Disassembling the 2.7L engine (Discovery 3)

Special tool

Injection Timing Rod - Automatic Transmission 303-1117	Injection Timing Rod - Manual Transmission 303-1116	Camshaft Pulley Locking Device 303-1145/1
Holder - Front Camshaft Pulley 303-1124	Faceplate Locking Tool 303-947	Flywheel Locking Device 303-1123

Disassembly

1. Disconnect the ground cable from the battery. For more information, refer to Specification

2.

CAUTION: Never work on a vehicle supported solely by a jack. Always support the vehicle securely.

Raise and support the vehicle.

3. Drain the engine oil. For more information, refer to Draining and Filling Engine Oil (12.60.05)

4. Remove the engine. For more information, refer to Engine - Vehicles Included: Automatic Transmission (12.41.01.99) For more information, please refer to Engine - Vehicle includes: Manual transmission (12.41.01.99).


5. Mount the engine on a suitable engine stand.

6. Remove the power steering pump bracket. Remove the 3 bolts.



7. Remove the air conditioning compressor.

• Disconnect the electrical connector.
• Remove 3 bolts.

8. Remove the air conditioning compressor bracket. Unscrew the 2 bolts.



9. Remove the left engine mount bracket. Remove 4 bolts.



10.

CAUTION: Plug all openings. Use new plugs.

Remove the dipstick and oil level indicator tube.

• Release the wiring harness clamp.
• Remove the bolt.
• Remove and discard the sealing ring.

11. Remove the left EGR valve and heat exchanger assembly.

• Disconnect the electrical connector.
• Remove the clamp and discard it.
• Release the clamp and disconnect the coolant hose.
• Remove 5 bolts.
• Select a bracket.

12. Remove the left exhaust manifold heat shield. Remove 2 bolts.



13. Remove the turbocharger heat shield. Remove 2 bolts.



14.

CAUTION: Plug all openings. Use new plugs.

Remove the turbocharger oil return line.

• Release the wiring harness clamp.
• Remove 3 bolts.
• Remove and discard the gasket.
• Remove and discard the sealing ring.

15. Release the turbocharger support bracket. Remove the 4 bolts.



16.

CAUTION: Plug all openings. Use new plugs.

Disconnect the turbocharger oil supply line.

• Unscrew the floor bolt.
• Remove and discard the 2 sealing washers.

17. Disconnect the exhaust system bypass pipe from the left exhaust manifold.

• Unscrew and discard 3 nuts.
• Remove and discard the gasket.

18. Remove the left exhaust manifold assembly with the turbocharger.

• Remove and discard 6 nuts.
• Remove and discard the gasket.

19. Remove the cylinder block coolant inlet pipe.

• Remove 2 bolts.
• Remove and discard the sealing ring.

20. Remove the crankshaft position sensor (CSP).

• Disconnect the electrical connector.
• Replace the cover of the access hole.
• Remove the bolt.

21. Remove the EGR valve assembly with the heat exchanger of the right cylinder bank.

• Disconnect the electrical connector.
• Remove the clamp and discard it.
• Release the clamp and disconnect the coolant hose.
• Remove 4 bolts.

22. Disconnect the generator electrical connectors.

• Move the rubber pad.
• Unscrew the nut.

23. Remove the generator. Unscrew 3 bolts.





24. Remove the right exhaust manifold heat shield. Remove 3 bolts.



25. Remove the right engine mount bracket. Unscrew the 4 bolts.



26. Remove the generator bracket. Unscrew 5 bolts.



27. Remove the right exhaust manifold assembly with the exhaust system bypass pipe.

• Remove and discard 6 nuts.
• Remove and discard the gasket.

28. Remove the EGR valve coolant line.

• Remove the bolt.
• Disconnect the electrical connector.
• Release from 2 clamps.
• Release the clamp.

29. Remove the coolant pump.

• Remove 3 bolts.
• Remove and discard the sealing ring.

30. Remove the auxiliary drive belt idler pulley. Remove the bolt.



31. Remove the cooling fan pulley. Remove 3 bolts.



32. Remove the crankshaft pulley. Unscrew the 6 bolts.



33. Remove the timing belt cover. Loosen the 16 bolts completely.



34.

NOTE: Record the installation position of the parts.

Remove 2 low pressure fuel lines. Disconnect the two quick release couplings.



35. Disconnect the electrical connector of the engine oil pressure (EOP) sensor. Release the wiring harness clamp.



36.

NOTE: Left side shown, same for right side

Disconnect the electrical connectors of the fuel injectors (6 pcs.). Release the 4 clamps of the electrical harness.



37. Disconnect the camshaft position (CMP) sensor electrical connector. Release the wiring harness clamp.



38. Disconnect the electrical connector of the engine oil temperature sensor. Release the clamp of the electrical harness.



39.

NOTE: Left side shown, same for right side.

Disconnect the 2 electrical connectors of the knock sensor (KS).



40. Disconnect the fuel temperature sensor electrical connector.



41. Remove the engine crankcase ventilation oil separator. Disconnect and release the 2 ventilation hoses.



42. Disconnect the fuel rail pressure (FRP) sensor electrical connector.



43. Disconnect the 2 electrical connectors of the high pressure fuel pump.



44. Remove the engine wiring harness.

• Unscrew the nut.
• Release the 2 clamps.

45.

CAUTION: Plug all openings. Use new plugs.

NOTE: Right side shown, same for left side

Remove and discard the 2 high pressure fuel supply lines from the fuel rail. Release the 2 clamps.



46.

CAUTION: Plug all openings. Use new plugs.

Remove and discard the high pressure fuel supply line from the intermediate manifold.



47.

CAUTION: Plug all openings. Use new plugs.

NOTE: Left side shown, same for right side

Remove and discard the 2 high pressure fuel supply lines from the fuel rail. Release the clamp.



48.

CAUTION: Make sure that the high pressure fuel supply line remains in contact with the fuel injector and fuel rail until both fittings have been disconnected and cleaned. Failure to do so may allow dirt to enter the fuel injection system.

CAUTION: Make sure that the fuel injector adapter nipple remains stationary when releasing the high-pressure fuel supply lines. Failure to do so may result in failure of the fuel injector or the fuel injector adapter nipple.

CAUTION: Plug all openings. Use new plugs.

Remove the 6 high pressure fuel supply lines and discard them.



49. Disconnect the fuel return line from the fuel injectors. Remove and discard the 6 clamps.



50. Remove the two fuel injector bolts.



51. Install the special tool studs.



52.

CAUTION: Make sure the puller jaws are properly engaged with the fuel injector. Failure to do so may result in damage to the component.

Place the special tool's paws on the studs.



53. Remove the fuel injector.

• Rotate the special tool bolts evenly clockwise.
• Remove the special tool.
• Remove and discard the fuel injector clamp.
• Remove and discard the sealing washer.

54. Remove the remaining fuel injectors.

55.

NOTE: Left side shown, same for right side.

Remove 2 fuel manifolds. Unscrew 4 bolts.



56. NOTE: Right side shown, same for left side.

Remove 2 fuel rail brackets. Remove 4 bolts.



57. Remove the high pressure fuel pump drive belt cover. Release the 2 clamps.



58. Remove and discard the high pressure fuel pump drive belt tensioner. Unscrew the bolt.



59. Remove the high pressure fuel pump drive belt and discard it.

60. Install the special tool on the rear camshaft pulley.

• Turn the crankshaft so that the special tool is parallel to the engine mounting bracket.
• Screw in and tighten the bolt.

61.

NOTE: Discard the bolt.

Using a special tool, remove the rear camshaft pulley mounting bolt.



62. Remove the special tool. Unscrew the bolt.



63. Remove the rear camshaft pulley.



64. Remove the high pressure fuel pump drive belt rear cover. Loosen the 2 bolts completely.



65. Unscrew the mounting studs of the left engine cover.



66. Remove the left valve cover.

• Disconnect the KS electrical connector from the valve cover.
• Loosen the 13 bolts completely.
• Remove the fuel line support bracket.
• Remove and discard the gasket.

67. Unscrew the mounting studs of the right engine cover.

• Unscrew the nut.
• Remove the bolt.
• Remove the bracket.

68. Remove the right valve cover.

• Disconnect the glow plug electrical connector from the valve cover.
• Disconnect the KS electrical connector from the valve cover.
• Loosen the 13 bolts completely.
• Remove and discard the gasket.

69. Remove the brake system vacuum pump.

• Remove 3 bolts.
• Remove the bracket.
• Remove and discard the gasket.

70. Remove the ventilation pipe.

• Remove the bolt.
• Release the clamp.

71. Remove the turbocharger oil supply line.

• Remove the bolt.
• Remove and discard the 2 O-rings.

72. Remove the cylinder head coolant outlet assembly.

• Remove 4 bolts.
• Remove and discard the sealing ring.

73.

CAUTION: Plug all openings. Use new plugs.

Disconnect the fuel line from the fuel cooler.



74.

CAUTION: Plug all openings. Use new plugs.

Remove and discard the fuel injector return line.



75. Turn the crankshaft clockwise to align the crankshaft adjustment hole in the flywheel or faceplate with the hole in the cylinder block.



76. Check that the camshaft pulley adjustment holes are correctly positioned. If the adjustment holes are not aligned, turn the crankshaft one full revolution clockwise.

77. Lock the faceplate with the special tool. Screw in the starter bolt to secure the special tool.



78. Using the special tool, lock the flywheel. Screw in the starter bolt to secure the special tool.



79.

CAUTION: Do not use special tools to lock the camshafts. Failure to do so may result in damage to the engine or special tools.

Loosen the 6 exhaust camshaft pulley mounting bolts.



80. Remove and discard the timing belt tensioner. Unscrew the bolt.



81. Remove the 2 timing belt idler pulleys.

• Remove 2 bolts.
• Locate the plastic screen from the back of the upper idler pulley.

82. Remove and discard the timing belt.

83.

NOTE: Left side shown, same for right side.

Remove 2 camshaft pulleys. Unscrew 6 bolts.



84. Using the special tool, remove the 2 camshaft pulley hubs. Unscrew and discard the 2 bolts.



85. Remove the cooling fan drive hub bearing. Remove 3 bolts.



86. Hold the right secondary timing chain tensioner piston.

• Reposition the secondary timing chain tensioner.
• Insert a 1.5mm diameter pin (0.060 inches) into the piston of the secondary timing chain tensioner.

87.

CAUTION: Release the camshaft bearing caps evenly and gradually.

Remove the right-hand cylinder bank camshaft bearing caps. Remove 18 bolts.



88. Remove the right-hand cylinder bank camshafts together with the secondary timing chain tensioner.

• Remove 2 bolts.
• Release the right secondary timing chain tensioner.

89. Remove the secondary timing chain tensioner for the right cylinder bank.



90. Remove the camshafts of the right bank of cylinders.

• Remove the secondary timing chain from the right camshafts.
• Remove and discard the seal.

91.

CAUTION: Never place the cylinder head with the mating surface facing down. Failure to do so may result in damage to the vehicle.

CAUTION: The old gasket may only be removed with a plastic scraper.

Remove the right bank cylinder head assembly.

• Remove and discard 8 bolts.
• Remove and discard the gasket.

92. Hold the piston of the left secondary timing chain tensioner.

• Reposition the secondary timing chain tensioner.
• Insert a 1.5mm diameter pin (0.060 inches) into the piston of the secondary timing chain tensioner.

93.

CAUTION: Release the camshaft bearing caps evenly and gradually.

Remove the camshaft bearing caps on the left bank of cylinders. Remove 18 bolts.



94. Remove the camshafts of the left cylinder bank together with the secondary timing chain tensioner.

• Release the left secondary timing chain tensioner.
• Remove 2 bolts.

95. Remove the secondary timing chain tensioner for the left cylinder bank.



96. Remove the camshafts of the left cylinder bank.

• Remove the secondary timing chain from the left camshafts.
• Remove and discard 2 seals.

97.

CAUTION: Never place the cylinder head with the mating surface facing down. Failure to do so may result in damage to the vehicle.

CAUTION: The old gasket may only be removed with a plastic scraper.

Remove the left row cylinder head assembly.

• Remove and discard 8 bolts.
• Remove and discard the gasket.

98. Remove the special tool from the faceplate.



99. Remove the faceplate.

• Lock the faceplate with a special tool.
• Remove 8 bolts.

100. Remove the special tool from the faceplate.



101. Install the special tool.



102.

CAUTION: Loosen the bolts gradually in a criss-cross pattern.

NOTE: Secure the flywheel.

Remove the clutch slave and pressure plates. Unscrew 6 bolts.



103.

NOTE: Secure the flywheel.

Remove the flywheel. Unscrew the 8 bolts.



104. Remove the special tool.



105. Remove the oil cooler assembly.

• Remove 8 bolts.
• Remove and discard the gasket.

106. Remove the high pressure fuel pump. Unscrew the 4 bolts.



107. Remove the oil pan.

• Remove 14 bolts.
• Remove and discard the gasket.

108. Remove the mesh filter and the oil pump oil intake pipe.

• Remove the bolt.
• Remove and discard the 2 O-rings.

109. Remove the oil pan extension.

• Remove 18 bolts.
• Remove and discard the gasket.