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

Special tool

Winch for engine lifting 303-1141

Installation

1. With assistance, connect the engine to the gearbox.

• Clean the contact surfaces of the parts.
• Route the transmission harness carefully when installing the engine.

2. Attach the engine to the gearbox. Tighten the bolts to 45 Nm.

3. Screw in the starter bolts. Tighten the bolts to 48 Nm.

4.

NOTE: Mark the position of the lower steering column shaft.

Establish the engine in gathering with a transmission.

5. Remove the special tool.



6. Screw in the gearbox support pad bolt and tighten to 175 Nm.

7. Attach the left and right engine mounts. Tighten nuts to 90 Nm.

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


9.

NOTE: Remove plugs and discard.

Connect the fuel lines.

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

11. Install the turbocharger support bracket.

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

12.

CAUTION: 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.

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

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

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

16. Move the lower coolant hose.

17.

NOTE: Remove plugs and tank them.

Connect the air conditioning compressor high pressure line.

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

18. Install the charge air cooler intake duct.

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

20. 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.

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

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

23.

NOTE: Remove plugs and discard.

Connect the A/C compressor low pressure line.

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

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

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

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

26. 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.

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

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

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

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

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

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

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

34.

NOTE: Install new bolts.

Attach the front propeller shaft to the transfer case drive flange.

• Install washers.
• Stage 1: Tighten the bolts to 45 Nm.
• Stage 2: Tighten the bolts another 90 degrees.

35. Attach the rear propeller shaft to the transfer case drive flange.

• Install washers.
• Tighten the bolts to 55 Nm.

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

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