Engine Front Cover (G1868093): Installation

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

CAUTION:
- Inspect the front cover and replace if necessary.
- Make sure that the surface of the front cover and the engine is clean and free of foreign material.
- Steps 1-4 must be completed within 7 minutes of starting to apply the RTV.
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Apply RTV sealant in the position shown.

Refer to: SPECIFICATIONS
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- Install the engine front cover.
- Use the alignment tool to align the front cover.
  Special Tool(s): JLR-303-1672
NOTE: Do not fully tighten the bolts at this stage.

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Install and finger tighten the 4 bolts.
CAUTION: Continuous forward pressure must be applied on the tool.

Fig 1: Engine Front Cover Tightening Sequence
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Fully tighten the 4 bolts in the sequence illustrated

Torque : 12 Nm
CAUTION: This step must be completed within 40 minutes of starting to apply the RTV.

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Install and tighten the 8 bolts.

Torque : 12 Nm
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Remove the front cover alignment tool.

Special Tool(s): JLR-303-1672
CAUTION: This step is only required if the front cover is re-used.

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- Install the special tool.
  Special Tool(s): JLR-303-1628
- Rotate the special tool and the crankshaft front seal 35° in a counter clockwise direction.
- Remove the special tool and the crankshaft front seal.
- Remove and discard the crankshaft front seal.
CAUTION: This step is only required if the front cover is re-used.

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- Install a new crankshaft front seal to the special tool.
  Special Tool(s): JLR-303-1628
  
  Renew Part: Crankshaft front oil seal Quantity: 1 .
- Install the special tool and the crankshaft front seal.
- Rotate the crankshaft front seal and special tool 35° in a clockwise direction.
- Remove the special tool.
CAUTION: Make sure that the component is correctly located on the dowel.

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- Install the crankshaft pulley.
- Install the special tool as illustrated.
  Special Tool(s): JLR-303-1630
CAUTION: Make sure that new bolts are installed.
- Install the crankshaft pulley bolts.
  Torque
  
  Stage 1: 37 Nm
  
  Stage 2: 90°
- Remove the special tool.
  Special Tool(s): JLR-303-1630
  
  Renew Part: Crankshaft pulley bolts Quantity: 4 .
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- Install the accessory drive belt idler pulley.
  Torque : 48 Nm
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- Install the accessory drive belt idler pulley.
  Torque : 25 Nm
- Install the charge air cooler mounting bracket.
  Torque : 47 Nm
- Install the charge air cooler mounting bracket nuts.
  Torque : 12 Nm
- Secure the wiring harness clip.
- Connect the electrical connector.
- Secure the wiring harness clips.
Install the charge air cooler.
Refer to: CHARGE AIR COOLER
Install the accessory drive belt.
Refer to: ACCESSORY DRIVE BELT
Fill the engine with oil.
Refer to: ENGINE OIL VACUUM DRAINING AND FILLING
Connect the 12 V system.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT