Malibu 2001-2005

Rear Main Seal

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Support the engine.
  4.  
  5. Remove or disconnect the following:
    WARNING
    Use care not to damage the crankshaft seal surface with a pry tool.



    Transaxle
     
    Flywheel
     
    Rear main seal by prying it from the housing
     

  6.  

To install:

Click image to see an enlarged view

Fig. Using the seal installer to install the rear main seal.

  1. Lubricate the seal bore and new seal with engine oil.
  2.  
  3. Install the new seal by performing the following procedure:
    1. Slide the new seal over the mandrel until the dust lip bottoms squarely against the tool collar.
    2.  
    3. Align the dowel pin of the tool with the dowel pin hole in the crankshaft and attach the tool to the crankshaft. Tighten the attaching screws to 24-60 inch lbs. (2.7-6.8 Nm).
    4.  
    5. Tighten the T-handle of the tool to push the seal into the bore. Continue until the tool collar is flush against the block.
    6.  
    7. Loosen the T-handle completely. Remove the attaching screws and the tool.
      NOTE
      Check to see that the seal is squarely seated in the bore.

    8.  

  4.  
  5. Install or connect the following:

    Flywheel
     
    Transaxle
     

  6.  
  7. Start the engine and check for leaks.
  8.  

2.2L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Support the engine.
  4.  
  5. Remove or disconnect the following:
    WARNING
    Use care not to damage the crankshaft seal surface with a pry tool.



    Transaxle
     
    Flywheel
     
    Rear main seal by prying it from the housing
     

  6.  

To install:

Click image to see an enlarged view

Fig. Using the seal installer to install the rear main seal

  1. Lubricate the seal bore and new seal with engine oil.
  2.  
  3. Install the new seal by performing the following procedure:
    1. Slide the new seal over the mandrel until the dust lip bottoms squarely against the tool collar.
    2.  
    3. Align the dowel pin of the tool with the dowel pin hole in the crankshaft and attach the tool to the crankshaft. Tighten the attaching screws to 24-60 inch lbs. (2.7-6.8 Nm).
    4.  
    5. Tighten the T-handle of the tool to push the seal into the bore. Continue until the tool collar is flush against the block.
    6.  
    7. Loosen the T-handle completely. Remove the attaching screws and the tool.
      NOTE
      Check to see that the seal is squarely seated in the bore.

    8.  

  4.  
  5. Install or connect the following:

    Flywheel. Tighten flywheel bolts to 39 ft. lbs. (53Nm).
     
    Transaxle
     

  6.  
  7. Start the engine and check for leaks.
  8.  

3.5L & 3.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Before replacement of the new design crankshaft rear main oil seal, ensure the Positive Crankcase Ventilation (PCV) system is operating correctly.

  2.  
  3. Support the engine.
  4.  
  5. Remove the transaxle.
  6.  
  7. Remove the engine flywheel.
  8.  
  9. The EN-48672 has a unique design to allow the technician to easily remove the rear main seal without nicking the crankshaft sealing surface when removing the seal. Before proceeding with removal, review the illustration to become familiar with the components.

    Click image to see an enlarged view

    Fig. EN-48672 rear seal removal tool

  10.  
  11. Install the removal plate and both threaded adjustment pins and jam nuts into the back of the crankshaft flange and secure the plate with adjustment pins and jam nuts.
  12.  
  13. Install the number 2 self drill screws 38 mm (1.5 in) long, 8 needed and tighten the screws down flush to the plate.
  14.  
  15. Before installing the force screw, apply a small amount of the extreme pressure lubricant J 23444-A, provided in the tool kit.
  16.  
  17. Install the force screw and back off both jam nuts. Continue to turn the force screw into the removal plate in order to remove the seal from the crankshaft.

    Click image to see an enlarged view

    Fig. Rear main oil seal removal with tool EN-48672 shown

  18.  
  19. Once the seal is removed from the crankshaft, remove and save all 8 screws. Discard the old seal.
  20.  

To install:


WARNING
Do not remove the protective sleeve from the seal. The sleeve assures the seal is installed correctly and protects the seal from damage. If removed, the EN-48108 installation tool will not work.


NOTE
Clean the crankshaft sealing surface with a clean, lint free towel. Inspect lead-in edge of crankshaft for burrs/sharp edges that could damage the rear main oil seal. Remove burrs/sharp edges with crocus cloth before proceeding.


WARNING
Do not remove protective nylon sleeve prior to installation. The rear main oil seal installation tool is designed to install the rear main seal with the protective sleeve in place. Never apply or use any oil, lubricants or sealing compounds on the crankshaft rear main oil seal.

A new design crankshaft rear main oil seal and installation tool, EN-48108 , has been released. This seal incorporates features that improve high mileage durability. Replace the crankshaft rear main oil seal with the new design rear main oil seal, GM P/N 12592195 (Canadian P/N 12592195).

  1. The EN-48108 has a unique design to allow the technician to easily install the rear main seal squarely to the correct depth and direction. Before proceeding with installation, review the illustration to become familiar with the components.

    Click image to see an enlarged view

    Fig. EN-48108 rear main oil seal Installation tool

  2.  
  3. Align the mandrel dowel pin to the dowel pin hole in the crankshaft.
  4.  
  5. Using a large flat-blade screwdriver, tighten the 2 mandrel screws to the crankshaft. Ensure the mandrel is snug to the crankshaft hub.

    Click image to see an enlarged view

    Fig. Tightening the 2 mandrel screws to the crankshaft

  6.  
  7. Install the rear main seal, with the protective nylon sleeve attached, onto the mandrel. The seal, if properly installed, will center on a step that protrudes from the center of the mandrel. As an error proof, the seal will fit only 1 way onto the mandrel.
    NOTE
    Before installing the outer drive drum, bearing, washer, and drive nut onto the threaded shaft, apply a small amount of the extreme pressure lubricant J 23444-A, provided in the tool kit.



    Click image to see an enlarged view

    Fig. Installation of the rear main seal onto the mandrel

  8.  
  9. Install the outer drive drum onto the mandrel.
  10.  
  11. Install the bearing, washer, and drive nut onto the threaded shaft.
  12.  
  13. Using a wrench, turn the drive nut on the mandrel, which will push the seal into the engine block bore. Turn the wrench until the drive drum is snug and flush against the engine block.

    Click image to see an enlarged view

    Fig. Installation of rear main seal until the drive drum is flush against the engine block

  14.  
  15. Loosen and remove the drive nut, washer, bearing, and drive drum. Discard the protective nylon sleeve.
  16.  
  17. Verify that the seal has seated properly.
  18.  
  19. Use a flat-blade screwdriver in order to remove the 2 attachment screws from the mandrel and remove the mandrel from the crankshaft hub.
  20.  
  21. Position the flywheel to the crankshaft.
  22.  
  23. Install the flywheel bolts finger tight.
  24.  
  25. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating.
  26.  
  27. Install the engine flywheel bolts and tighten to 52 ft. lbs. (70 Nm).
  28.  
  29. Install the automatic transaxle.
  30.  
  31. Start the engine and check for leaks.
  32.  

 
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