Cylinder block frame (Discovery 3)

Special tool

Cylinder Block Frame Insert Adjustment Tool 303-596

Removal

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

2.

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

Raise and support the vehicle.

3. Remove the front wheels and tires.

4. Remove the starter. For more information, refer to Starter (86.60.01)

5. Remove the front axle tube. For more information, refer to Half-axle tube (47.10.42)

6. Remove the oil pan. For more information, refer to Oil Pan (12.60.44)

7. Remove the front stabilizer bar. For more information, refer to Front Stabilizer Bar (60.10.01)

8. Remove the radiator access panel. Remove 4 bolts.



9. Clear the engine oil cooler lines.

• Remove the bolt.
• Unscrew the nut.
• Move the lines to the side and tie them down.

10.

CAUTION: Before disconnecting or removing parts, make sure the area around mating surfaces and connections is clean. To prevent contamination of the system, plug all open connections.

Release the transmission lines.

• Place a container to collect any spilled liquid.
• Remove the bolt.
• Release the clamp.
• Remove and discard both O-rings.

11.

CAUTION: Before disconnecting or removing parts, make sure the area around mating surfaces and connections is clean. To prevent contamination of the system, plug all open connections.

Remove the oil temperature sensor.

• Disconnect the electrical connector.
• Remove the sealing ring and discard it.

12. Remove the oil inlet pipe with the mesh filter assembly.

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

13. Remove the dipstick.

14. Move the transmission lines and engine wiring harness away from the cylinder block frame flange and tie them down.

15.

NOTE: Mark the installation position of the 2 sealing washers.

Remove 8 cylinder block frame bolts. Remove and discard 2 sealing washers.



16.

CAUTION: If the set screws are not loosened, the cylinder block frame may be damaged.

Using the special tool, loosen the 8 cylinder block frame mounting screws.



17. Remove the cylinder block frame.

• Remove the 2 rear bolts.
• Remove 2 Torx screws.
• Unscrew 2 nuts.
• Remove 20 bolts.
• Remove the gasket and discard it.

Installation

1. Clean the cylinder block frame.

• Clean the contact surfaces of the parts.
• Remove the sealant from the cavities of the main bearing caps.

2.

CAUTION: If the set screws are not loosened, the cylinder block frame may be damaged.

Install the cylinder block frame set screws. Using the special tool, adjust the set screws so that they are below the cylinder block frame ledge surface.



3.

NOTE: Frame must be installed within 20 minutes after applying sealant.

Apply sealant to the cylinder block frame. Apply sealant to the 6 areas shown.



4.

CAUTION: Make sure the gasket is installed correctly.

Install the cylinder block frame.

• Install a new gasket.
• Screw in and then tighten the outer bolts, nuts and Torx screws evenly and gradually.

5. Align the cylinder block frame with the rear surface of the cylinder block.

• Install and tighten the 2 rear bolts.
• Loosen the 2 rear bolts.
• Lightly tighten the 2 rear bolts.

6. Tighten the outer bolts, nuts and Torx screws evenly and gradually. (tightening torque 10 Nm).

7. Tighten the 2 rear bolts (tightening torque 43 Nm).

8. Using the special tool, tighten the 8 cylinder block frame set screws. Tighten the set screws in the sequence shown. (tightening torque 7 Nm).



9.

NOTE: Sealing washers are installed on silver bolts. Silver bolts are installed in the 2 front holes.

Install the 8 cylinder block frame bolts and tighten them in 2 stages.

• Install 2 new sealing washers.
• Tighten the bolts in the sequence shown. (tightening torque 15 Nm).
• Tighten the bolts in the sequence shown. (tightening torque 34 Nm).

10.

NOTE: Lubricate new seals with clean engine oil.

Install the oil temperature sensor.

• Clean the contact surfaces of the parts.
• Install a new O-ring.
• Tighten the oil temperature sensor (tightening torque 20 Nm).
• Connect the electrical connector.

11.

NOTE: Lubricate new seals with clean engine oil.

Install the oil inlet pipe with the mesh filter assembly.

• Clean the parts.
• Install new O-rings.
• Tighten the bolt (tightening torque 10 Nm).

12. Install the oil pan. For more information, refer to Oil Pan (12.60.44)

13. Insert the dipstick. Clean the part.

14. Reinstall the engine oil cooler lines. Tighten the bolt and nut. (tightening torque 25 Nm).

15. Connect the transmission pipes.

• Clean the parts.
• Install new O-rings.
• Secure the clamp.
• Tighten the bolt (tightening torque 10 Nm).

16. Install the starter. For more information, refer to Starter (86.60.01)

17. Install the front stabilizer bar. For more information, refer to Front Stabilizer Bar (60.10.01)

18. Install the front axle tube. For more information, refer to Half-axle tube (47.10.42)

19. Install the radiator access panel. Tighten the 4 bolts. (tightening torque 10 Nm).

20. Install the front wheels and tires.

21. Connect the ground cable to the battery. For more information, refer to Specifications

22. Check the transmission fluid level and add fluid if necessary. For more information, refer to Checking the Transmission Fluid Level (44.24.06)