Engine Rear Cover

Engine Rear Cover





Special Tool(s)





Material

Removal
1. Remove the starter.
2. Remove the transmission.





3. Remove the bolts and the flexplate.
^ Discard the bolts.





4. NOTE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pin.

Remove the flywheel front adapter.





5. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.

Punch two holes in the rear main seal, across from each other.





6. Using the special tool, remove the rear main seal.

7. NOTE: Production engines will not have a wear sleeve.

If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.





8. Clean and inspect the crankshaft sealing surface.








9. Remove the bolts and the turbocharger heat shield.





10. 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.





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

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





12. 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 5-1/2-inch long thin blade scraper will be needed to properly cut the sealant.

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





13. 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 5-1/2-inch long thin blade scraper will be needed to properly cut the sealant.

Use a thin blade scraper 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. NOTE: Early build shown, late build similar.

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





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





4. Install the turbocharger heat shield and bolts.





5. NOTE: The crankshaft rear oil seal and wear sleeve are installed as an assembly.

NOTE: Lubricate the outer diameter of the rubber seal with a solution of dish soap and water (approximately 50/50) prior to assembly. Do not use any other type of lubricant.

NOTE: Apply a bead of high strength thread locker around the circumference of the outer rear edge of the secondary crankshaft flange.

NOTE: The rear main seal and wear sleeve are correctly seated when the crankshaft begins to rotate.

Using the special tool, install the crankshaft rear oil seal.





6. Install the front flywheel adapter.





7. Install the flexplate.
^ Install the new bolts.
^ Tighten to 5 Nm (44 inch lbs.).
^ Tighten to 94 Nm (69 ft. lbs.) in the sequence shown.

8. Install the transmission.
9. Install the starter.