Disco 1 300tdi disco engine removal tips

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ONE LIFE LIVE IT. D90

ONE LIFE LIVE IT. D90

Active Member
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953
Hi guys.

I'm 90% through removing the engine on a 1997 300tdi disco.

I'm following the workshop manual, but can't find where to disconect the engine harness and thread through the bulkhead. The manual states LH footwell but the image doesn't look the same as the connections I can see.

Secondly, how the hell do I get to the top bell housing bolts? Is there a bolt at 12 or are they positioned at 11 and 1?

Any other tips for removal of the engine?

Thanks alot
 
For starters you don't need the engine harness unless you really want it. Three bolts.... You've got two options

1 remove engine mounts, lower the engine so it drops at the front then you can get extension bars and socket on it.

2 by far the easiest way is to attack the dash board and heater matrix with a big hammer until you expose the bulkhead from the inside, remove a square panel with an angle grinder to expose the three nuts.

I've done both and if you are scrapping the discovery the second is by far the easiest and quickest especially if you are working on your own.
 
Marmaduke said:
For starters you don't need the engine harness unless you really want it. Three bolts.... You've got two options

1 remove engine mounts, lower the engine so it drops at the front then you can get extension bars and socket on it.

2 by far the easiest way is to attack the dash board and heater matrix with a big hammer until you expose the bulkhead from the inside, remove a square panel with an angle grinder to expose the three nuts.

I've done both and if you are scrapping the discovery the second is by far the easiest and quickest especially if you are working on your own.
Click to expand...

Thanks Again marmaduke.
I don't need the engine harness, but i can't even find it to disconnect it so it doesn't get tangled or caught on removal.

Unfortunately, hacking into the dash is out the question as my friend is buying the rest off me to break.

Where do you lift the engine from? Because there's no lifting eyes, and I certainly can't get to fit one off the defender at the back of the engine.

I was hoping you wouldn't say there was a bolt at 12. I'm hoping that's all ready out then. I think I only have 3 or 4 bolts left.
 
Take the dash to pieces then but seriously how much money are you going to get for a used heater matrix?
The one I did by removing the mounts was minus the cylinder head because the engine was goosed so I put it back in with the head missing by but I suppose you would have to use a couple of ropes or decent ratchet straps through round the engine.
 
Marmaduke said:
Take the dash to pieces then but seriously how much money are you going to get for a used heater matrix?
The one I did by removing the mounts was minus the cylinder head because the engine was goosed so I put it back in with the head missing by but I suppose you would have to use a couple of ropes or decent ratchet straps through round the engine.
Click to expand...

That's very true. I'll give that ago then if all else fails.
Is it possible to remove the two engine mounts and lower the engine then get to those bolts? I take it if I do that, I should remove the jack that I've got under the gearbox for support.

I manged to get the front lifting bracket on from my defender. Could I just loop a strap round the bottom of the engine for the rear? (Never removed an engine before so thank you for your help)
 
If you are doing it by removing the mounts and lowering the front of the engine then yes you'll need to remove the jack as you need the gearbox to pivot on its mountings, also put some of the bolts back in as you only want to disconnect the engine when it's level to avoid any damage to the gearbox and to stop the engine swinging forwards.
 
I got those top bolts out by dropping the gearbox right down and used a ratchet and all my extensions through the hole left by the gearstick

I put straps right round the engine to lift it out oh and a jcb that helped speed the job up !
 
Thanks for the replys chaps.

Even though it took me half a day, I managed to get all the bell housing bolts/nuts out.

I did it by welding an angled spanner, to fit in the gap of the bulkhead and block. Thankfully it worked. I'll post a picture tomorrow as this may help others in future.

Tomorrow is engine removal day; never removed one before. So should I pull it forward before lifting it up?
If so, how many inches should I pull forward before raising and lifting it out the engine bay?

Many thanks
 
Right, once the mounts are removed get the engine and box roughly level and put something like a jack under the front of the gearbox then take the weight of the engine and box so it sits just clear of the support and pull the hoist towards you. There is no saying it will just come apart cos sometimes they get stuck together or the angle of separation is wrong and you need to use a drift to split the bellhousing from the flywheel cover but you might get lucky...

Have you checked that your hoist will lift the engine high enough to clear the front of the Discovery or are you going to cut the front panel off to make access easier?
 
Marmaduke said:
Right, once the mounts are removed get the engine and box roughly level and put something like a jack under the front of the gearbox then take the weight of the engine and box so it sits just clear of the support and pull the hoist towards you. There is no saying it will just come apart cos sometimes they get stuck together or the angle of separation is wrong and you need to use a drift to split the bellhousing from the flywheel cover but you might get lucky...

Have you checked that your hoist will lift the engine high enough to clear the front of the Discovery or are you going to cut the front panel off to make access easier?
Click to expand...

The bellhousing is starting to split as it is now. Only by 5mm but still. Hopefully we will be okay.

I'm borrowing an engine hoist from a mechanic, but if it does struggle height wise, I could always lower the front end onto some pieces of wood under the discs, instead of the wheels.
 
ONE LIFE LIVE IT. D90 said:
The bellhousing is starting to split as it is now. Only by 5mm but still. Hopefully we will be okay.

I'm borrowing an engine hoist from a mechanic, but if it does struggle height wise, I could always lower the front end onto some pieces of wood under the discs, instead of the wheels.
Click to expand...
That's a good sign are you using ropes or a leveller? Try to get the lifting hook as close to the top of the engine as you can. I've got a clarke engine hoist and I ended up chopping the chain down that holds the hook to get it to lift higher. The only problem with lowering the front of the vehicle is it'll change the angle of the engine as well unless you do it when the engine is hanging free.

Time for bed for me as I'm up at three am for work, it'll have a look in the morning over breakfast.
 
Marmaduke said:
That's a good sign are you using ropes or a leveller? Try to get the lifting hook as close to the top of the engine as you can. I've got a clarke engine hoist and I ended up chopping the chain down that holds the hook to get it to lift higher. The only problem with lowering the front of the vehicle is it'll change the angle of the engine as well unless you do it when the engine is hanging free.

Time for bed for me as I'm up at three am for work, it'll have a look in the morning over breakfast.
Click to expand...

Thanks for your help with this Marmaduke. Got the engine out this afternoon, it all went very well thanks to your advise.

Now to tick off the jobs while it's on the engine stand.

Cheers
 
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