Block frame (Discovery 3)

Special tool

Cylinder block frame insert adjustment tool 303-596

Removing

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

2.

WARNING: Do not work on or under a vehicle that is only supported by a jack. Always place secure supports under the vehicle.

Raise and support the vehicle.

3. Remove the front wheels complete with tires.

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

5. Remove the front axle tube. For more information refer to Axle tube (47.10.42)

6. Remove the oil pan. For more information refer to Oil Sump (12.60.44)

7. Remove the front stabilizer. For more information, refer to Front Anti-roll Bar (60.10.01)

8. Remove the radiator access panel. Remove 4 bolts.



9. Release the engine oil cooler lines.

• Turn out a bolt.
• Loosen the nut.
• Take the highways aside and tie them down.

10.

CAUTION: Before disconnecting or removing parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.

Release the transmission lines.

• Install a container to catch spilled liquid.
• Turn out a bolt.
• Release the clamp.
• Remove and discard both O-rings.

11.

CAUTION: Before disconnecting or removing parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.

Remove the oil temperature sensor.

• Disconnect the electrical connector.
• Remove the O-ring and discard it.

12. Remove the oil pickup tube with strainer assembly.

• Turn out a bolt.
• Remove and discard two o-rings.

13. Remove the dipstick.

14. Remove transmission lines and engine wiring harness from cylinder block frame flange and tie them.

15.

NOTE: Mark the installation position of the 2 sealing washers.

Turn out 8 bolts of a frame of the block of cylinders. Remove and discard 2 sealing washers.



16.

CAUTION: If the set screws are not loosened, the cylinder block frame may be damaged.

Using the special tool, loosen the 8 cylinder block frame set screws.



17. Remove the cylinder block frame.

• Remove 2 rear bolts.
• Remove 2 Torx screws.
• Loosen 2 nuts.
• Remove 20 bolts.
• Remove the gasket and discard it.

Installation

1. Clean the cylinder block frame.

• Clean the contact surfaces of the parts.
• Remove the sealant from the cavities of the main bearing caps.

2.

CAUTION: If the set screws are not loosened, the cylinder block frame may be damaged.

Install the cylinder block frame set screws. Using the special tool, adjust the set screws so that they are below the lug surface of the cylinder block frame.



3.

NOTE: Frame must be installed within 20 minutes of applying sealant.

Apply sealant to the cylinder block frame. Apply sealant to the 6 indicated areas.



4.

CAUTION: Make sure the gasket is installed correctly.

Install the cylinder block frame.

• Install a new gasket.
• Screw in and then evenly and lightly tighten the outer bolts, nuts and Torx screws.

5. Align the cylinder block frame with the rear surface of the cylinder block.

• Install and tighten the 2 rear bolts.
• Loosen the 2 rear bolts.
• Lightly tighten the 2 rear bolts.

6. Tighten the outer bolts, nuts and Torx screws evenly and progressively (tightening torque 10 Nm).

7. Tighten the 2 rear bolts (tightening torque 43 Nm).

8. Using the special tool, tighten the 8 cylinder block frame set screws. Tighten the set screws in the sequence shown (tightening torque 7 Nm).



9.

NOTE: Sealing washers are mounted on silver bolts. Silver bolts are installed in the 2 front holes.

Screw in 8 bolts of a frame of the block of cylinders and tighten them 2 stages.

• Install 2 new sealing washers.
• Tighten bolts in sequence (tightening torque 15 Nm).
• Tighten bolts in sequence (tightening torque 34 Nm).

10.

NOTE: Lubricate new seals with clean engine oil.

Install the oil temperature sensor.

• Clean the contact surfaces of the parts.
• Install a new sealing ring.
• Tighten oil temperature gauge (tightening torque 20 Nm).
• Connect the electrical connector.

11.

NOTE: Lubricate new seals with clean engine oil.

Install the oil pickup tube with strainer assembly.

• Clear the details.
• Install new o-rings.
• tighten bolt (tightening torque 10 Nm).

12. Install the oil pan. For more information refer to Oil Sump (12.60.44)

13. Insert the level probe. Clean up the part.

14. Reinstall the engine oil cooler lines. Tighten bolt and nut (tightening torque 25 Nm).

15. Connect transmission pipelines.

• Clear the details.
• Install new o-rings.
• Fasten the clamp.
• tighten bolt (tightening torque 10 Nm).

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

17. Install the front stabilizer. For more information, refer to Front Anti-roll Bar (60.10.01)

18. Install the front axle tube. For more information refer to Axle tube (47.10.42)

19. Install the radiator access panel. Tighten 4 bolts (tightening torque 10 Nm).

20. Install the front wheel assembly with tires.

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

22. Check the transmission fluid level and top up if necessary. For more information, refer to Checking the Transmission Fluid Level (44.24.06)