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

Special tool

Engine Lifting Winch 303-1141

Installation

1. Using outside help, connect the engine to the gearbox.

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

2. Attach the engine to the gearbox. Tighten the bolts to 45 Nm.

3. Screw in the starter bolts. Tighten the bolts to 48 Nm.

4.

NOTE: Mark the position of the lower steering column shaft.

Install the engine assembly with the gearbox.

5. Remove the special tool.



6. Screw in the gearbox support bolt and tighten to 175 Nm.

7. Secure the left and right engine mounts. Tighten the nuts to 90 Nm.

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

9.

NOTE: Remove and discard plugs.

Connect the fuel lines.

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

11. Install the turbocharger support bracket.

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

12.

CAUTION: 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.

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

14. Secure the positive battery cable. Secure with a clamp.

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

16. Move the lower coolant hose.

17.

NOTE: Remove the plugs and drain them.

Connect the high pressure line of the air conditioning compressor.

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

18. Install the charge air cooler intake duct.

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

20. 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.

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

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

23.

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.

24. Secure the charge air cooler inlet pipe.

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

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



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

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

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

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

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

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

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

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

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

34.

NOTE: Install new bolts.

Secure the front propeller shaft to the transfer case drive flange.

• Install the washers.
• Step 1: Tighten the bolts to 45 Nm.
• Step 2: Tighten the bolts another 90 degrees.

35. Secure the rear propeller shaft to the transfer case drive flange.

• Install the washers.
• Tighten the bolts to 55 Nm.

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

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