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This assumes that:
Given the above you should be looking at something like this - this is for a TI rear cover so there's no upper engine mounts above the water pump, in case you're wondering about the visual differences to a CDI motor's rear cover:
The process is the same for CDI or TI motors. If you haven't already, clean up the surfaces on the rear cover:
You want the mating surfaces to be free from any residue from the old gasket material or silicone or whatever else previous owners have left:
The back of the impeller cover looks like this - the old rubber gasket is in place still:
The old rubber gasket is pretty well flat:
Pry it out with a pick or similar tool:
Looks vaguely like Saturn and it's rings.
There's likely to be gasket residue and general crud in the recess that the gasket sits in; clean it out.
New genuine gaskets are available fairly cheaply and are part number 11396-415-000 (eBay US, eBay AU, eBay UK):
Otherwise a regular O-ring will work - 127x3mm can be squashed into the right shape. Fit the new gasket into place:
As you can see, this one is much less flat than the old:
New gasket installed:
Now, there's two locating dowels on either side of the impeller - make sure they're there. They may still be stuck in the block or they may have come out with the impeller cover.
Assuming they're in place the cover simply fits over the impeller - don't force it at an angle, make sure it's going on straight:
There's two larger bolts and two smaller ones - install them all and torque the larger bolts first to ~18ft/lb with a 12mm socket:
The smaller bolts take an 8mm socket and should be tightened to ~10Nm:
Now you should be done!
If you are doing this as part of the triple bypass procedure you can go back to the main triple bypass page here.
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