Extended oil pan section (Discovery 3)

Removal

1. Disconnect the battery ground cable. For more information, refer to Specification.

2. Remove the upper heat shield from the engine compartment. Unscrew the screw.



3. Replace the sound insulation of the injectors.



4. Remove the oil level indicator tube and dipstick from the oil pan extension.

• Remove the bolt.
• Remove the O-ring and discard it.

5.

CAUTION: Never work on a vehicle supported only by a jack. Always support the vehicle securely.

Raise the vehicle and support it on jack stands.

6. Remove the front wheels and tires.

7. Remove the front axle tube. For more information, refer to Half-axle tube (47.10.42)

8. Remove the oil pan. For more information, refer to Oil Pan (12.60.44)

9. Remove the starter. For more information, refer to Starter (86.60.01)

10. Remove the oil receiver intake tube with the mesh filter assembly.

• Remove the bolt.
• Remove the O-ring and discard it.

11. Unscrew the 3 bolts of the wire going from the battery to the starter solenoid.



12. Remove the bolt from the accessory belt tensioner bracket.



13. Remove the lower bolt from the air conditioning (A/C) compressor.





14. Release the turbocharger return oil line.

• Release the wiring harness clamp.
• Remove the bolt.

15. Remove the turbocharger return oil line.

• Remove 2 bolts.
• Remove and discard the gasket.
• Remove and discard the O-rings.
• To avoid contamination of the system, close all open connections with plugs.

16. Remove 2 bolts from turbocharger support bracket.





17. Remove the 3 lower bolts securing the gearbox to the engine.



18. Remove the front axle crossmember. Unscrew 4 bolts.



19. Using a transmission jack, support the front axle assembly.

20. Remove the front axle mounting bolt. Carefully lower the front axle assembly.



21.

NOTE: Before removing bolts, record their locations.

Remove the oil pan extension.

• Remove 18 bolts.
• Remove and discard the gasket.

Installation

1.

NOTE: Make sure the mating surfaces of the components are clean.

NOTE: It is important that the oil pan extension be bolted to the crankshaft main bearing housing within 20 minutes of applying the sealant.

Apply an 8 mm bead of sealant to the areas of the cylinder block shown. Use sealant WSS-M4G323-A4-RTV.



2. Remove the oil pan extension.

• Install a new gasket.
• Install, but do not tighten, the oil pan extension mounting bolts.

3. Tighten the bolts in the sequence shown.

• 1) Tighten bolts A (tightening torque 10 Nm). Tighten the bolts B (tightening torque 4 Nm).
• 2) Tighten bolts A (tightening torque 24 Nm). Tighten the bolts B (tightening torque 10 Nm).

4. Align and secure the front axle assembly. Tighten the M14 bolt. (tightening torque 105 Nm).



5. Install the front axle crossmember. Tighten the 4 bolts to 115 Nm.

6. Install the 3 lower transmission-to-engine mounting bolts. Tighten the bolts. (tightening torque 45 Nm).

7. Screw 2 bolts into the turbocharger support bracket. Tighten the two bolts to 23 Nm.

8.

NOTE: Make sure the mating surfaces of the components are clean.

NOTE: Remove and discard plugs.

Install the turbocharger oil return line.

• Install new O-rings.
• Install a new gasket.
• Tighten the two bolts to 10 Nm.

9. Install the turbocharger oil return line bolt. Secure the wiring harness to the turbocharger oil return line.

10. Screw the lower bolt into the air conditioner compressor. Tighten the bolt. (tightening torque 24 Nm).

11. Install the bolt into the accessory belt tensioner bracket. Tighten the new bolt. (tightening torque 24 Nm).

12. Secure the wire from the battery to the starter solenoid.

• Tighten the M8 bolts (tightening torque 22 Nm).
• Tighten the M6 bolts (tightening torque 10 Nm).

13.

NOTE: Make sure the mating surfaces of the components are clean.

Install the oil inlet pipe with the mesh filter assembly.

• Install a new O-ring.
• Tighten the bolt to 10 Nm.

14. Install the starter. For more information, refer to Starter (86.60.01)

15. Remove the oil pan. For more information, refer to Oil Pan (12.60.44)

16. Install the front axle tube. For more information, refer to Half-axle tube (47.10.42)

17. Install the front wheels and tires. Tighten the wheel nuts to a torque of 140 Nm.

18.

NOTE: Make sure the mating surfaces of the components are clean.

Secure the oil level indicator tube and dipstick to the oil pan extension.

• Install a new O-ring.
• Screw in the bolt.

19. Replace the sound insulation of the injectors.

20. Install the upper engine heat shield. Screw in the screw.

21. Connect the ground cable to the battery. For more information, refer to Specification.