Oil Pan (G2244089): Installation

WARNING: This page is about a different variant/trim than selected.

NOTE: This step is only required if the component has previously been removed.

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- Install a new oil level sensor O-ring seal.
  Renew Part: Oil level sensor O-ring seal(s) Quantity: 1 .
- Install the oil level sensor.
- Install and tighten the 3 bolts.
  Torque : 11 Nm
CAUTION: Make sure that the mating faces are clean and free of foreign material.

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- Using a suitable plastic scraper clean the remaining sealing material from the mating surfaces.
- Apply RTV sealant (Loctite 5901G) in a 2-3 mm diameter to the areas shown, and tighten the oil pan retaining bolts within 7 minutes.
  Refer to: SPECIFICATIONS
CAUTION: Make sure that the mating faces are clean and free of foreign material.

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- Using a suitable plastic scraper clean the remaining sealing material from the mating surfaces.
- Apply RTV sealant (Loctite 5901G) in a 2-3 mm diameter to the areas shown, and tighten the oil pan retaining bolts within 7 minutes.
  Refer to: SPECIFICATIONS
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Carefully install the oil pan into the correct position.
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Install the oil pan in the sequence illustrated.
CAUTION: Install the bolts in the positions noted on removal.

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Install and tighten the 16 bolts finger tight only at this stage.
Fig 1: Oil Pan Tightening Sequence
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Tighten the 16 bolts in the illustrated sequence.

Torque : 25 Nm
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Install the wiring harness bracket and secure with the 2 clips.
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Install and tighten the 4 bolts on the rear of the engine assembly.

Torque : 12 Nm
CAUTION: Make sure that the mating faces are clean and free of foreign material.

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Apply RTV sealant (Loctite 5901G) in a 2-3 mm diameter to the areas shown, and tighten the front cover retaining bolts within 7 minutes.

Refer to: SPECIFICATIONS
CAUTION: Make sure that the mating faces are clean and free of foreign material.

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Install a new front cover using the special tool.

Special Tool(s): 303-1433

Renew Part: Lower timing cover Quantity: 1 .
NOTE: Special tools shown removed for clarity.

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Install and tighten the 4 bolts as illustrated finger tight only at this stage.
NOTE: Special tools shown removed for clarity.

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Fully tighten the 4 bolts in the sequence illustrated.

Torque : 12 Nm
NOTE: Special tools shown removed for clarity.

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- Install and tighten the 8 bolts.
  Torque : 12 Nm
- Remove the special tool from the front cover.
  Special Tool(s): 303-1433
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Secure the 4 wiring harness clips.
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- Secure the 2 wiring harness clips.
- Connect the oil level sensor electrical connector.
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- Install the Crankshaft Position (CKP) sensor.
- Install and tighten the bolt.
  Torque : 10 Nm
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Connect the CKP sensor electrical connector.
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Install the front differential assembly and tighten the 4 bolts.

Torque : 115 Nm
NOTE: Lubricate the high pressure (HP) fuel pump tappets with clean engine oil.

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Install the High Pressure (HP) fuel pump tappets.
NOTE: Lubricate the HP fuel pump O-ring seal with clean engine oil.

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Install the HP fuel pump and tighten the 2 Torx screws a turn at a time until the correct torque is achieved.

Torque : 11 Nm
NOTE: Lubricate the HP fuel pump O-ring seal with clean engine oil.

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Install the HP fuel pump and tighten the 2 Torx screws a turn at a time until the correct torque is achieved.

Torque : 11 Nm
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Install the HP fuel pump covers.
CAUTION: Lubricate only the union threads with clean engine oil.

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- Install new HP fuel delivery lines.
  Renew Part: Fuel rail supply pipe(s) Quantity: 1 .
- Tighten the 2 bolts and the 2 unions finger tight only at this stage.
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Fully tighten the bolts and unions in the sequence as illustrated.

Torque

Unions (1): 21 Nm

M6 bolt (2): 11 Nm

M8 bolt (3): 25 Nm
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- Wait 30 seconds and check the tightness of the 2 HP fuel line unions.
  Torque : 21 Nm
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- Install the HP fuel pump delivery lines.
- Tighten the 2 unions finger tight only at this stage.
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Install and tighten the bolt.

Torque : 12 Nm
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- Fully tighten the 2 unions.
  Torque : 21 Nm
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- Install the fuel line cover.
- Install and tighten the 2 bolts.
  Torque
  
  M10 bolt: 29 Nm
  
  M6 bolt: 11 Nm
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- Install the engine mount bracket.
- Install and tighten the 4 bolts.
  Torque : 48 Nm
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Install the wiring harness into the correct position.
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Secure the 2 wiring harness clips.
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Secure the wiring harness clip.
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- Connect the 2 electrical connectors.
NOTE: Install the nut and unions finger tight before final tightening.

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- Install and tighten the 2 unions.
  Torque : 21 Nm
- Install and tighten the nut.
  Torque : 6 Nm
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- Install and tighten the 2 unions.
  Torque : 21 Nm
- Install and tighten the 4 bolts.
  Torque : 8 Nm
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Wait 30 seconds and check the tightness of the 2 unions.

Torque : 21 Nm
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Secure the wiring harness clip.
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- Install the idler pulley.
- Install and tighten the 3 bolts.
  Torque : 25 Nm
NOTE: Lubricate the seal with clean engine oil.

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- Install a new O-ring seal to the vacuum pump.
  Renew Part: Brake vacuum pump O-ring seal Quantity: 1 .
- Install the vacuum pump.
- Install and tighten the 2 bolts.
  Torque : 12 Nm
CAUTION: Install all the bolts finger tight before final tightening.

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Install the generator and tighten the 3 bolts in the illustrated sequence.

Torque : 48 Nm
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Connect the generator electrical connector.
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Install the generator positive cable and tighten the nut.

Torque : 12 Nm
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Install the generator positive cable cover.
CAUTION: Inspect the seal, install a new component if damaged.

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Install the front halfshaft support bearing and tighten the 3 bolts.

Torque : 25 Nm
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Install the special tool and tighten the 2 bolts.

Special Tool(s): JLR-303-1304

Torque : 10 Nm
NOTE: Make sure the crankshaft and drive plate mating faces are clean before installation.

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- Install the drive plate in the correct position and tighten the 10 bolts.
  Torque
  
  Stage 1: 45 Nm
  
  Stage 2: 90°
- Release the 2 bolts from the special tool and remove the special tool.
  Special Tool(s): JLR-303-1304
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- Apply RTV sealant to the crankshaft pulley keyway.
  Refer to the appropriate service information. .
- Make sure that the RTV sealant is applied in a 2 mm diameter bead.
- Make sure that the RTV sealant is applied level with the top of the keyway.
NOTE: Make sure to clean the threads in the end of the crankshaft and that the crank nose is free of any foreign materials.

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- Install the crankshaft pulley.
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Install the special tool.

Special Tool(s): 303-1440
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- Install the special tool.
  Special Tool(s): 303-1439
- Install and tighten the 4 special tool bolts.
  Torque : 25 Nm
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Install the special tool.

Special Tool(s): 303-1441
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- Rotate the crankshaft pulley installation tool until the pulley is fully located.
- Make sure the special tool is not over tightened, as this may result in damage to the components.
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Remove the special tool.

Special Tool(s): 303-1441
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- Remove the 4 bolts from the special tool.
- Remove the special tool from the crankshaft pulley.
  Special Tool(s): 303-1439
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Remove the special tool.

Special Tool(s): 303-1440
NOTE: The original M10 bolts can be reused.

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- Clean the original crankshaft pulley bolts and apply loctite 270 to the threads before installation.
  Refer to: SPECIFICATIONS
- Install and tighten the 2 crankshaft pulley bolts as illustrated.
  Torque : 65 Nm
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Install, but do not fully tighten the crankshaft pulley bolt.

Renew Part: Crankshaft pulley bolt Quantity: 1 .
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Install the special tools.

Special Tool(s): 303-1437 , 303-1438
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Install and tighten the 2 special tool bolts.

Torque : 25 Nm
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Using a suitable axle stand, support the special tools.

Special Tool(s): 303-1437 , 303-1438

General Equipment: Axle stands
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- Remove the 2 special tool bolts.
- Remove the special tool.
  Special Tool(s): JLR-303-1304
NOTE: The use of a torque multiplier capable of 600 Nm will be required.

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Tighten the crankshaft pulley bolt. Make sure that the socket is turned through 270 degrees not the torque wrench.

Torque

Stage 1: 200 Nm

Stage 2: 270°
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- Install the special tool.
  Special Tool(s): JLR-303-1304
- Install and tighten the 2 special tool bolts.
  Torque : 10 Nm
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Remove the special tools.

Special Tool(s): 303-1437 , 303-1438
NOTE: The original M10 bolts can be reused.

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- Clean the original crankshaft pulley bolts and apply Loctite 270 to the threads before installation.
  Refer to: SPECIFICATIONS
- Install and tighten the 2 crankshaft pulley bolts as illustrated.
  Torque : 65 Nm
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- Remove the 2 special tool bolts.
- Remove the special tool.
  Special Tool(s): JLR-303-1304
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- Using a suitable tool release the tension from the accessory drive belt tensioner.
- Install the accessory drive belt over the crankshaft pulley.
- Allow the accessory drive belt to be fully tensioned and remove the tool from the accesory drive belt tensioner.
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- Using a suitable tool release the supercharger belt tensioner assembly.
- Install the supercharger belt, make sure the supercharger belt is correctly located on each pulley.
- Allow the supercharger belt to be fully tensioned and remove the suitable tool from the tensioner assembly.
Install the engine assembly.
Refer to: ENGINE - AWD - V8 S/C 5.0L PETROL (G2260899) .
Fill the front differential oil.
Refer to: DIFFERENTIAL DRAINING AND FILLING
Connect the startup battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT
Fill the engine oil.
Refer to: ENGINE OIL VACUUM DRAINING AND FILLING