Engine Rear Cover - Body On: Removal

All vehicles 

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 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 CHARGING AND CONTROLS - TURBOCHARGER .
3. Remove the EGR-Oxidation Catalytic Converter (OC) pipe from the vehicle.
   Fig 1: Locating EGR-Oxidation Catalytic Converter Pipe

   Courtesy of FORD MOTOR CO.
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.
     Fig 2: Locating RH Turbocharger Inlet Pipe

     Courtesy of FORD MOTOR CO.
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.
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 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.
9. Remove and discard the fuel rail supply tubes.
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.
10. Disconnect the fuel injector return tube fitting from the check valve.
11. Remove the 2 high-pressure fuel injection pump supply tube bracket nuts.
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 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.
12. 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.
NOTE: Use a thin gasket 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 crankshaft rear seal. For additional information, refer to CRANKSHAFT REAR SEAL .
18. Remove the starter. For additional information, refer to STARTING SYSTEM - DIESEL ENGINES .

    Manual transmission vehicles 

19. Remove the 3 engine rear cover bolts.

    All vehicles 

NOTE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.
20. Remove the 8 bolts from the engine rear cover.
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.
Fig 3: Cutting Sealant Where Crankcase And Lower Crankcase Meet
Courtesy of FORD MOTOR CO.
21. Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.
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.
Fig 4: Cutting Sealant Where Crankcase And Lower Crankcase Meet
Courtesy of FORD MOTOR CO.
22. 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.