Engine installation (Discovery 3)

Installation

1. Remove the torque converter holder.

2. Install the engine.

• Attach the lifting chains.
• Carefully lower the engine until it is approximately 35mm above the engine mounts.
• With the help of another mechanic, align the engine with the transmission and mounts.

3. Install the right engine mount.

4. Screw in the gearbox mounting bolts.

• Clean the contact surfaces of the parts.
• Remove the guide pins.
• Tighten the bolts (tightening torque 45 Nm).

5. Tighten the engine mount nuts. (tightening torque 90 Nm).

6. Remove the engine lifting device.

• Disconnect the lifting chains.
• Remove 7 bolts.
• Unscrew 12 nuts.

7. Install the flexible plate onto the torque converter.

• Turn the crankshaft to gain access to the mounting bolts.
• Tighten the bolts (tightening torque 45 Nm).
• Install the sealing bushing.

8. Connect the crankshaft position (CKP) sensor electrical connector. Clean the contact surfaces of the parts.

9. Connect the heated oxygen sensor electrical connectors.

10. Install the engine wiring harness support bracket.

11. Connect the electrical connector of the engine oil temperature sensor.

12. Install the starter.

• Clean the contact surfaces of the parts.
• Tighten the bolts (tightening torque 45 Nm).

13. Install the fuel and purge line heat shield in place and secure it with bolts.

14. Connect the right catalytic converter to the exhaust manifold.

• Clean the parts.
• Tighten the new bolts. (tightening torque 22 Nm).

15.

CAUTION: Make sure that the distance (A) between the nearest surfaces of the left catalytic converter and the front drive shaft is 25-30 mm.

Connect the left catalytic converter to the exhaust manifold.

• Clean the parts.
• Tighten the new bolts. (tightening torque 22 Nm).

16. Install the transmission heat shield.

17. Connect the engine oil cooler hoses. Secure the clamps.

18. Connect the coolant pump hose. Secure the clamp.

19. Install the lower steering column universal joint assembly. Install and tighten the new capped bolts. (tightening torque 25 Nm).

20. Connect the engine coolant temperature (ECT) sensor electrical connector.

21. Install the EGR pipe.

• Clean the contact surfaces of the parts.
• Install the part onto the exhaust manifold, but do not fully tighten the union nut at this stage.

22. Install the transmission cooling system pipes.

• Install the support bracket.
• Tighten the nut (tightening torque 10 Nm).

23. Connect the engine ground wire, making sure that the contact surfaces of the parts are clean.

• Tighten the nut (tightening torque 25 Nm).
• Install the lid.

24. Install the A/C compressor support bracket assembly.

• Clean the contact surfaces of the parts.
• Tighten the bolts (tightening torque 45 Nm).
• Install the KS electrical connector clamp.
• Connect the air conditioning compressor electrical connector.

25. Install the generator support bracket.

• Clean the contact surfaces of the parts.
• Tighten the bolts (tightening torque 45 Nm).
• Secure the clamp.
• Install a new wire tie.

26. Connect the electrical connector of the engine oil pressure (EOP) sensor.

27. Connect the generator electrical connectors.

28. Install the accessory drive belt. For more information, refer to Accessory Drive Belt (86.10.03)

29. Install the lower cooling fan shroud.

• Remove the radiator guard.
• Install and secure with clamps.

30. Attach the wiring harness to the manifold. Secure the clamps.

31. Connect the ECM electrical connectors.

32. Install the battery tray. For more information, refer to Battery tray (76.10.30)

33. Install the intake manifold. For more information, refer to Intake Manifold (30.15.02)

34. Tighten the nuts securing the EGR pipe to the exhaust manifold and EGR valve. (tightening torque 25 Nm).

35. Fill the engine with oil. For more information, refer to Draining and filling engine oil (12.60.05)

36. Fill the cooling system with coolant and bleed air from it. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)

37. Remove the hood from the service position.

• Release the 2 clamps.
• Attach the posts and secure them with clamps.

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