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In the automotive engines, knowledge on the thermo-elasticity a priori is very informative in the early design stage. Especially, increasing demand on engine performance and fuel economy has resulted in progressively higher loadings on internal components of combustion engines with lighter weight. Therefore the structural integrity should be confirmed in the early engine design stage otherwise engine development cost will be huge. Cover type components like front cover have shown very high and localized hot spot at the bolt boss flange in many of the engine analyses. A lot of time and effort had been put to reduce this high stress by changing the design, but those have not always been effective. Therefore an effective guideline for cover flange design became necessary. This study describes an efficient and reliable analysis technique for minimizing stress of front cover flange by using automated computer modeling and numerical method.