LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2002 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2436 (Engine - 6.4L 99R Diesel -- F250-F550 Super Duty) >> In-Vehicle Servicing >> Engine Rear Cover - Body Off >> Removal

Engine Rear Cover - Body Off: Removal

WARNING: This page is about a different car, the 2008 Ford Pickup, 2008 Ford F550 Super Duty, 2008 Ford F450 Super Duty, and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles 

NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Engine Rear Cover - Body On .
    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.
    NOTE: 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.
  1. Shut the engine off and wait until the engine is cool or 5 minutes, whichever is longer, to allow the high-pressure fuel system pressure to bleed off and the fuel to cool.
  2. Remove the crankshaft rear seal. For additional information, refer to Crankshaft Rear Seal - Early Build  or Crankshaft Rear Seal - Late Build .
  3. Remove the turbocharger inlet pipes. Carry out the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - 6.4L Diesel, Body Off procedure. For additional information, refer to EXHAUST SYSTEM article.
  4. Remove the 3 push nuts and the glow plug module heat shield.
    • Discard the push nuts.
  5. Remove the 3 RH high-pressure fuel injection pump heat shield bolts.
  6. Remove the 2 RH high-pressure fuel injection pump heat shield nuts and position the engine-to-body ground wire aside. Remove the RH high-pressure fuel injection pump heat shield.
  7. Remove the 3 nuts, the fuel tube bracket and the LH high-pressure fuel injection pump heat shield.
  8. Remove the 2 fuel rail supply tube bracket bolts.
    9. NOTE: 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.
  9. Remove and discard the fuel rail supply tubes.
  10. Disconnect the high-pressure fuel injection pump electrical connector.
    11. NOTE: 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.
  11. Disconnect the fuel injector return tube fitting from the check valve.
  12. Loosen the 2 high-pressure fuel injection pump supply tube bracket nuts.
    13. NOTE: 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 pump from turning.
  13. Remove the nuts and the copper sealing washers from the high-pressure fuel injection pump. Remove the return tube and position the high-pressure fuel injection pump supply aside.
    • Discard the copper sealing washers.
    14. NOTE: Rotate the cover to the right when removing the cover.
  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-blade scraper to separate the gasket from the crankcase.
  16. 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 starter. For additional information, refer to STARTING SYSTEM - DIESEL ENGINE article.

    18. Manual transmission vehicles 

  18. Remove the 3 engine rear cover bolts.

    19. All vehicles 

    NOTE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.
  19. Remove the 8 bolts from the engine rear cover.
    20. NOTE: 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.
  20. Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.
    21. Fig 1: Using Thin-Blade Scraper To Cut Sealant Where Crankcase And Lower Crankcase Meet
    GF0005725Courtesy of FORD MOTOR CO.
    NOTE: 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.
  21. Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.
    22. Fig 2: Using Thin-Blade Scraper To Cut Sealant Where Crankcase And Lower Crankcase Meet
    GF0005726Courtesy of FORD MOTOR CO.
  22. Using a thin blade scraper, remove the rear cover off the engine.
    • Remove and discard the press-in-place gasket.
    • Clean and inspect the sealing surfaces.
scientia non olet · About LEMON Manuals