Engine Rear Cover - Body On: Installation

All vehicles 

1. Apply a dime-sized bead of sealant at the back seam of the crankcase.
   Fig 1: Locating Sealant At Back Seam Of Upper And Lower Crankcase

   Courtesy of FORD MOTOR CO.
NOTE: 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.
2. 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 - DIESEL ENGINES .
5. Install the crankshaft rear seal. For additional information, refer to CRANKSHAFT REAR SEAL .
6. Clean the cover mounting surface and apply a dime-sized bead of sealant at the seams.
   Fig 2: Locating Bead Of Sealant At Seams

   Courtesy of FORD MOTOR CO.
NOTE: 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.
7. 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.
NOTE: Do not remove the Fuel System Caps from the high-pressure fuel injection pump until the fuel tubes are being installed.
9. 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.
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 CHARGING AND CONTROLS - 6.4L DIESEL .
NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.
11. Install new sealing washers, high-pressure fuel injection pump supply tube, return tube and nuts at the high-pressure fuel injection pump.
    • For Viton® 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).
NOTE: Use a crowfoot wrench to aid in tightening the fitting.
13. Connect the fuel injector return tube fitting to the check valve.
    • Calculate the correct torque wrench setting for the following torque. Refer to the illustration   . See Fig 3.
      Fig 3: Torque Wrench Adapter Formulas

      
    • Tighten to 28 Nm (21 lb-ft).
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 CHARGING AND CONTROLS - 6.4L DIESEL .
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.
14. Install the new fuel rail supply tubes in the following sequence.
    1. Remove the Fuel System Caps from the fuel rail supply tube openings.
    NOTE: Support the tubes while hand snugging the nut to make sure of correct assembly of the joints.
    2. 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. Refer to the illustration   . See Fig 4.
         Fig 4: Torque Wrench Adapter Formulas

         
       • 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. Refer to the illustration   . See Fig 5.
         Fig 5: Torque Wrench Adapter Formulas

         
       • Tighten to 12 Nm (106 lb-in).
    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.
    5. 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).
NOTE: Use a socket to aid in installing the pushnuts.
16. Install the glow plug module heat shield and 3 new pushnuts.
17. Position the RH turbocharger inlet pipe in the vehicle.
    Fig 6: Locating RH Turbocharger Inlet Pipe

    Courtesy of FORD MOTOR CO.
NOTE: Failure to correctly install the high-pressure fuel injection pump heat shield may result in engine damage.
18. 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.
    Fig 7: Locating EGR-Oxidation Catalytic Converter Pipe

    Courtesy of FORD MOTOR CO.
21. Install the turbocharger. Carry out the Turbocharger - Body On procedure. For additional information, refer to FUEL CHARGING AND CONTROLS - TURBOCHARGER .