Engine Rear Cover

Engine Rear Cover

Special Tool(s):

Material:

Removal

All vehicles
1. Remove the starter.
2. Remove the transmission.

Vehicles with manual transmission
3. Remove the clutch disc and pressure plate.

All vehicles
4. Remove the bolts and the flexplate or flywheel.
^ Discard the bolts.





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

Remove the flywheel front adapter.





6. 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.

NOTE: The drill bit used must be the appropriate size for the body dent puller used in the following step.

Using the appropriate drill bit, drill a hole on the RH side of the seal and another directly across from it on the LH side of the seal, as shown.





7. NOTE: It will be necessary to alternate between the 2 holes, drilled in the previous step, to walk the seal out of the engine rear cover.

Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.





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

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





9. Clean and inspect the crankshaft sealing surface.





10. Remove the nuts from the heat shield bracket and disconnect the ground wire from the stud.





11. Disconnect the wiring retainer from the heat shield bracket.





12. Remove the bolts and heat shield bracket.





13. Remove the 3 bolts and the turbocharger heat shield.





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

Remove the 11 bolts from the rear engine cover.





15. 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.





16. 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.





17. 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

All vehicles

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. Position the press in place gasket, the rear engine cover and install the bolts.
^ Tighten to 24 Nm (18 ft. lbs.).





4. Position the turbocharger heat shield and install the 3 bolts.
1 Tighten to 49 Nm (36 ft. lbs.).
2 Tighten to 11 Nm (8 ft. lbs.).





5. Install the heat shield bracket and bolts.





6. Connect the wiring harness retainer to the back of the heat shield bracket.





7. Position back the ground wire and install the nuts





8. NOTE: The crankshaft rear 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 Threadlock 262 around the circumference of the outer rear edge of the secondary crankshaft flange.

Using the special tool, install a new crankshaft rear seal.





9. Install the front flywheel adapter.





10. Position the flexplate or flywheel and install the new bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 94 Nm (69 ft. lbs.).





Vehicles with manual transmission
11. Install the clutch and pressure plate.

All vehicles
12. Install the transmission.
13. Install the starter.