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

Special tool

Engine Lifting Winch 303-1141

Removal

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. Remove the wheels.

4. Disconnect the rear propeller shaft from the drive flange on the transfer case.

• Remove 6 bolts.
• Remove three washers.

5. Disconnect the front propeller shaft from the drive flange on the transfer case.

• Remove and discard 6 bolts.
• Remove three washers.

6. Remove the body. For more information, refer to Body - Diesel.



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

8. Remove the air intake throttle valve. For more information, refer to Air Intake Valve (19.70.32)

9. Remove the air intake throttle valve elbow support bracket. Remove the three bolts.



10. Disconnect the upper coolant hose from the coolant manifold. Remove the clamp.



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11. Disconnect the EGR coolant hose for the right bank of cylinders. Release the clamp.



12. Remove the accessory drive belt. Turn the accessory drive belt tensioner counterclockwise.





13. Remove the two heat shields from the left upper control arm and brake pipe.

• Unscrew the two nuts.
• Remove three bolts.

14. Disconnect the ventilation hose. Release the clamp.



15. Release the charge air cooler inlet pipe.

• Unscrew the two nuts.
• Remove the bolt.

16.

CAUTION: Plug all openings. Use new plugs.

Disconnect the low pressure line from the air conditioning (A/C) compressor.

• Remove the bolt.
• Remove the sealing ring and discard it.

17. Disconnect the charge air cooler inlet hose. Loosen the clamp.



18. Disconnect the charge air cooler inlet hose. Loosen the clamp.



19. Disconnect the lower coolant hose. Loosen the clamp.





20. Remove the rear power steering pump mounting bolt.



21. Remove the power steering pump. Remove the three bolts.



22. Remove the charge air cooler inlet pipe.

23.

CAUTION: Plug all openings. Use new plugs.

CAUTION: Be careful not to damage mating surfaces.

Disconnect the high pressure line of the air conditioning compressor.

• Remove the bolt.
• Remove the sealing ring and discard it.

24. Move the lower coolant hose.

25. Remove the turbocharger inlet pipe. Loosen the clamp.



26. Disconnect the positive cable from the battery. Release the clamp.



27. Disconnect the exhaust system from the turbocharger.

• Unscrew and discard three nuts.
• Remove the gasket and discard it.

28. Remove the turbocharger support bracket.

• Remove two bolts.
• Unscrew the nut.

29. Release the exhaust cross pipe bracket. Remove 6 bolts.



30.

CAUTION: Plug all openings. Use new plugs.

Disconnect the two fuel lines.



31. Release the transmission ventilation lines. Remove the bolt.



32. Disconnect the engine ground wire. Remove the bolt.





33. Unscrew the nut of the left engine support.



34. Unscrew the nut of the right engine support.



35. Remove the gearbox support cushion bolt.



36. Install the special tool.



37.

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

Using a special tool, remove the engine assembly with the gearbox.



38. Remove the two starter bolts.



39.

NOTE: Mark the transmission wiring harness routing.

With the help of a second mechanic, carefully separate the engine from the transmission.

• Remove 14 bolts.
• Carefully move the transmission wiring harness out of the way when removing the engine.