Installing a 4.4L Engine (Discovery 3)

Special tool

Engine Lifting Winch 303-1144

Fuel System Spring Lock Release Tool 310-D005

Ball Joint Puller 205-754(LRT-54-027)

Installation

1. Install the engine.

• Attach the lifting chains.
• Raise the engine.
• Clean the contact surfaces of the parts.
• Clean the dowel pins.

2. Carefully lower the engine until it is approximately 35mm above the engine mounts.
3. Install the front engine mount bracket.

• Tighten the new bolts to 45 Nm, then tighten them an additional 60 degrees.
• Connect the engine ground wire and screw in the bolt. (tightening torque 25 Nm).

4. Clean the contact surfaces of the parts.

5. With the help of another mechanic, align the engine with the transmission and mounts.

• Screw in the gearbox mounting bolts.
• Tighten the bolts (tightening torque 45 Nm).
• Tighten the engine mount nuts (tightening torque 90 Nm).

6. Install the flexible plate onto the torque converter.

• Turn the crankshaft to gain access to the mounting bolts.
• Tighten the bolts evenly in 2 stages.
• Tighten the bolts to 15 Nm.
• Tighten the bolts (tightening torque 110 Nm).
• Install the sealing bushing.

7. Install the transmission heat shield.



8. Install the transmission cooling system pipes.

• Clean the contact surfaces of the parts.
• Install new O-rings.
• Install the clamp.
• Tighten the bolt (tightening torque 25 Nm).

9. Install the air conditioning compressor assembly. Tighten the bolts. (tightening torque 25 Nm).





10. Install the power steering pump. Tighten the bolts. (tightening torque 25 Nm).



11. Install the exhaust system. For more information, refer to Exhaust System (10/30/08)

12. Install the engine oil cooler in place. Tighten the Allen bolt. (tightening torque 60 Nm).

13. Disconnect the lifting chains.

14. Disconnect the special tools. Remove the lifting brackets.



15. Install the EGR valve into the EGR pipe, then insert the bolts and tighten them. (tightening torque 25 Nm). Install and align the new gasket.





16. Install the upper control arm and brake line heat shields.

• Insert and tighten the bolts (tightening torque 10 Nm).
• Tighten the nuts (tightening torque 10 Nm).

17. Connect the fuel line to the fuel rail.

• Clean the contact surfaces of the parts.
• Secure the clamps.

18. Connect the brake booster vacuum hose to the intake manifold.



19. Connect the engine wiring harness.

• Connect the ground wire.
• Connect the electrical connectors.
• Install the cassette.

20. Connect the fuel vapor recovery system canister hose to the intake manifold.



21. Connect the positive battery cable to the battery junction box (BJB). Tighten the bolt. (tightening torque 10 Nm).



22. Connect and secure the coolant hoses.



23. Install the accessory drive belt tensioner. Tighten the bolt. (tightening torque 45 Nm).





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

25. Install the right air cleaner assembly. For more information, refer to Air Cleaner (10/19/01)

26. Install the extra battery tray. For more information, refer to Extra Battery Shelf (76.10.31)

27. Install the battery tray. For more information, refer to Additional Battery Shelf (76.10.31)

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

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

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

31. Remove the hood from the service position.

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