Front engine cover (Discovery 3)

Removal

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

2. Drain the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)

3. Remove the intake manifold. For more information, refer to Intake Manifold (30.15.02)

4. Remove the crankshaft pulley. For more information, refer to Crankshaft Pulley (12.21.01)

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5. Remove the lower cooling fan shroud.

• Release the 2 lower cooling fan shroud clips.
• Loosen and remove the lower cooling fan shroud from the radiator.

6. Move the air conditioning compressor support bracket to the side.

• Remove 4 bolts.
• Move the piece to the side and tie it.

7. Disconnect 2 hoses from the coolant pump.

• Disconnect the cooling system flange on the cylinder head to facilitate removal of the coolant hose.
• Remove 3 bolts.
• Move the coolant hoses to the side for better access.

8. Disconnect the engine ground wire. Unscrew the nut.



9. Release the transmission line support bracket.

• Unscrew the nut.
• Move the part to the side.

10. Remove the front engine cover.

• Remove 5 studs.
• Remove 4 bolts.
• Remove 5 cylinder block frame bolts.
• Remove the gasket and discard it.

11.

NOTE: Do not perform further disassembly if the part is removed only for access.

Remove the coolant pump.

• Remove 12 bolts.
• Remove the gasket and discard it.

Installation

1. Install the coolant pump.

• Clean the contact surfaces of the parts.
• Install a new gasket.
• Tighten the bolts to 10 Nm.

2.

CAUTION: Use caution when removing sealant from the gasket to avoid damaging the mating surfaces.

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

NOTE: Make sure the cylinder block frame gasket is properly positioned relative to the front oil seal.

Install the front engine cover.

• Clean the contact surfaces of the parts.
• Clean the contact surfaces of the gasket with solvent.
• Install a new gasket.
• Apply sealant to the 4 areas indicated.

3.

NOTE: Tighten the bolts in two stages.

Install the front engine cover bolts.

• Tighten the bolts and studs evenly and gradually. (tightening torque 8 Nm).
• Tighten the M6 bolts (tightening torque 10 Nm).
• Tighten the M8 bolts and studs (tightening torque 20 Nm).

4. Install the transmission support bracket. Tighten the nut. (tightening torque 20 Nm).

5.

NOTE: Use caution when installing ground connections. If the ground connection is poor, one or both banks of the engine will not start.

Connect the engine ground wire, making sure that the contact surfaces of the parts are clean. Tighten the nut. (tightening torque 20 Nm).

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

• Release the wire tie.
• Tighten the bolts (tightening torque 45 Nm).

7. Install the crankshaft pulley. For more information, refer to Crankshaft Pulley (12.21.01)

8. Install the cooling fan shroud.

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

10. 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)

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