Engine installation (Discovery 3)

Installation

1. Remove the torque converter holder.

2. Install the engine.

• Attach lifting chains.
• Carefully lower the engine until it is approximately 35mm above the engine mounts.
• With the help of another mechanic, align the engine with the gearbox and mounts.

3. Install the right engine mount.

4. Screw in bolts of fastening of a transmission.

• Clean the contact surfaces of the parts.
• Remove guide pins.
• Tighten the bolts (tightening torque 45 Nm).

5. Tighten the engine mount nuts (tightening torque 90 Nm).

6. Remove the engine jack.

• Disconnect the lifting chains.
• Remove 7 bolts.
• Remove 12 nuts.

7. Install the flexible plate on the torque converter.

• Rotate the crankshaft to gain access to the mounting bolts.
• Tighten the bolts (tightening torque 45 Nm).
• Install the sealing sleeve.

8. Connect the electrical connector of the crankshaft position sensor (CKP). Clean the contact surfaces of the parts.

9. Connect the heated oxygen sensor electrical connectors.

10. Install the engine wiring harness support bracket.

11. Connect the electrical connector of the engine oil temperature sensor.

12. Install the starter.

• Clean the contact surfaces of the parts.
• Tighten the bolts (tightening torque 45 Nm).

13. Replace the fuel line and purge line heat shield and secure with bolts.

14. Connect the right catalytic converter to a final collector.

• Clear the details.
• Tighten new bolts (tightening torque 22 Nm).

15.

WARNING: Make sure the distance (A) between the nearest surfaces of the left catalytic converter and the front drive shaft is 25-30 mm.

Connect the left catalytic converter to the exhaust manifold.

• Clear the details.
• Tighten new bolts (tightening torque 22 Nm).

16. Install the transmission heat shield.

17. Connect the engine oil cooler hoses. Fasten the clamps.

18. Connect the coolant pump hose. Fasten the clamp.

19. Establish the lower universal joint of a steering column in gathering. Install and tighten new encapsulated bolts (tightening torque 25 Nm).

20. Connect the engine coolant temperature sensor electrical connector (ECT).

21. Install the EGR pipeline.

• Clean the contact surfaces of the parts.
• Install the part to the exhaust manifold, but do not fully tighten the union nut at this stage.

22. Establish pipelines of system of cooling of a transmission.

• Install the support bracket.
• tighten the nut (tightening torque 10 Nm).

23. Connect the engine ground wire, making sure that the contact surfaces of the parts are clean.

• tighten the nut (tightening torque 25 Nm).
• Install the cover.

24. Install the A/C compressor support bracket assembly.

• Clean the contact surfaces of the parts.
• Tighten the bolts (tightening torque 45 Nm).
• Install the KS electrical connector clip.
• Connect the A/C compressor electrical connector.

25. Install the generator support bracket.

• Clean the contact surfaces of the parts.
• Tighten the bolts (tightening torque 45 Nm).
• Fasten the clamp.
• Install a new wire tie.

26. Connect the electrical connector of the engine oil pressure sensor (EOP).

27. Connect electric sockets of the generator.


28. Install the accessory drive belt. For more information refer to Drive Belt Accessories (86.10.03)

29. Install the lower cooling fan shroud.

• Remove the radiator protection.
• Install and secure with clips.

30. Attach the wiring harness to the manifold. Fasten the clamps.

31. Connect the electrical connectors of the ECM.

32. Install the battery tray. For more information, refer to Battery Mounting Shelf (76.10.30)

33. Install the intake manifold. For more information refer to Intake Manifold (30.15.02)

34. Tighten nuts securing EGR pipe to exhaust manifold and EGR valve (tightening torque 25 Nm).

35. Fill the engine with oil. For more information, refer to Draining and Refilling Engine Oil (12.60.05)

36. Fill in a cooling liquid in the cooling system and let out air from it. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (26.10.01)

37. Remove the hood from the service position.

• Release 2 clips.
• Attach the racks and secure them with clips.

38. Connect the wire "masses" to the battery. For more information, refer to Specification