Engine, Ignition System, & Fuel System Sensors & Switches Land Rover Discovery L318

INTRODUCTION

Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

DISCONNECTING BATTERY

When vehicle battery is disconnected vehicle systems are affected. On Discovery and Range Rover, see SERVICE PRECAUTIONS in SELF-DIAGNOSTICS - DISCOVERY & RANGE ROVER article. On Freelander, see SERVICE PRECAUTIONS in SELF-DIAGNOSTICS - FREELANDER article.

Freelander

Raise and support vehicle. Remove engine lower cover. (Scheme 1) To remove (upper) engine acoustic cover, disconnect air intake hose from acoustic cover. Disconnect air intake hose and air by-pass hose from throttle body. Release 2 acoustic cover fasteners connected to left cylinder head. Release acoustic cover retaining strap. Remove acoustic cover. (Scheme 2) To install engine covers, reverse removal procedure.

Scheme 1

Scheme 2

DRAINING, REFILLING & BLEEDING COOLING SYSTEM

Draining Cooling System (Discovery Series II)

1. Allow cooling system to cool for several hours. Visually inspect engine and cooling system for coolant leaks. Examine hoses for signs of cracking, distortion and good connections. Perform repairs as necessary. Position drain tray to collect coolant. Remove expansion tank filler cap.
2. Remove left and right drain plugs from sides of cylinder block. Disconnect bottom hose from radiator and allow cooling system to drain. Disconnect top hose from thermostat and position open end of hose below level of water pump intake, to allow coolant to drain completely from cooling system. When cooling system repairs are completed, go to «REFILLING & BLEEDING COOLING SYSTEM (DISCOVERY SERIES II)»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__refilling-bleeding-cooling-system-discovery) .

Refilling & Bleeding Cooling System (Discovery Series II)

1. Using water under low pressure, flush cooling system. Apply Loctite No. 577 to threads of cylinder block drain plugs. Install drain plugs to cylinder block and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) . Connect bottom radiator hose to radiator and top hose to thermostat housing.
2. Release upper radiator hose from retaining lugs on the fan cowl, leaving hose to rest on lugs and connected to radiator. Remove bleed screw from middle of upper radiator hose. Release coolant expansion tank overflow hose from battery box. Remove expansion tank from its mounting bracket. Slowly fill the expansion tank with approximately 4.2 Qts. (4.0 L) of coolant. Raise expansion tank up approximately 8 inches until coolant begins to drain into the cooling system.
3. Refill coolant expansion tank until a steady flow of coolant is discharged from the bleed hole. Install bleed screw then. With expansion tank still raised, continue filling cooling system until coolant level reaches the base of the coolant expansion tank filler neck. With a steady flow of coolant from bleed hole and expansion tank still raised, install bleed screw. With the expansion tank still raised, continue filling system until the coolant level reaches the base of the expansion tank filler neck. Install coolant expansion tank filler cap and remount expansion tank and overflow hose.
4. Install top radiator hose into lugs on the fan cowl. Start engine and allow to idle until normal operating temperature is reached. Monitor temperature gauge to ensure engine does not overheat. Check cooling system for leaks. Turn engine off and allow to cool. Recheck for leaks and refill coolant to COLD LEVEL mark on expansion tank.

Draining Cooling System (Freelander)

1. Allow cooling system to cool for several hours. Raise and support vehicle. Remove engine lower cover and (upper) engine acoustic cover. See «ENGINE COVERS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches) . Visually inspect engine and cooling system for coolant leaks. Examine hoses for signs of cracking, distortion and good connections. Perform repairs as necessary. Position drain tray to collect coolant. Remove expansion tank filler cap.
2. Remove cylinder block coolant drain plug. Disconnect bottom hose from radiator and allow cooling system to drain. Using water under low pressure, flush cooling system. Clean cylinder block coolant drain plug threads. Apply Sealant (Part No. STC 50552) to first 3 threads of cylinder block coolant drain plug. Install cylinder block coolant drain plug. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) . Connect bottom radiator hose to radiator and reinstall clamp. When cooling system repairs are completed, go to «REFILLING & BLEEDING COOLING SYSTEM (FREELANDER)»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__refilling-bleeding-cooling-system-freelander) .

Refilling & Bleeding Cooling System (Freelander)

1. Remove bleed screw from heater return hose. Slowly fill cooling system through coolant expansion tank. Continue filling cooling system until a steady flow of coolant flows from bleed hole. With coolant flowing from bleed hole, install and close bleed screw in heater return hose. Continue filling cooling system until coolant reaches to base of coolant expansion tank bleed hose. Install coolant expansion tank filler cap.
2. Start and run engine at idle speed for 5 minutes. DO NOT operate air conditioning. Turn engine off. Squeeze bottom radiator hose several times to remove any trapped air. Start engine and vary speed between idle speed and 3500 RPM for 7 minutes. Turn off engine and allow to cool. Remove coolant expansion tank filler cap. Add coolant until it reaches the MAX mark on coolant expansion tank. Install coolant expansion tank filler cap. Start and run engine until normal operating temperature is reached. Verify bottom radiator hose is warm/ hot, this will ensure thermostat is fully open.
3. Verify warm air is available at vents inside vehicle. If warm air is available, go to next step. If warm air is not available, an air-lock may be present in heater matrix. Allow engine to cool. Remove coolant expansion tank filler cap. Repeat bleed operation at heater hose. Turn off engine and allow to cool.
4. Check system for leaks. Fill coolant to MAX mark on coolant expansion tank. Reinstall lower engine cover and (upper) engine acoustic cover.

Draining Cooling System (Range Rover)

1. Allow cooling system to cool for several hours. Raise and support front of vehicle. Remove expansion tank filler cap to assist draining. Position clean container under radiator and remove radiator drain plug. Allow coolant to drain until desired amount is drained. If cooling system is to be partially drained, go to «REFILLING COOLING SYSTEM (RANGE ROVER)»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__refilling-cooling-system-range-rover) . If entire cooling system is to be drained, go to next step.
2. When radiator is drained, reposition container under left side of engine. Remove left side cylinder block drain plug. Allow coolant to drain. DO NOT remove right side cylinder block drain plug. Clean drain plug threads. Apply Loctite No. 577 to threads of drain plug and install into cylinder block. Tighten drain plug securely. When cooling system repairs are completed, go to «REFILLING COOLING SYSTEM (RANGE ROVER)»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__refilling-cooling-system-range-rover) .

Refilling Cooling System (Range Rover)

1. Ensure radiator drain plug "O" ring is not damaged. Replace "O" ring if necessary. Install radiator drain plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) . Lower vehicle.
2. Disconnect radiator overflow hose from top of radiator. Using compressed air, carefully blow through overflow hose towards expansion tank to clear any residual coolant. Reconnect overflow hose. If radiator overflow hose is not cleared of coolant, air may become trapped at top of radiator during refill, leading to subsequent engine overheating.
3. Fill expansion tank until coolant is level with base of neck. Start engine and allow to idle. Continue filling at expansion tank until coolant level stabilizes at the COLD LEVEL marking. Start engine and allow to idle until thermostat opens and top radiator hose becomes warm. Monitor temperature gauge to ensure engine does not overheat. Turn engine off and allow to cool. Recheck coolant level and add coolant as necessary. Install expansion tank filler cap.

Removal & Installation (Discovery Series II)

Disconnect negative battery cable. Remove passenger side kick panel and remove "A" post lower trim. Remove 2 nuts and ECM from studs. Lower ECM into footwell, disconnect 5 connectors and remove ECM. To install, reverse removal procedure. Using TestBook/T4, program ECM and reset adaptations.

Removal & Installation (Freelander)

Disconnect negative battery cable. The ECM is located in the engine compartment, in the "E" box. Remove 5 "E" box Allen screws. Disconnect 5 ECM connectors. Release 2 ECM clips. Remove ECM. To install, reverse removal procedure.

Removal & Installation (Range Rover)

Note. ECM connectors must be disconnected sequentially to release them from the unit.

Remove battery cover and disconnect negative battery cable. Position cruise control actuator and pump assembly aside. Lift 2 plastic clips at the top of the "E" box and pull "E" box lid upward and out. (Scheme 3) Release ECM housing cover. Disconnect ECM cooling fan connector. Remove ECM from housing cover. ECM is held in position in the lid of the box by 2 plastic brackets. Release plastic brackets and remove ECM. To install, reverse removal procedure.

Scheme 3

Removal & Installation (Discovery Series II & Range Rover)

1. Remove battery cover and disconnect negative battery cable. Drain sufficient coolant to ensure no spillage during removal of ECT sensor. See «DRAINING, REFILLING & BLEEDING COOLING SYSTEM»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__draining-refilling-bleeding-cooling-system) .
2. Remove accessory drive belt. Remove alternator from support bracket and position aside. Disconnect ECT sensor connector. Remove sensor from intake manifold and discard sealing washer. Clean sealant from threads in manifold.
3. Apply Loctite No. 577 to threads of ECT sensor. Install ECT sensor using a NEW sealing washer and tighten to specification and reconnect connector. Install alternator and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) . To complete installation, reverse removal procedure. Refill cooling system. See «DRAINING, REFILLING & BLEEDING COOLING SYSTEM»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__draining-refilling-bleeding-cooling-system) .

Disconnect negative battery cable. Removal of ECT sensor requires removal of upper intake manifold, fuel rail cover, coolant thermostat, and necessary components to facilitate procedure. Remove upper intake manifold. (Scheme 4) Remove fuel rail cover. Remove coolant thermostat. (Scheme 5) Disconnect ECT sensor 2-pin electrical connector. ECT sensor is located near thermostat assembly. Remove ECT sensor and discard sealing washer. DO NOT discard ECT sensor steel shim. To install, clean ECT sensor cylinder block mating surface. Install a NEW sealing washer, then steel shim to ECT sensor. Position ECT sensor and tighten to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Use NEW intake manifold seals and "O" rings during reassembly. Use NEW coolant thermostat "O" rings and lubricate during reassembly. See TORQUE SPECIFICATIONS.

Scheme 4

Scheme 5

HEATED OXYGEN SENSOR (HO2S)

Note. New HO2S is pre-treated with anti-seize compound. If reusing HO2S, coat threads with anti-seize compound. DO NOT allow anti-seize compound to come in contact with HO2S nose or enter exhaust system.

1. Sensors are located in front of and after each catalytic converter (total of 4 sensors). Raise and support vehicle. HO2S is equipped with a permanent pigtail which must be protected from damage when sensor is removed. Disconnect HO2S harness connector and remove sensor lead from routing clips. Ensure sensor connector is free of contaminants, avoid using cleaning solvents of any type.
2. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Using HO2S Sensor Remover/Installer (LST-124), remove HO2S. To install, reverse removal procedure. If reusing HO2S, coat threads with anti-seize compound and use a NEW sealing washer. Do not allow anti-seize compound to contact nose of HO2S. Tighten sensor to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) .

1. Sensors are located in front of and after each catalytic converter (total of 4 sensors). Raise and support vehicle. HO2S is equipped with a permanent pigtail which must be protected from damage when sensor is removed. To access front HO2S, remove engine covers. See «ENGINE COVERS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches) . On front or rear HO2S, disconnect HO2S harness connector and remove sensor lead from routing clips. Ensure sensor connector is free of contaminants, avoid using cleaning solvents of any type.
2. Using appropriate tool, remove HO2S. To install, reverse removal procedure. If reusing HO2S, coat threads with anti-seize compound and use a NEW sealing washer. Do not allow anti-seize compound to contact nose of HO2S. Tighten sensor to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) .

KNOCK SENSOR (KS)

One KS is located in each side of engine block between cylinders 2 and 4, and between cylinders 3 and 5. Disconnect negative battery cable. Raise and support vehicle. Remove under engine panels as necessary to facilitate removal. Remove KS mounting bolt and remove KS. To install, reverse removal procedure. Ensure KS mating surfaces are clean. Tighten KS bolt to specification. See TORQUE SPECIFICATIONS .

Two knock sensors are located in the cylinder block, between cylinder heads. Disconnect negative battery cable. Remove (upper) engine acoustic cover. See ENGINE COVERS. Removal of KS requires removal of upper intake manifold, left intake manifold, draining cooling system and necessary components to facilitate procedure. Drain cooling system. Remove upper intake manifold and left intake manifold. (Scheme 4) Remove KS mounting bolt and remove KS. (Scheme 6) To install, reverse removal procedure. Ensure KS mating surfaces are clean. Tighten KS bolt to specification. See TORQUE SPECIFICATIONS.

Scheme 6

1. Remove battery cover. Disconnect negative battery ground terminal. Raise and support front of vehicle. On Discovery Series II, remove belly pan and oil filter. On all models, disconnect CMP sensor 3-pin connector and remove from bracket. Remove clamp securing CMP sensor and sensor. Discard "O" ring.
2. To install, reverse removal procedure using a NEW CMP sensor "O" ring. Ensure CMP sensor is clean. Tighten sensor mounting bolt to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) . On Discovery Series II, install oil filter and belly pan. Ensure oil level is correct.

Disconnect negative battery cable. Remove (upper) engine acoustic cover. See ENGINE COVERS. Disconnect CMP sensor electrical connector. Remove CMP sensor bolt. Remove CMP sensor and discard seal. (Scheme 7) To install, reverse removal procedure. Ensure CMP mating surfaces are clean. Lubricate NEW CMP seal with engine oil before installation. Tighten CMP sensor bolt to specification. See TORQUE SPECIFICATIONS.

Scheme 7

1. CKP sensor is located on the left side of flywheel housing and uses different thicknesses of spacers for manual and automatic transmissions. Disconnect negative battery cable. Raise and support front of vehicle. Disconnect CKP sensor electrical connector and remove heat shield. Remove 2 sensor mounting nuts, CKP sensor and spacers.
2. Ensure all CKP sensor related components are clean. Install sensor mounting, CKP sensor and spacers. Tighten sensor retaining nuts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) . To complete installation, reverse removal procedures.

Disconnect negative battery cable. Remove engine lower cover and (upper) engine acoustic cover. See ENGINE COVERS. Disconnect CKP sensor electrical connector. Remove CKP sensor bolt. Remove CKP sensor. (Scheme 8) To install, reverse removal procedure. Ensure CKP mating surfaces are clean. Tighten CKP sensor bolt to specification. See TORQUE SPECIFICATIONS.

Scheme 8

Relieving Fuel Pressure

Discovery Series II - Turn ignition off. Locate Schrader valve on fuel rail. Remove Schrader valve cap. Place a shop towel under Schrader valve. Cover Schrader valve with a shop rag. Open Schrader valve to release fuel pressure.

Freelander - Turn ignition off. Locate Schrader valve on fuel rail, above accumulator. Remove Schrader valve cap. Place a shop towel under Schrader valve. Cover Schrader valve with a shop rag. Open Schrader valve to release fuel pressure.

Range Rover - Turn ignition off. Fuel pressure can be relieved at fuel feed fitting at fuel rail. Position cloth around fitting to catch fuel spray. Using 2 wrenches, loosen fitting, allowing fuel system to depressurize.

Discovery Series II

A coarse filter is attached to the base of the fuel pump/fuel pressure regulator/fuel gauge sender located inside fuel tank. A gauze filter prevents contaminants from entering fuel pump. A large fine paper filter surrounding the pump further protects the fuel system from contamination. The paper filter is not serviceable. Discovery Series II does not have an external in-line fuel filter.

1. The fuel pump assembly is located in a plastic body which incorporates a coarse mesh filter and a serviceable fine mesh filter. The serviceable fine mesh filter is located in the fuel pump assembly swirl pot. Remove fuel pump assembly. See «FUEL PUMP»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__fuel-pump).
2. Release 2 fasteners from top of fuel pump assembly. (Scheme 9) Release 3 slots in top of fuel pump assembly from lugs in base. Carefully remove top of fuel pump assembly from base. Ensure fuel feed hose does not become strained when removing top of fuel pump assembly.
3. Remove compression spring from fuel filter. Release 3 sprag clips securing fuel filter. Release fuel filter from inlet and outlet connections. Remove fuel filter and "O" rings. Discard fuel filter and "O" rings. (Scheme 10)
4. To install, reverse removal procedure. Lubricate NEW "O" rings with silicone grease before installation. Ensure fuel pressure regulator grounding spring is correctly positioned. Ensure fuel filter grounding tag is correctly positioned to contact base of fuel filter.

Scheme 9

Scheme 10

Range Rover

In-line fuel filter is located under vehicle forward of fuel tank. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect fuel lines from fuel filter. Remove "O" rings and discard. Remove fuel filter mounting bolt. Remove fuel filter. To install, reverse removal procedure. Use new "O" rings during fuel filter installation. Tighten fuel lines to specification. See TORQUE SPECIFICATIONS .

FUEL PUMP

Note. The fuel pump and fuel gauge tank unit are integral parts of the fuel pump assembly and cannot be replaced separately.

1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches). Remove right side third row seat (if equipped). See «THIRD ROW SEAT REMOVAL & INSTALLATION (DISCOVERY SERIES II)»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__third-row-seat-removal-installation).
2. Remove right rear "D" post trim casing trim clips. (Scheme 11) If vehicle is equipped with rear In-Car Entertainment (ICE) controls, remove ICE controls. Partially remove rear door seal in the area of the RH side trim casing. Remove rear light access panel. Remove lower "E" post trim clip.
3. If equipped with third row seats, remove third row seat belt mounting bolt. Remove right rear trim casing. Pull load space carpet back from fuel pump access panel. Remove fuel pump assembly access panel. Disconnect fuel pump assembly connector and fuel hose. Install plugs into exposed openings to prevent contamination. Disconnect fuel tank pressure sensor pipe from fuel pump assembly. WARNING: Fuel spillage is unavoidable during fuel pump assembly removal. Take necessary precautions to prevent personal injury and damage to vehicle interior.
4. Using Retaining Ring Remover/Installer (LRT-19-009), remove fuel pump retaining ring and sealing ring. (Scheme 12) Remove fuel pump assembly from vehicle. To install, reverse removal procedure. Use NEW rubber sealing ring. Tighten fasteners and fittings to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications). Run engine and check fuel system for leaks.

Scheme 11

Scheme 12

Third Row Seat Removal & Installation (Discovery Series II)

1. Fabricate a third row seat spring retainer bracket to the dimensions specified. (Scheme 13) Position third row seat in deployed position. Remove cup holder (if equipped). Remove saddle bracket cover from lower rear quarter to allow access to third row seat mounting bolts and nuts.
2. Remove top 2 mounting bolts securing seat to lower rear quarter panel. Position fabricated third row seat spring retainer bracket across the seat mounting. Ensure that the lugs on the end of the retainer fit below the seat mounting bar, then partially fold the seat so that the retainer bracket is held in position. (Scheme 14) Remove 2 lower nuts securing seat to lower rear quarter panel. The action of the spring will now hold the retainer bracket in position. Remove seat from vehicle.
3. Before installing third row seat, ensure spring retainer bracket is in position on the seat spring. Position third row seat onto its mounting studs. Install nuts securing third row seat to lower rear quarter panel and tighten to 16 ft. lbs. (22 N.m). Remove fabricated retainer bracket. Install mounting bolts securing third row seat to lower rear quarter panel and tighten to 16 ft. lbs. (22 N.m). Install saddle bracket cover to third row seat securing bolts, fit the cup holder (where applicable) and stow the seat.

Scheme 13

Scheme 14

1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches). Fold right rear seat forward. Remove 2 front and rear carpet fasteners. Pull back carpet from fuel pump access panel. Remove 6 screws from fuel pump access panel. Remove fuel pump access panel. WARNING: Fuel spillage is unavoidable during fuel pump assembly removal. Take necessary precautions to prevent personal injury and damage to vehicle interior.
2. Disconnect fuel pump assembly electrical connector and fuel line. Using Retaining Ring Remover/Installer (LRT-19-009), remove fuel pump retaining ring and sealing ring. (Scheme 12) Carefully remove fuel pump assembly from vehicle. Discard lock ring sealing ring.
3. To install, reverse removal procedure. Install a NEW lock ring seal ring. Tighten fuel pump lock ring to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications). Inspect fuel system for leaks after completing installation.

Note. Fuel pump removal requires fuel tank removal.

1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches). If fuel tank is less than 3/4 full, go to next step. If fuel tank is more than 3/4 full, disconnect fuel return connection at fuel rail or connection located under floor, near fuel filter. Position a shop towel around appropriate fitting to catch excess fuel. Connect drain hose to fuel return line connection. Remove at least 2.6 gallons (10 liters) of fuel into an approved container and go to next step.
2. Raise and support vehicle. Remove right rear wheel arch panel. Remove fuel filler cap. Remove nut holding filler neck bracket to body stud. Disconnect vent line quick-fit connectors at fuel vapor separator and under body connection. Disconnect fuel tank pressure sensor breather hose. Remove break-away bolt from filler neck assembly-to-fuel tank stub clamp. Discard clamp. Remove filler neck bracket from body stud. Remove filler neck assembly from fuel tank fill stub. Insert a plastic tube into fuel tank inner filler stub and continue to drain remaining contents of fuel tank into an approved container.
3. Support fuel tank with jack. Remove 3 nuts and 2 bolts securing fuel tank cradle to floor pan. Lower cradle and fuel tank about 6 inches and disconnect fuel pump electrical connectors. Remove fuel tank from vehicle. Disconnect breather hose from fuel tank pressure sensor. Disconnect fuel feed and return lines from fuel pump assembly. Using Retaining Ring Remover/Installer (LRT-19-009), remove fuel pump assembly retaining ring.
4. Fuel pump assembly will contain a small amount of fuel. Use care to reduce spillage during fuel pump assembly removal from fuel tank. Remove fuel pump assembly using lifting eyelet located between fuel feed and fuel return stubs. DO NOT lift fuel pump assembly using either the fuel feed or fuel return stubs. Doing so may damage the stubs. Discard sealing ring. (Scheme 12)
5. To install, reverse removal procedure. Use NEW rubber sealing ring and "O" rings. Ensure locating tag on fuel pump assembly is correctly fitted to fuel tank opening lip. Tighten fasteners and fittings to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications). Run engine and check fuel system for leaks.

FUEL PRESSURE REGULATOR

Note. Manufacturer does not identify if fuel pressure regulator is serviceable separately.

Discovery Series II & Range Rover - Fuel pressure regulator is located on top of fuel pump assembly inside fuel tank. Fuel pressure should be 51 psi (3.5 bar).

Freelander - Fuel pressure regulator is located on top of fuel pump assembly inside fuel tank. Fuel pressure should be 51 psi (3.5 bar). A Schrader valve is provided on the fuel rail (above the accumulator) for measuring fuel pressure. An accumulator is attached to the left cylinder head fuel rail. The accumulator dampens out pressure pulses from the pump and ensures the fuel rail pressure is constant.

Removal (Discovery Series II)

Note. It is necessary to remove upper intake manifold and gasket to gain access to fuel rail and injectors.

1. Disconnect negative battery terminal. Remove hood. Loosen air intake hose retaining clips and remove cable tie and remove air intake hose. Disconnect throttle and cruise control cables. Release cables from abutment bracket and position aside. Disconnect throttle position sensor connector. Remove breather hose from throttle body. Disconnect EVAP vacuum hose from intake plenum.
2. Position a drain tray beneath the engine to collect coolant. Drain sufficient coolant to allow for removal of throttle body. See «DRAINING COOLING SYSTEM (DISCOVERY SERIES II)»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__draining-cooling-system-discovery-series-ii) . Disconnect coolant hoses from throttle body. Disconnect vacuum power brake vacuum booster hose from intake plenum. Disconnect breather hose from intake plenum.
3. Remove coolant rail mounting bolt. Release engine harness from bulkhead clips and position aside. Remove 4 bolts securing ignition coils and position ignition coils aside. Release spark plug leads from upper manifold clips. Disconnect connector from IACV and disconnect IACV hose. Remove 6 upper intake manifold bolts and remove upper intake manifold and intake manifold gasket. Carefully reposition ignition coil assembly from between intake manifold and bulkhead.
4. Position absorbent cloth beneath fuel feed hose to catch spillage. Disconnect fuel feed hose from fuel rail. Plug open connections to prevent contamination. Release injector harness from fuel rail and disconnect injector connectors. Remove 4 fuel rail bolts from intake manifold. Release injectors from intake manifold and remove fuel rail and injectors. Release spring clips securing injectors to fuel rail and remove fuel injectors. Remove and discard 2 "O" rings from each injector. Install a protective cap to each end of injectors.

Installation (Discovery Series II)

1. Clean upper and lower intake manifold mating faces, dowels and dowel holes. Using a new gasket, position upper intake manifold. Fit bolts and, working in a diagonal sequence, tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) . Connect hose and TP sensor connector.
2. Connect IACV connector. Connect IACV hose to intake plenum. Secure spark plug wires to upper intake manifold clips. Install ignition coils and bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) . Ensure clip under ignition coils is located on fuel pipe.
3. Secure engine wiring harness in bulkhead clips. Install coolant rail mounting bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) . Connect breather hose and power brake vacuum booster hose to intake plenum. Connect EVAP vacuum hose to intake plenum.
4. Connect coolant hoses and breather hose to throttle body. Connect throttle position sensor connector. Connect throttle and cruise control cables to throttle body cams. Ensure throttle and cruise control cables are properly adjusted. Connect air intake hose. Connect wiring harness to air intake hose using a NEW cable tie. Refill cooling system «REFILLING & BLEEDING COOLING SYSTEM (DISCOVERY SERIES II)»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__refilling-bleeding-cooling-system-discovery) . Install hood and adjust so that it is flush with the fenders and gaps are equal on both sides. Connect negative battery terminal.

Note. It is necessary to remove upper intake manifold and gasket to gain access to fuel rail and injectors.

1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches). Remove engine lower cover and (upper) engine acoustic cover. See «ENGINE COVERS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches).
2. Remove upper intake manifold and necessary components to facilitate procedure. Disconnect fuel supply line from fuel rail. Disconnect fuel injector electrical connectors. Remove fuel rail bolts. Remove fuel rail and injectors as an assembly. (Scheme 4) Remove fuel injector clips. Remove fuel injectors from fuel rail. Discard 2 "O" rings from each fuel injector. Plug open connections to prevent contamination.
3. To install, reverse removal procedure. Use NEW intake manifold seals and "O" rings during reassembly. Use NEW fuel injector "O" rings and lubricate with engine oil during reassembly. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications).

Removal (Range Rover)

Note. It is necessary to remove upper intake manifold and gasket to gain access to fuel rail and injectors.

1. Remove battery cover and disconnect negative battery cable. Remove gas struts from hood and, with assistance, support hood on hinge extension arms. Loosen 2 clips securing air intake hose, disconnect harness from clip on hose. Release clip securing IAC hose to air intake hose and remove air intake hose.
2. Remove 2 bolts securing support bracket for throttle and cruise control cables to plenum chamber. Disconnect throttle and cruise control cables from throttle cams, and position out of the way. Disconnect EVAP pipe from plenum chamber and clip on upper manifold. Disconnect TP sensor connector. Disconnect breather hose from throttle body.
3. Drain sufficient coolant to allow for removal of throttle body. See «DRAINING COOLING SYSTEM (RANGE ROVER)»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__draining-cooling-system-range-rover) . Disconnect IAC hose from plenum chamber. Position a clean container under throttle body coolant hoses and disconnect coolant hoses from throttle body. Disconnect engine breather hose from plenum chamber. Remove bolt securing coolant line support.
4. Remove 2 cable ties securing engine harness to clip on upper manifold. Disconnect IAC valve connector. Release spark plug wires from clips on valve covers and from spark plugs. Disconnect coil connectors. Remove 2 bolts securing top of coils. Loosen 2 bolts securing bottom of coils to block but do not remove bolts and remove coils. Remove 6 bolts securing upper manifold, upper manifold and upper manifold gasket.
5. Position absorbent cloth under fuel pipe to catch spillage. Disconnect fuel feed hose from fuel rail and plug connections. Release injector harness clips from fuel rail and disconnect injector connectors. Remove 4 bolts securing fuel rail to intake manifold. Release injectors from intake manifold and remove fuel rail and injectors. Release spring clips securing injectors to fuel rail and remove fuel injectors. Remove and discard 2 "O" rings from each injector and install protective caps to end of each injector.

Installation (Range Rover)

1. Clean injectors and recesses in fuel rail and intake manifold. Lubricate NEW "O" rings with silicone grease and install to each end of injectors. Install injectors to fuel rail and secure using spring clips. Position fuel rail assembly and push-fit each injector into intake manifold. Install fuel rail bolts into intake manifold and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) .
2. Connect fuel feed hose to fuel rail. Connect injector harness connectors and secure to fuel rail. Carefully position coil assembly, install 2 lower bolts, but do not tighten. Connect coil connectors. Install spark plugs wires and clips on valve covers. Clean intake manifold and upper manifold mating faces, dowels and dowel holes. Install NEW upper intake manifold gasket and position intake manifold. Install bolts, and tighten to specification in a diagonal sequence. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) .
3. Install 2 top bolts securing coils to manifold and tighten all coil fixing bolts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) . Connect IAC valve connector. Secure spark plug wires to upper manifold clips. Connect TP sensor connector. Using NEW cable ties, secure engine harness to manifold clip. Install coolant rail bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/discovery/l318-1998-2002/remont/engine-control-systems/#engine-ignition-system-fuel-system-sensors-switches__torque-specifications) .
4. Connect breather hose and IAC hose to plenum chamber and secure with clips. Install coolant hoses to throttle body and secure hose clips. Install breather hose to throttle body and secure clip. Connect EVAP pipe to plenum chamber and clip to upper manifold. Connect throttle and cruise control cables to clips and secure in throttle body cams. Install throttle and cruise control cables' support bracket to upper manifold. Install air intake hose and connect harness to clip on hose. Connect IAC hose to air intake hose. Ensure coolant level is correct. Lower hood and connect gas struts. Connect negative battery terminal and install battery cover.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• DISCONNECTING BATTERY
• REFILLING & BLEEDING COOLING SYSTEM (DISCOVERY SERIES II)
• TORQUE SPECIFICATIONS
• ENGINE COVERS
• REFILLING & BLEEDING COOLING SYSTEM (FREELANDER)
• REFILLING COOLING SYSTEM (RANGE ROVER)
• DRAINING, REFILLING & BLEEDING COOLING SYSTEM
• FUEL PUMP
• THIRD ROW SEAT REMOVAL & INSTALLATION (DISCOVERY SERIES II)
• DRAINING COOLING SYSTEM (DISCOVERY SERIES II)
• DRAINING COOLING SYSTEM (RANGE ROVER)