Installing a 2.7L engine with automatic transmission (Discovery 3)

Special tool

Engine Lifting Winch 303-1141

Installation

1.

CAUTION: Apply recommended grease to the torque converter guide bushing.

CAUTION: Make sure the torque converter is fully engaged into the oil pump drive.

With the help of a second mechanic, carefully install the engine.

• Clean the contact surfaces of the parts.
• Carefully route the transmission wiring harness when installing the engine.
• Carefully route the positive battery cable when installing the motor.

2.

CAUTION: Make sure the torque converter remains connected to the transmission.

Attach the engine to the gearbox.

• Tighten the bolts to 45 Nm.
• Remove the jack supporting the transmission.

3. Secure the left and right engine mounts.

• Lower the engine onto its mounts.
• Tighten the nuts to 90 Nm.

4. Remove the special tool. Unscrew the bolts.



5.

NOTE: Use new bolts.

Install the faceplate onto the torque converter.

• Tighten the bolts to 45 Nm.
• Install the access plug.

6. Install the starter. Tighten the bolts to 48 Nm.

7. Connect the two starter wiring harness connectors to the starter solenoid.

• Tighten the solenoid connector nut to 8 Nm.
• Tighten the positive battery cable nut to 11 Nm. Install the rubber insulator.

8. Install the starter support bracket. Tighten the bolts to 10 Nm.

9. Secure the engine ground wire. Tighten the bolt to 22 Nm.

10. Install the fuel cooler. Tighten the bolt to 10 Nm.
11.

NOTE: Remove and discard plugs.

Connect the fuel lines.

12. Secure the fuel lines.

• Tighten the bolt to 22 Nm.
• Secure with clamps.

13. Secure the transmission ventilation lines. Tighten the bolt to 7 Nm.

14. Install the turbocharger support bracket.

• Tighten the bolts to 48 Nm.
• Tighten the nut to 22 Nm.

15.

NOTE: Use new nuts.

NOTE: Make sure the mating surfaces of the components are clean.

Connect the exhaust system to the turbocharger.

• Install a new gasket.
• Tighten the nuts to 48 Nm.

16. Secure the exhaust cross pipe bracket. Tighten the bolts to 25 Nm.

17. Secure the positive battery cable with a clamp.

18. Secure the transmission fluid lines. Tighten the nut to 10 Nm.

19. Install the turbocharger inlet pipe. Tighten the clamp.

20. Move the lower coolant hose.

21.

NOTE: Remove and discard plugs.

Connect the high pressure line of the air conditioning compressor.

• Install a new O-ring.
• Tighten the bolt to 9 Nm.

22. Install the charge air cooler intake duct.

23. Install the power steering pump to the power steering pump bracket. Install the rear bolt, but do not tighten it.



24. Secure the power steering pump.

• Tighten the three front bolts to 22 Nm.
• Loosen the three front bolts a quarter turn.
• Tighten the rear bolt to 22 Nm.
• Tighten the three front bolts to 22 Nm.

25. Connect the lower coolant hose. Secure with a clamp.

26. Connect the charge air cooler inlet hoses. Tighten the clamps.

27.

NOTE: Remove and discard plugs.

Connect the low pressure line of the air conditioning compressor.

• Install a new O-ring.
• Tighten the bolt to 9 Nm.

28. Secure the charge air cooler inlet pipe.

• Tighten the bolts to 10 Nm.
• Tighten the nut to 10 Nm.

29. Connect the ventilation hose. Secure with a clamp.

30. Install the left upper control arm and brake line heat shield.

• Tighten the bolts to 10 Nm.
• Tighten the nuts to 10 Nm.

31. Install the accessory drive belt. Turn the accessory drive belt tensioner counterclockwise.

32. Connect the EGR coolant hose of the right cylinder bank. Secure with a clamp.

33. Connect the upper coolant hose to the coolant manifold. Install the clamp.

34. Install the air intake throttle valve elbow support bracket. Tighten the bolts to 10 Nm.

35. Install the air intake shut-off valve. For more information, refer to Air Intake Damper (19.70.32)

36. Install the cooling fan shroud. For more information, refer to Cooling Fan Shroud (26.25.11)

37. Install the body. For more information, refer to Body - Diesel.

38. Install the wheels. Tighten the wheel nuts to 140 Nm.

39. Connect the ground cable to the battery. For more information, refer to Specification.