Removing the 2.7L engine from the manual transmission (Discovery 3)

Special tool

Winch for engine lifting 303-1141

Removing

1. Disconnect a wire of weight from the storage battery. For more information refer to Specification.

2.

WARNING: It is forbidden to carry out work on a vehicle supported only by a jack. Always place secure supports under the vehicle.

Raise and support the vehicle.

3. Remove wheels.

4. Disconnect the rear propeller shaft from the drive flange on the transfer case.

• Turn out 6 bolts.
• Remove three washers.

5. Disconnect the front propeller shaft from the drive flange on the transfer case.

• Remove and discard 6 bolts.
• Remove three washers.

6. Remove the body. For more information, refer to Body - Diesel.


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

8. Remove the air intake throttle. For more information refer to Air Intake Damper (19.70.32)

9. Remove the air intake throttle elbow support bracket. Turn out three bolts.



10. Disconnect the upper coolant hose from the coolant manifold. Remove clamp.



11. Disconnect the EGR coolant hose (EGR) for the right bank of cylinders. Release the clamp.



12. Remove the accessory drive belt. Turn the accessory drive belt tensioner counterclockwise.




13. Remove the two heat shields of the left upper suspension arm and brake line.

• Remove two nuts.
• Turn out three bolts.

14. Disconnect the ventilation hose. Release the clamp.



15. Release the inlet pipe of the charge air cooler.

• Remove two nuts.
• Turn out a bolt.

16.

CAUTION: Plug all openings. Use new plugs.

Disconnect the A/C compressor low pressure line (A/C).

• Turn out a bolt.
• Remove the O-ring and discard it.

17. Disconnect the charge air cooler inlet hose. Release the clamp.



18. Disconnect the charge air cooler inlet hose. Release the clamp.



19. Disconnect the lower coolant hose. Release the clamp.




20. Turn out a back bolt of fastening of the pump of the amplifier of a steering.



21. Remove the power steering pump. Turn out three bolts.



22. Remove the inlet pipe of the charge air cooler.

23.

CAUTION: Plug all openings. Use new plugs.

CAUTION: Be careful not to damage mating surfaces.

Disconnect the A/C compressor high pressure line.

• Turn out a bolt.
• Remove the O-ring and discard it.

24. Move the lower coolant hose.

25. Remove the turbocharger inlet pipe. Release the clamp.



26. Disconnect the positive cable from the battery. Release the clamp.



27. Disconnect the exhaust system from the turbocharger.

• Loosen and discard three nuts.
• Remove the gasket and discard it.

28. Remove the turbocharger support bracket.

• Turn out two bolts.
• Loosen the nut.

29. Release an arm of a cross pipe of system of release. Turn out 6 bolts.



30.

CAUTION: Plug all openings. Use new plugs.

Disconnect two fuel lines.



31. Release transmission ventilation lines. Turn out a bolt.



32. Disconnect the engine ground wire. Turn out a bolt.



33. Turn away a nut of the left support of the engine.



34. Turn away a nut of the right support of the engine.



35. Turn out a bolt of a basic pillow of a transmission.



36. Install the special tool.



37.

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

Using the special tool, remove the engine and transmission assembly.



38. Turn out two bolts of a starter.



39.

NOTE: Note the transmission wiring harness wiring.

With the help of a second mechanic, carefully separate the engine from the gearbox.

• Remove 14 bolts.
• Carefully move the transmission wiring harness to the side when removing the engine.