oil seal wear and/or engine assembly oil leaks.

1. Install the engine front cover gasket (3) and engine front cover (2).
2. Install the engine front cover retaining bolts (1).

DO NOT fully tighten at this stage.

3. Position the J 41480 (1), and start the engine front cover aligning tool to front cover bolts (2).

DO NOT fully tighten at this stage.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the engine front cover aligning tool to cylinder block retaining bolts (3).

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

Important: Align the tapered legs of the J 41476 (3) with the machined alignment surfaces on the front cover.

5. Install the J 41476 (3).
6. Install the crankshaft balancer retaining bolt and tighten the crankshaft balancer bolt by hand until firm. Do not over tighten.
7. Tighten the engine front cover aligning tool to front cover bolts (2).

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

8. Tighten the engine front cover to cylinder block retaining bolts (4).

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

9. Remove the J 41476 (3).
10. Remove the J 41480 (1).
11. Measure the oil pan surface flatness, front cover-to-engine block.

11.1. | 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.

11.2. | 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 (A) below flush.

Specification
Dimension (A): 0.5 mm (0.02 in)

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.