Installing the 2.7L engine with automatic transmission (Discovery 3)

Special tool

Winch for engine lifting 303-1141

Installation

1.

CAUTION: Apply recommended grease to torque converter guide bushing.

CAUTION: Make sure the torque converter is fully engaged in the oil pump drive.

With the help of a second mechanic, carefully install the engine.

• Clean the contact surfaces of the parts.
• Route the transmission harness carefully when installing the engine.
• Route the positive battery cable carefully when installing the motor.

2.

CAUTION: Make sure the torque converter remains connected to the transmission.

Attach the engine to the gearbox.

• Tighten the bolts to 45 Nm.
• Remove the jack supporting the gearbox.

3. Attach the left and right engine mounts.

• Lower the engine onto its supports.
• Tighten nuts to 90 Nm.

4. Remove the special tool. Turn out bolts.



5.

NOTE: Use new bolts.

Install the faceplate on the torque converter.

• Tighten the bolts to 45 Nm.
• Install the access cover.

6. Install starter. Tighten the bolts to 48 Nm.

7. Connect the two starter harness connectors to the starter solenoid.

• Tighten the solenoid connector nut to 8 Nm.
• Tighten the battery positive cable nut to 11 Nm. Install rubber insulator.

8. Install starter support bracket. Tighten the bolts to 10 Nm.

9. Fix a wire of weight of the engine. Tighten the bolt to 22 Nm.

10. Install the fuel cooler. Tighten the bolt to 10 Nm.
11.

NOTE: Remove plugs and discard.

Connect the fuel lines.

12. Secure the fuel lines.

• Tighten the bolt to 22 Nm.
• Fasten with clips.

13. Fix highways of ventilation of a transmission. Tighten the bolt to 7 Nm.

14. Install the turbocharger support bracket.

• Tighten the bolts to 48 Nm.
• Tighten the nut to 22 Nm.

15.

NOTE: Use new nuts.

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

Connect the exhaust system to the turbocharger.

• Install a new gasket.
• Tighten the nuts to 48 Nm.

16. Fix an arm of a cross pipe of system of release. Tighten the bolts to 25 Nm.

17. Attach the positive battery cable. Secure with a clip.

18. Install transmission fluid lines. Tighten the nut to 10 Nm.

19. Install the turbocharger inlet pipe. Tighten the clamp.

20. Move the lower coolant hose.

21.

NOTE: Remove plugs and discard.

Connect the A/C compressor high pressure line.

• Install a new sealing ring.
• Tighten the bolt to 9 Nm.

22. Install the charge air cooler intake duct.

23. Install the power steering pump to the appropriate bracket. Screw in the rear bolt, but do not tighten it.


24. Install the power steering pump.

• Tighten the three front bolts to 22 Nm.
• Loosen the three front bolts a quarter of a turn.
• Tighten the rear bolt to 22 Nm.
• Tighten the three front bolts to 22 Nm.

25. Connect the lower coolant hose. Secure with a clamp.

26. Connect the charge air cooler intake hoses. Tighten the clamps.

27.

NOTE: Remove plugs and discard.

Connect the A/C compressor low pressure line.

• Install a new sealing ring.
• Tighten the bolt to 9 Nm.

28. Fix the inlet pipeline of a charge air cooler.

• Tighten the bolts to 10 Nm.
• Tighten the nut to 10 Nm.

29. Connect the ventilation hose. Secure with a clamp.

30. Install the heat shield for the left upper suspension arm and brake line.

• Tighten the bolts to 10 Nm.
• Tighten the nuts to 10 Nm.

31. Install the accessory drive belt. Turn the accessory drive belt tensioner counterclockwise.

32. Connect a hose of a cooling liquid of system EGR of the right number of cylinders. Secure with a clamp.

33. Connect the upper coolant hose to the coolant manifold. Install clamp.

34. Install the air intake throttle elbow support bracket. Tighten the bolts to 10 Nm.

35. Install the air intake shut-off valve. For more information, refer to Air Intake Damper (19.70.32)

36. Install the cooling fan shroud. For more information, refer to Cooling Fan Shroud (26.25.11)

37. Install the housing. For more information, refer to Body - Diesel.

38. Install the wheels. Tighten the wheel nuts to 140 Nm.

39. Connect a wire of weight to the storage battery. For more information, refer to Specification.