Access Cover: Service and Repair

Engine Rear Cover

Material:

Removal

1. Remove the starter.
2. Remove the crankshaft rear seal.
3. If equipped with a heat shield bracket, remove the retaining nuts from the heat shield bracket.
^ Disconnect the ground wire from the stud.





4. If equipped with a heat shield bracket, disconnect the wiring retainer from the heat shield bracket.





5. If equipped with a heat shield bracket, remove the bolts and heat shield bracket.





6. NOTE: Early build shown, late build similar.

Remove the bolts for the turbocharger heat shield. Position aside or remove the turbocharger heat shield.





7. CAUTION: To prevent engine damage, replace damaged or missing dowel pins before installing the rear engine cover.

Remove the 8 bolts from the rear engine cover.





8. NOTE: Use care when removing the engine rear cover so that the oil pump cover gasket is not pulled out on removal.

Using a thin-blade scraper, cut the sealant at the oil pump cover joint.





9. CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 139.7 mm (5.5 inch) long thin-blade scraper will be needed to correctly cut the sealant.

Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.





11. CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 139.7 mm (5.5 inch) long thin-blade scraper will be needed to correctly cut the sealant.

Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove the rear cover.
^ Remove and discard the press-in-place gasket.
^ Clean and inspect the sealing surfaces.





Installation

1. Apply a bead of sealant at the back seam of the upper and lower crankcase.





2. Apply a bead of sealant at the oil pump cover joint.





3. CAUTION: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.

NOTE: Prior to installing the engine rear cover, check that the alignment dowels are centered so that 10 mm (0.39 in) of the dowel extends toward the engine and 10 mm (0.39 in) extends toward the transmission.

Install the engine rear cover
^ Install the press in place gasket.
^ Install the engine rear cover.
^ Install the bolts.





4. Position back or install the turbocharger heat shield and bolts.





5. If equipped with a heat shield bracket, install the heat shield bracket and bolts.





6. If equipped with a heat shield bracket, connect the wiring retainer to the back of the heat shield bracket.





7. If equppied with a heat shield bracket, position back the ground wire and install the retaining nuts





8. Install the crankshaft rear seal.

9. Install the starter.