Engine Rear Cover - Body On

Engine Rear Cover - Body On









Glow Plug Module Heat Shield









High-Pressure Fuel Injection Pump Heat Shield









Fuel Rail Supply Tubes









High-Pressure Fuel Injection Pump Supply and Return Tubes









High-Pressure Fuel Injection Pump Cover









Engine Rear Cover

NOTE: Manual transmission engine rear cover shown, automatic transmission engine rear cover similar.











Removal

All vehicles

NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to Engine Rear Cover - Body Off Engine Rear Cover - Body Off.

1. WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

NOTICE: Failure to remove the high-pressure fuel injection pump cover when servicing the engine rear cover may result in damage to the high-pressure fuel injection pump cover gasket.

Shut the engine off and wait until the engine is cool or 5 minutes, whichever is longer, to allow the high-pressure fuel system to bleed off and the fuel to cool.

2. Remove the turbocharger. Carry out the Turbocharger - Body On procedure. For additional information, refer to Fuel Delivery and Air Induction.

3. Remove the EGR-Oxidation Catalytic Converter (OC) pipe from the vehicle.





4. Remove the bolt and the 5 retaining nuts for the high-pressure fuel injection pump heat shield. Remove the fuel tube bracket and position the engine-to-body ground wire.

5. Remove the remaining 2 bolts and the high-pressure fuel injection pump heat shield.

6. Remove the RH turbocharger inlet pipe.
- In order to remove the RH turbocharger inlet pipe, roll it to the left side of the vehicle and then remove the turbocharger inlet pipe.





7. Remove the 3 pushnuts and the glow plug module heat shield.
- Discard the pushnuts.

8. Remove the 2 fuel rail supply tube bracket bolts.

9. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in Fuel Delivery and Air Induction.

NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.

Remove and discard the fuel rail supply tubes.

10. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

Disconnect the fuel injector return tube fitting from the check valve.

11. Remove the 2 high-pressure fuel injection pump supply tube bracket nuts.

12. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in Fuel Delivery and Air Induction.

NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.

Remove the caps and the sealing washers from the high-pressure fuel injection pump. Remove the high-pressure fuel injection pump supply and return tubes.
- Discard the sealing washers.

13. Disconnect the high-pressure fuel injection pump electrical connector.

14. Remove the 5 bolts and the high-pressure fuel injection pump cover.

15. Remove and discard the press-in-place gasket from the high-pressure fuel injection pump cover.

16. NOTE: Use a thin gasket scraper to separate the gasket from the crankcase.

Disconnect the pressure control valve and volume control valve electrical connectors. Remove and discard the high-pressure fuel injection pump cover gasket.

17. Remove the crankshaft rear seal. For additional information, refer to Crankshaft Rear Seal Service and Repair.

18. Remove the starter. For additional information, refer to Starting System.

Manual transmission vehicles

19. Remove the 3 engine rear cover bolts.

All vehicles

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

Remove the 8 bolts from the engine rear cover.

21. NOTICE: 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 in) 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.





22. NOTICE: 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 in) 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.





23. Using a thin-blade scraper, remove the rear engine cover off the engine.
- Remove and discard the press-in-place gasket.

- Clean and inspect the sealing surfaces.

Installation

All vehicles

1. Apply a dime-sized bead of sealant at the back seam of the crankcase.





2. NOTICE: 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 (0.393 in) of the dowel extends toward the engine and 10 mm (0.393 in) extends toward the transmission.

Position the new press-in-place gasket, the engine rear cover and install the 8 bolts.

- Tighten to 31 Nm (23 lb-ft).

Manual transmission vehicles

3. Install the 3 engine rear cover bolts.
- Tighten to 62 Nm (46 lb-ft).

All vehicles

4. Install the starter. For additional information, refer to Starting System.

5. Install the crankshaft rear seal. For additional information, refer to Crankshaft Rear Seal Service and Repair.

6. Clean the cover mounting surface and apply a dime-sized bead of sealant at the seams.





7. NOTICE: Inspect the volume control valve and the pressure control valve electrical connectors for damage or obstructions at the connector and mating high-pressure fuel injection pump connector. Verify that the connectors are completely latched to the valve housings or engine damage may occur.

Install a new high-pressure fuel injection pump cover gasket. Connect the pressure control valve and volume control valve electrical connectors.

8. Install a new press-in-place gasket in the high-pressure fuel injection pump cover.

9. NOTE: Do not remove the Fuel System Caps from the high-pressure fuel injection pump until the fuel tubes are being installed.

Install the high-pressure fuel injection pump cover and 5 bolts.

- Tighten to 13 Nm (115 lb-in).

10. Connect the high-pressure fuel injection pump electrical connector.

11. NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in Fuel Delivery and Air Induction.

NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.

Install new sealing washers, high-pressure fuel injection pump supply tube, return tube and nuts at the high-pressure fuel injection pump.
- For Viton(R) sealing washers, tighten to 25 Nm (18 lb-ft).

- For copper sealing washer, tighten to 38 Nm (28 lb-ft).

12. Install the 2 high-pressure fuel injection pump supply tube bracket nuts.
- Tighten to 11 Nm (97 lb-in).

13. NOTE: Use a crowfoot wrench to aid in tightening the fitting.

Connect the fuel injector return tube fitting to the check valve.

- Calculate the correct torque wrench setting for the following torque.

- Tighten to 28 Nm (21 lb-ft).

14. NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in Fuel Delivery and Air Induction.

NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.

NOTE: Use a crowfoot wrench to aid in tightening the fuel rail supply tube.
Install the new fuel rail supply tubes in the following sequence.

1. Remove the Fuel System Caps from the fuel rail supply tube openings.

2. NOTE: Support the tubes while hand snugging the nut to make sure of correct assembly of the joints.

Position the fuel rail supply tubes between the high-pressure fuel injection pump and the high-pressure fuel rail. Fully hand start and seat the 4 fuel rail supply tube fittings onto the high-pressure fuel injection pump and high-pressure fuel rails.

3. Snug the 4 fuel rail tube fittings.
- Calculate the correct torque wrench setting for the following torque.

- Tighten to 2 Nm (18 lb-in).

4. Pre-tighten the 4 fuel rail supply tube fittings.
- Calculate the correct torque wrench setting for the following torque.

- Tighten to 12 Nm (106 lb-in).

5. NOTE: Place a visible mark with a permanent marker on the 4 fuel rail supply tube threaded connections. Turning the fuel injector supply tube nuts one flat of the fitting is equal to 60 degrees.

Final-tighten the fuel rail supply tube fittings.
- Tighten the 4 fuel rail supply tube fittings 60 degrees.

15. Install the 2 fuel rail supply tube bracket bolts.
- Tighten to 13 Nm (115 lb-in).

16. NOTE: Use a socket to aid in installing the pushnuts.

Install the glow plug module heat shield and 3 new pushnuts.

17. Position the RH turbocharger inlet pipe in the vehicle.





18. NOTICE: Failure to correctly install the high-pressure fuel injection pump heat shield may result in engine damage.

Install the high-pressure fuel injection pump heat shield in the vehicle and install the 2 center bolts.

- Tighten to 13 Nm (115 lb-in).

19. Position the fuel tube bracket and engine-to-body ground wire. Install the 5 retaining nuts and bolt for the high-pressure fuel injection pump heat shield.
- Tighten the fuel line bracket nuts to 7 Nm (62 lb-in).

- Tighten the remaining fasteners to 13 Nm (115 lb-in).

20. Position the EGR-OC pipe in the vehicle.





21. Install the turbocharger. Carry out the Turbocharger - Body On procedure. For additional information, refer to Fuel Delivery and Air Induction.