4.4L engine installation (Discovery 3)

Special tool

Winch for engine lifting 303-1144

Spring release tool for fuel system 310-D005

Ball joint puller 205-754 (LRT-54-027)

Installation

1. Install the engine.

• Attach lifting chains.
• Raise the engine.
• Clean the contact surfaces of the parts.
• Clean the dowel pins.

2. Carefully lower the engine until it is approximately 35mm above the engine mounts.
3. Install the front engine mount bracket.

• Tighten the new bolts to 45 Nm, and then tighten another 60 degrees.
• Connect wire "masses" engine and screw in the bolt (tightening torque 25 Nm).

4. Clean the contact surfaces of the parts.

5. With the help of another mechanic, align the engine with the gearbox and mounts.

• Screw in bolts of fastening of a transmission.
• Tighten the bolts (tightening torque 45 Nm).
• Tighten the engine mount nuts (tightening torque 90 Nm).

6. Install the flexible plate on the torque converter.

• Rotate the crankshaft to gain access to the mounting bolts.
• Evenly, in 2 stages, tighten the bolts.
• Tighten the bolts with a torque of 15 Nm.
• Tighten the bolts (tightening torque 110 Nm).
• Install the sealing sleeve.

7. Install the transmission heat shield.



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

• Clean the contact surfaces of the parts.
• Install new o-rings.
• Install the clamp.
• tighten bolt (tightening torque 25 Nm).

9. Install the A/C compressor assembly. Tighten the bolts (tightening torque 25 Nm).



10. Install the power steering pump. Tighten the bolts (tightening torque 25 Nm).



11. Install the exhaust system. For more information refer to Exhaust System (30.10.08)


12. Reinstall the engine oil cooler. Tighten the hex bolt (tightening torque 60 Nm).

13. Disconnect the lifting chains.

14. Disconnect special tools. Remove the lifting brackets.



15. Install the EGR valve into the EGR pipe, and then insert the bolts and tighten them (tightening torque 25 Nm). Install and align the new gasket.



16. Install heat shields for upper suspension arm and brake pipe.

• Insert and tighten bolts (tightening torque 10 Nm).
• Tighten nuts (tightening torque 10 Nm).

17. Connect the fuel line to the fuel rail.

• Clean the contact surfaces of the parts.
• Fasten the clamps.

18. Connect the brake booster vacuum hose to the intake manifold.



19. Connect the engine wiring harness.

• Connect wire "masses".
• Connect electrical connectors.
• Install the cassette.

20. Attach the canister hose of the evaporative emission system to the intake manifold.



21. Connect the positive battery cable to the battery junction box (BJB). tighten bolt (tightening torque 10 Nm).



22. Attach and secure the coolant hoses.



23. Install the accessory drive belt tensioner. tighten bolt (tightening torque 45 Nm).



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

25. Install the right air cleaner assembly. For more information refer to Air Filter (19.10.01)

26. Install the optional battery tray. For more information, refer to Additional Battery Shelf (76.10.31)

27. Install the battery tray. For more information, refer to Additional Battery Shelf (76.10.31)

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

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

thirty. Pour coolant into the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (26.10.01)

31. Remove the hood from the service position.

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