Removal & Installation Land Rover Discovery L318

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION

CABLE - THROTTLE

1. Loosen outer cable locknuts.
2. Adjust the rear locknut until it is in contact with the back of the abutment bracket, and the gap between the throttle and the inner driven lever is 0.5 mm +/- 0.4 mm (0.020" +/- 0.015"). (Scheme 83)
3. Tighten cable front nut to lock cable to abutment bracket.

Scheme 83

CABLE - CRUISE CONTROL

1. Ensure that the throttle cable is correctly adjusted. See «CABLE - THROTTLE»(/land-rover/discovery/l318-2002-2004/remont/cruise-control-systems/#removal-installation__cable-throttle).
2. Loosen outer cable locknuts.
3. Adjust the rear locknut to obtain a 1.0 mm +/- 0.5 mm (0.04" +/- 0.02") gap, dimension "A", between the cruise control cable lever and the throttle cable driven lever. (Scheme 84)
4. Tighten cable front locknut.

Scheme 84

1. Noting their fitted position, disconnect High Tension (HT) leads from spark plugs.
2. Using a spark plug socket, remove 8 spark plugs.

Scheme 85

1. Fit terminals to new spark plugs.
2. Fit spark plugs and tighten to 25 N.m (18 ft. lbs.).
3. Connect HT leads to spark plugs ensuring they are in the correct position.

1. Remove upper inlet manifold assembly. See «GASKET -- INLET MANIFOLD»(ref-158799-S11640340422005013100000).
2. Disconnect multiplugs from ignition coils. (Scheme 86)
3. Release High Tension (HT) leads from rocker covers and disconnect HT leads from spark plugs. (Scheme 87)
4. Carefully maneuver ignition coil assembly from between engine and bulkhead.
5. Noting their fitted position disconnect HT leads from ignition coil. (Scheme 88)
6. Remove 3 screws securing ignition coil to support bracket and remove coils. (Scheme 88)

Scheme 86

Scheme 87

Scheme 88

1. Position ignition coil to support bracket, fit and tighten screws.
2. Connect HT leads to ignition coil ensuring they are in the correct position.
3. Carefully position ignition coil assembly between engine and bulkhead.
4. Connect HT leads to spark plugs and secure HT leads to rocker covers.
5. Connect multiplugs to ignition coils.
6. Fit upper inlet manifold assembly. See «GASKET -- INLET MANIFOLD»(ref-158799-S11640340422005013100000) .

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove fixings securing fascia RH closing panel, release diagnostic socket RH drive models, and remove panel. (Scheme 89)
4. Remove 2 fixings and remove "A" post lower trim. (Scheme 90)
5. Remove 2 nuts and release ECM from studs and location on "A" post lower panel.
6. Lower ECM into footwell and disconnect 5 multiplugs. (Scheme 91)
7. Remove ECM.

Scheme 89

Scheme 90

Scheme 91

1. Position new ECM and connect multiplugs.
2. Fit ECM and secure with nuts.
3. Fit lower trim panel to "A" post and secure with fixings.
4. Fit diagnostic socket to closing panel, fit closing panel and secure with fixings.
5. Connect battery earth lead.
6. Fit battery cover and secure with fixings.
7. Program ECM and reset adaptions using Textbook/T4.

1. Release turnbuckles and remove battery cover.
2. Disconnect battery earth lead.
3. Remove auxiliary drive belt. See «GENERATORS & REGULATORS»(/land-rover/discovery/l318-2002-2004/remont/charging-system/#generators-regulators).
4. Remove 2 bolts securing alternator, release alternator from support bracket and position aside. (Scheme 92)
5. Disconnect multiplug from ECT sensor. (Scheme 93)
6. Remove sensor from inlet manifold and discard sealing washer.

Scheme 92

Scheme 93

1. Clean sealant from threads in manifold.
2. Apply sealant, Part No. STC 50552 to sensor threads.
3. Fit new sealing washer to ECT sensor and tighten sensor to 10 Nm (7 ft. lbs.).
4. Connect multiplug to ECT sensor.
5. Position alternator, fit bolts and tighten to 45 Nm (33 ft. lbs.).
6. Fit auxiliary drive belt. See «GENERATORS & REGULATORS»(/land-rover/discovery/l318-2002-2004/remont/charging-system/#generators-regulators) .
7. Top up cooling system.
8. Connect battery earth lead.
9. Fit battery cover and secure with fixings.

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise front of vehicle.
4. Release fixings and remove underbelly panel.
5. Release CKP sensor multiplug from bracket. (Scheme 94)
6. Remove 2 bolts securing CKP sensor heat shield and position aside.
7. Remove 2 nuts securing CKP sensor, remove 2 spacers, CKP sensor and sensor mounting.
8. Disconnect CKP sensor multiplug from engine harness.

Scheme 94

1. Ensure all components are clean.
2. Connect CKP sensor multiplug to engine harness.
3. Fit sensor mounting, CKP sensor, 2 spacers and tighten CKP sensor retaining nuts to 6 Nm (4.4 ft. lbs.).
4. Fit CKP sensor heat shield and secure with bolts.
5. Fit underbelly panel and secure with fixings.
6. Remove stand(s) and lower vehicle.
7. Connect battery earth lead.
8. Fit battery cover and secure the fixings.
9. Reset adaptions using Textbook/T4.

1. Disconnect battery earth lead.
2. Position container to collect coolant spillage.
3. Disconnect multiplug from sensor.
4. Remove sensor and discard sealing washer. (Scheme 95)

Scheme 95

1. Fit new sealing washer to sensor.
2. Fit and tighten sensor.
3. Connect multiplug to sensor.
4. Refill cooling system.
5. Connect battery earth lead.

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise front of vehicle.
4. Release fixings and remove underbelly panel.
5. Remove engine oil filter. See «ENGINE MECHANICAL»(ref-158799).
6. Disconnect engine harness from CMP sensor and release CMP sensor multiplug from bracket.
7. Remove bolt from clamp securing CMP sensor to timing gear cover. (Scheme 96)
8. Remove clamp and CMP sensor. Discard "O" ring from CMP sensor.

Scheme 96

1. Ensure CMP sensor is clean, fit NEW "O" ring and sensor to cover.
2. Fit clamp to CMP sensor and tighten bolt to 8 Nm (6 ft. lbs.).
3. Fit sensor multiplug to bracket and connect engine harness to multiplug.
4. Fit engine oil filter. See «ENGINE MECHANICAL»(ref-158799) .
5. Fit underbelly panel and secure with fixings.
6. Lower vehicle and connect battery earth lead.
7. Fit battery cover and secure with fixings.

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise front of vehicle.
4. Remove fixings securing underbelly panel and remove panel.
5. Disconnect multiplug from KS. (Scheme 97)
6. Remove nut securing KS to cylinder block and remove KS.

Scheme 97

1. Clean mating faces of KS and cylinder block.
2. Fit KS to cylinder block and tighten nut to 22 Nm (16 ft. lbs.).
3. Connect multiplug to KS.
4. Fit underbelly panel and secure with fixings.
5. Remove stand(s) and lower vehicle.
6. Connect battery earth lead.
7. Fit battery cover and secure the fixings.

1. Remove 2 nuts securing air intake ducting. (Scheme 98)
2. Remove both parts of air intake ducting.
3. Release 2 clips securing MAF sensor, release 2 clips securing air intake hose. (Scheme 99)
4. Release air intake hose and position aside.
5. Remove and discard MAF sensor "O" ring. (Scheme 100)
6. Release air cleaner assembly from 3 grommets and remove assembly. (Scheme 100)

Scheme 98

Scheme 99

Scheme 100

1. Position air cleaner assembly and secure in grommets.
2. Fit new "O" ring to MAF sensor.
3. Position air intake hose, secure MAF sensor clips and tighten intake hose clips.
4. Fit air intake ducting and secure with nuts.

1. Release 2 clips and disconnect MAF sensor from air filter cover, remove and discard "O" ring.
2. Release 2 clips and remove cover from air filter. (Scheme 101)
3. Remove air filter element.

Scheme 101

1. Clean air filter body and cover.
2. Fit new air filter element.
3. Position air cleaner cover and secure clips.
4. Fit a new MAF sensor "O" ring, position MAF sensor and secure clips.

1. Release 3 fasteners and remove drivers side closing panel and move aside. (Scheme 89)
2. Release inner cable from throttle pedal. (Scheme 102)
3. Release outer cable from bulkhead. (Scheme 102)
4. Release outer cable from clip, loosen lock nuts and remove outer cable from abutment bracket. (Scheme 103)
5. Release inner cable from operating lever and remove cable. (Scheme 103)

Scheme 102

Scheme 103

1. Position cable, secure to bulkhead and connect inner cable to throttle pedal.
2. Position inner cable to operating lever and connect outer cable to abutment bracket and retaining clip.
3. Position closing panel and secure fasteners.
4. Adjust throttle cable. See «CABLE - THROTTLE»(/land-rover/discovery/l318-2002-2004/remont/cruise-control-systems/#removal-installation__cable-throttle) .

1. Disconnect multiplug from MAF sensor. (Scheme 104)
2. Loosen clip and release air intake hose from MAF sensor.
3. Release 2 clips and remove MAF sensor from air cleaner, remove and discard "O" ring.

Scheme 104

1. Fit new MAF sensor "O" ring, position MAF sensor to air cleaner and secure with clips.
2. Position air intake hose to MAF sensor and secure with clip.
3. Connect multiplug to MAF sensor.

1. Loosen 3 clips securing air intake hose, release air intake hose and position aside. (Scheme 105)
2. Disconnect throttle and cruise control cables from throttle body. (Scheme 106)
3. Loosen clip securing breather hose and release hose. (Scheme 107)
4. Disconnect multiplug from throttle body.
5. Position a container below the throttle body to collect coolant spillage.
6. Loosen 2 clips securing coolant hoses to throttle body and release hoses. (Scheme 108)
7. Remove 4 bolts securing throttle body to plenum chamber.
8. Remove throttle body and discard gasket.

Scheme 105

Scheme 106

Scheme 107

Scheme 108

1. Clean plenum chamber and throttle body mating faces.
2. Using a new gasket, position throttle body, fit bolts and tighten to 10 Nm (7 ft. lbs.).
3. Connect coolant hoses to throttle body and secure clips.
4. Connect breather hose to throttle body and secure clip.
5. Connect multiplug to throttle body.
6. Connect throttle and cruise control cables. See «CABLE - CRUISE CONTROL»(/land-rover/discovery/l318-2002-2004/remont/cruise-control-systems/#removal-installation__cable-cruise-control) . See «CABLE - THROTTLE»(/land-rover/discovery/l318-2002-2004/remont/cruise-control-systems/#removal-installation__cable-throttle) .
7. Position air intake hose and secure clips.
8. Top-up cooling system.

1. Remove upper manifold gasket. See «GASKET -- INLET MANIFOLD»(ref-158799-S11640340422005013100000).
2. Remove 2 bolts securing throttle cable abutment bracket and remove bracket. (Scheme 109)
3. Remove breather hose adaptor.
4. Remove 4 bolts securing plenum chamber to upper manifold and remove plenum chamber. (Scheme 109)
5. Collect plenum chamber gaskets. (Scheme 109)

Scheme 109

1. Clean plenum chamber and upper manifold mating faces.
2. Using new gaskets, position plenum chamber fit bolts and tighten to 22 Nm (16 ft. lbs.).
3. Fit breather adaptor and tighten to 6 Nm (4.4 ft. lbs.).
4. Position throttle cable abutment bracket, fit bolts and tighten to 9 Nm (7 ft. lbs.).
5. Fit upper manifold gasket. See «GASKET -- INLET MANIFOLD»(ref-158799-S11640340422005013100000) .

1. Disconnect multiplug from TP sensor. (Scheme 110)
2. Remove 2 screws securing TP sensor to throttle body.
3. Remove TP sensor and discard "O" ring.

Scheme 110

1. Clean TP sensor and throttle body mating faces.
2. Using a new "O" ring, position TP sensor. Fit screws and tighten to 2.2 Nm (1.6 ft. lbs.).
3. Connect multiplug to TP sensor.

1. Disconnect multiplug from IACV.
2. Loosen 2 clips securing air hoses and release hoses. (Scheme 111)
3. Remove 2 screws securing IACV to inlet manifold.
4. Collect clamps and remove IACV.

Scheme 111

1. Position IACV to inlet manifold, locate clamps, fit screws and tighten to 8 Nm (6 ft. lbs.).
2. Position air hoses to IACV and secure clips.
3. Connect multiplug to IACV.

1. Remove upper manifold. See «GASKET -- INLET MANIFOLD»(ref-158799-S11640340422005013100000).
2. Carefully maneuver ignition coil assembly from between inlet manifold and bulkhead. (Scheme 112)
3. Position absorbent cloth beneath fuel pipe to catch spillage.
4. Disconnect fuel feed hose from fuel rail.
5. Release injector harness from fuel rail and disconnect injector multiplugs.
6. Remove 4 bolts securing fuel rail to inlet manifold. (Scheme 113)
7. Release injectors from inlet manifold and remove fuel rail and injectors.
8. Release spring clips securing injectors to fuel rail and remove fuel injectors.
9. Remove and discard 2 "O" rings from each injector.
10. Fit protective caps to each end of injectors.

Scheme 112

Scheme 113

1. Clean injectors and recesses in fuel rail and inlet manifold.
2. Lubricate new "O" rings with silicone grease and fit to each end of injectors.
3. Fit injectors to fuel rail and secure with spring clips.
4. Position fuel rail assembly and push-fit each injector into inlet manifold.
5. Fit bolts securing fuel rail to inlet manifold and tighten to 9 Nm (7 ft. lbs.).
6. Connect fuel feed hose to fuel rail.
7. Connect injector harness multiplugs and secure to fuel rail.
8. Carefully position ignition coil assembly between inlet manifold and bulkhead.
9. Fit upper manifold. See «GASKET -- INLET MANIFOLD»(ref-158799-S11640340422005013100000) .

1. Release clip and disconnect inner cable from actuator. (Scheme 114)
2. Release outer cable from actuator mounting bracket.
3. Release vacuum hose from actuator.
4. Remove nut, and remove actuator from mounting bracket.

Scheme 114

1. Position actuator and tighten retaining nut.
2. Connect vacuum hose to actuator.
3. Connect outer cable to mounting bracket.
4. Connect inner cable to actuator.

1. Disconnect vacuum hose from actuator. (Scheme 115)
2. Disconnect multiplug from vacuum control unit. (Scheme 116)
3. Release 3 rubber mountings securing control unit, and remove from mounting bracket.
4. Remove vacuum hose from control unit.

Scheme 115

Scheme 116

1. Position vacuum hose to control unit.
2. Position control unit and secure mountings.
3. Connect multiplug and vacuum hose.

1. If fitted: Remove 2 nuts securing heat shield and remove heat shield. (Scheme 117)
2. Disconnect vacuum hose from actuator. (Scheme 118)
3. Disconnect multiplug from control unit. (Scheme 119)
4. Release 3 rubber mounting securing control unit to mounting bracket and remove control unit.

Scheme 117

Scheme 118

Scheme 119

1. Position control unit and secure mountings.
2. Connect multiplug and vacuum hose.
3. If fitted: Fit heat shield, fit nuts and tighten to 10 Nm (7 ft. lbs.).

1. Release clip and disconnect inner cable from actuator.
2. Release outer cable from actuator mounting bracket. (Scheme 120)
3. Loosen cable locknuts, release outer cable from abutment bracket and retaining clip. (Scheme 121)
4. Release inner cable from operating lever and remove cable.

Scheme 120

Scheme 121

1. Position cable and connect to operating lever.
2. Position cable to abutment bracket.
3. Position outer cable to actuator mounting bracket and connect inner cable to actuator.
4. Adjust cruise control cable. See «CABLE - CRUISE CONTROL»(/land-rover/discovery/l318-2002-2004/remont/cruise-control-systems/#removal-installation__cable-cruise-control) .

1. Carefully remove switch from instrument cowl.
2. Disconnect multiplug and remove switch.

1. Position new switch and connect multiplug.
2. Carefully push switch into instrument cowl.

1. Remove the key from the starter switch. Disconnect both battery leads, negative lead first. Wait ten minutes before starting work.
2. Remove driver's AIRBAG module. See «AIR BAG RESTRAINT SYSTEMS»(/land-rover/discovery/l318-2002-2004/remont/airbag/#air-bag-restraint-systems).
3. Release remote control switches multiplug and leads from steering wheel base. (Scheme 122)
4. Disconnect remote control switches multiplug from harness.
5. Remove 2 screws securing remote control switches to steering wheel base.
6. Release and remove remote control switches from steering wheel.

Scheme 122

1. Fit remote control switches to steering wheel and secure with screws.
2. Connect remote control switches multiplug to harness.
3. Secure leads and multiplug to base of steering wheel.
4. Fit driver's AIRBAG module. See «AIR BAG RESTRAINT SYSTEMS»(/land-rover/discovery/l318-2002-2004/remont/airbag/#air-bag-restraint-systems) .

1. Remove 3 fasteners and move driver's side lower closing panel aside. (Scheme 123)
2. Disconnect multiplug from clutch pedal switch. (Scheme 124)
3. Remove switch from pedal bracket.

Scheme 123

Scheme 124

1. Engage switch fully into pedal bracket location and connect multiplug.
2. Position lower closing panel and secure with fasteners.

1. Remove fixings securing fascia RH closing panel and remove panel.
2. Remove 2 fixings and remove "A" post lower trim. (Scheme 125)
3. Remove 2 nuts and remove ECU from studs. (Scheme 126)
4. Disconnect multiplug from ECU and remove ECU.

Scheme 125

Scheme 126

1. Position new ECU and connect multiplug.
2. Fit ECU to studs and secure with nuts.
3. Fit lower trim panel to "A" post and secure with fixings.
4. Fit closing panel and secure with fixings.
5. Program the ECU using Textbook/T4.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• GENERATORS & REGULATORS
• AIR BAG RESTRAINT SYSTEMS
• CABLE - THROTTLE
• CABLE - CRUISE CONTROL