Engine Management - Removal & Installation Land Rover Range Rover L322

SPARK PLUGS

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove ignition coils. See «IGNITION COILS - MULTIPLE - SET»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__ignition-coils-multiple-set) .
3. Clean area around spark plugs.
4. Remove 8 spark plugs.

1. Fit 8 spark plugs and tighten to 31 Nm (23 ft. lbs).
2. Fit 8 ignition coils. See «IGNITION COILS - MULTIPLE - SET»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__ignition-coils-multiple-set) .
3. Connect battery earth lead.

RELAY - IGNITION COILS

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove 10 Allen screws securing E-box cover and remove cover. (Scheme 1)
3. Release relay from E-box and disconnect multiplug. (Scheme 2)

Scheme 1

Scheme 2

1. Position relay, connect multiplug and fit relay to E-box.
2. Fit E-box cover and tighten Allen screws to 2 Nm (1.5 ft. lbs).
3. Connect battery earth lead.

IGNITION COILS - MULTIPLE - SET

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Remove engine acoustic cover. See «ACOUSTIC COVER -- ENGINE»(ref-158804-S20286524212005013100000).
2. Remove LH ignition coil cover. See «COVER - IGNITION COILS - LH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-lh).
3. Remove RH ignition coil cover. See «COVER - IGNITION COILS - RH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-rh).
4. Remove 2 nuts and disconnect earth leads from camshaft covers. (Scheme 3)
5. Disconnect multiplugs from ignition coils. (Scheme 4)
6. Discard ignition coil cover gasket.
7. Remove 14 ignition coil securing nuts. Remove 8 ignition coils. (Scheme 5)

Scheme 3

Scheme 4

Scheme 5

1. Fit 8 ignition coils.
2. Fit 14 nuts securing ignition coil and tighten to 4 Nm (3 ft. lbs).
3. Fit new ignition coil cover gasket.
4. Connect multiplugs to ignition coils.
5. Connect earth lead to camshaft cover and tighten nut to 4 Nm (3 ft. lbs).
6. Fit RH ignition coil cover. See «COVER - IGNITION COILS - RH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-rh) .
7. Fit LH ignition coil cover. See «COVER - IGNITION COILS - LH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-lh) .
8. Fit engine acoustic cover. See «ACOUSTIC COVER -- ENGINE»(ref-158804-S20286524212005013100000) .

COVER - IGNITION COILS - LH

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See «ACOUSTIC COVER -- ENGINE»(ref-158804-S20286524212005013100000).
3. Remove 2 access covers from ignition coil cover. (Scheme 6)
4. Remove 2 bolts securing ignition coil cover to camshaft cover.
5. Remove LH ignition coil cover.
6. Remove 2 bolt spacers from ignition coil cover. NOTE: DO NOT carry out further dismantling if component is removed for access only.
7. Remove nut and disconnect earth lead from camshaft cover. (Scheme 3)
8. Disconnect multiplugs from ignition coils. (Scheme 4)
9. Discard ignition coil cover gasket.

Scheme 6

1. Fit new ignition coil cover gasket.
2. Connect multiplugs to ignition coils.
3. Connect earth lead to camshaft cover and tighten nut to 4 Nm (3 ft. lbs).
4. Fit 2 bolt spacers to ignition coil cover.
5. Fit ignition coil cover, fit and tighten 2 bolts.
6. Fit 2 access covers to ignition coil cover.
7. Fit engine acoustic cover. See «ACOUSTIC COVER -- ENGINE»(ref-158804-S20286524212005013100000) .
8. Connect battery earth lead.

COVER - IGNITION COILS - RH

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See «ACOUSTIC COVER -- ENGINE»(ref-158804-S20286524212005013100000).
3. Remove 2 access covers from ignition coil cover. (Scheme 6)
4. Remove 2 bolts securing ignition coil cover to camshaft cover.
5. Remove RH ignition coil cover.
6. Remove 2 bolt spacers from ignition coil cover. NOTE: DO NOT carry out further dismantling if component is removed for access only.
7. Remove nut and disconnect earth lead from camshaft cover.
8. Disconnect multiplugs from ignition coils. (Scheme 4)
9. Discard ignition coil cover gasket.

1. Fit new ignition coil cover gasket.
2. Connect multiplugs to ignition coils.
3. Connect earth lead to camshaft cover and tighten nut to 4 Nm (3 ft. lbs).
4. Fit 2 bolt spacers to ignition coil cover.
5. Fit ignition coil cover, fit and tighten 2 bolts.
6. Fit 2 access covers to ignition coil cover.
7. Fit engine acoustic cover. See «ACOUSTIC COVER -- ENGINE»(ref-158804-S20286524212005013100000) .

ENGINE CONTROL MODULE (ECM)

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove 10 Allen screws securing E-box cover and remove cover. (Scheme 1)
3. Disconnect 5 multiplugs from ECM. (Scheme 7)
4. Release 2 clips and remove ECM.

Scheme 7

1. Fit new ECM and connect multiplugs.
2. Fit E-box cover and tighten Allen screws to 2 Nm (1.5 ft. lbs).
3. Connect battery earth lead.
4. Reprogram a new ECM using TestBook/T4. NOTE: The ECM can only be reprogrammed a maximum of 14 times.

RELAY - COMBINED IGNITION & FUEL ECU

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove 10 Allen screws securing E-box cover and remove cover. (Scheme 1)
3. Disconnect and remove, ECM relay from E-box multiplug. (Scheme 8)

Scheme 8

1. Position relay to E-box mounting and connect multiplug.
2. Fit E-box cover and tighten Allen screws to 2 Nm (1.5 ft. lbs).
3. Connect the battery earth lead.

SENSOR - ENGINE COOLANT TEMPERATURE (ECT)

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Disconnect multiplug from ECT sensor. (Scheme 9)
3. Position container beneath ECT sensor to collect coolant.
4. Using a deep socket, carefully remove ECT sensor and discard seal. (Scheme 10)

Scheme 9

Scheme 10

1. Ensure mating faces of ECT sensor and coolant pump are clean.
2. Fit new seal and tighten ECT sensor to 15 Nm (11 ft. lbs).
3. Connect multiplug to ECT sensor.
4. Remove container.
5. Dispose of coolant and clean container.
6. Connect battery earth lead.
7. Check and top up cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/accessory-drive-belts/#specifications-drive-belt-routing__draining-refilling-cooling-system) .
8. If a replacement sensor has been fitted re-set adaptions using TestBook/T4.

SENSOR - CRANKSHAFT POSITION (CKP)

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Raise vehicle and disconnect multiplug from CKP sensor. (Scheme 11)
4. Clean area surrounding CKP sensor.
5. Remove Allen screw and remove CKP sensor.

Scheme 11

1. Clean casing mating face.
2. If one or more spacers are fitted between transmission and CKP sensor, the distance between the sensor and teeth on the incremental gear must be measured.
3. Rotate crankshaft until a full TRIGGER tooth is visible through aperture in casing. Ensure the tooth is centered to the hole.
4. Using a depth micrometer, measure depth from sensor mating face to TRIGGER tooth. Record measurement. (Scheme 12)
5. Measure length of CKP sensor between tip and mounting face, dimension "A". Record dimension. (Scheme 13)
6. Subtract length of CKP sensor, from sensor mating face to TRIGGER tooth dimension and record the resulting gap. The Air gap should be adjusted to 0.55 mm +/- 0.2 mm (0.022 in +/- 0.0080 in), using available shims.
7. Fit shim to CKP sensor if required. Align CKP sensor to casing, fit bolt and tighten to 10 Nm (7 ft. lbs).
8. Connect CKP sensor multiplug.
9. Connect battery earth lead.
10. If a replacement sensor has been fitted re-set adaptions using TestBook/T4.

Scheme 12

Scheme 13

SENSOR - CAMSHAFT POSITION (CMP) - LH

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See «ACOUSTIC COVER -- ENGINE»(ref-158804-S20286524212005013100000).
3. Disconnect multiplug from CMP sensor. (Scheme 14)
4. Release CMP sensor harness from clip on camshaft cover.
5. Remove bolt securing CMP sensor and remove sensor. Discard "O" ring. (Scheme 15)

Scheme 14

Scheme 15

1. Clean CMP sensor and mating face.
2. Fit new "O" ring to CMP sensor.
3. Fit CMP sensor, fit bolt and tighten to 10 Nm (7 ft. lbs).
4. Connect multiplug to CMP sensor.
5. Secure CMP sensor harness to clip on camshaft cover.
6. Fit engine acoustic cover. See «ACOUSTIC COVER -- ENGINE»(ref-158804-S20286524212005013100000) .
7. Connect battery earth lead.
8. If a replacement sensor has been fitted, re-set adaptions using TestBook/T4.

SENSOR - CAMSHAFT POSITION (CMP) - RH

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation).
3. Cut 3 cable ties to release CMP sensor harness. (Scheme 16)
4. Disconnect multiplug from CMP sensor. (Scheme 17)
5. Remove bolt securing CMP sensor and remove sensor. Discard "O" ring. (Scheme 18)

Scheme 16

Scheme 17

Scheme 18

1. Clean CMP sensor and mating face.
2. Fit new "O" ring.
3. Fit CMP sensor, fit bolt and tighten to 10 Nm (7 ft. lbs).
4. Secure CMP sensor harness with 3 cable ties.
5. Connect multiplug to CMP sensor.
6. Connect air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation) .
7. Connect battery earth lead.
8. If a replacement sensor has been fitted, re-set adaptions using TestBook/T4.

SENSOR - KNOCK (KS) - LH

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove coolant pump to coolant manifold pipes. See «PIPES -- WATER PUMP TO COOLANT MANIFOLD»(ref-158804-S19252440252005013100000).
3. Remove 2 bolts securing KS to cylinder block, remove sensors. (Scheme 19)

Scheme 19

1. Clean KS and mating faces on cylinder block.
2. Position KS to engine block, fit bolts securing KS and tighten to 20 Nm (15 ft. lbs).
3. Fit coolant pump to coolant manifold pipes. See «PIPES -- WATER PUMP TO COOLANT MANIFOLD»(ref-158804-S19252440252005013100000) .
4. Connect battery earth lead.
5. If a replacement sensor has been fitted, re-set adaptions using TestBook/T4.

SENSOR - KNOCK (KS) - RH

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove inlet manifold. See «GASKET -- INDUCTION MANIFOLD»(ref-158804-S08283388712005013100000).
3. Remove 2 bolts securing KS to cylinder block, remove sensors. (Scheme 20)

Scheme 20

1. Clean KS and mating faces on cylinder block.
2. Position KS to engine block, fit bolts securing KS and tighten to 20 Nm (15 ft. lbs).
3. Fit inlet manifold. See «GASKET -- INDUCTION MANIFOLD»(ref-158804-S08283388712005013100000) .
4. Connect battery earth lead.
5. If a replacement sensor has been fitted, re-set adaptions using TestBook/T4.

SENSOR - TEMPERATURE - E-BOX

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove 10 Allen screws securing E-box cover and remove cover. (Scheme 1)
3. Disconnect multiplug from E-box temperature sensor.
4. Remove E-box temperature sensor. (Scheme 21)

Scheme 21

1. Fit E-box temperature sensor to mounting.
2. Connect multiplug to E-box temperature sensor.
3. Fit E-box cover and tighten Allen screws to 2 Nm (1.5 ft. lbs).
4. Connect battery earth lead.
5. If a replacement sensor has been fitted, re-set adaptions using TestBook/T4.

1. Remove air cleaner element. See «ELEMENT - AIR CLEANER»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation).
2. Remove bolt securing air cleaner lower housing. (Scheme 22)
3. Release clip securing air intake pipe to lower air cleaner housing. (Scheme 23)
4. Remove lower air cleaner housing. NOTE: DO NOT carry out further dismantling if component is removed for access only.
5. Remove mountings from lower air cleaner housing.

Scheme 22

Scheme 23

1. Fit mountings to lower air cleaner housing.
2. Fit lower air cleaner housing, connect to air intake pipe and tighten securing bolt. (Scheme 24) NOTE: Make sure that the air intake pipe is located into the lugs of the lower air filter housing before the lower air filter housing is fully seated onto its mountings.
3. Fully seat air intake pipe securing clip to lower air cleaner housing.
4. Fit air cleaner element. See «ELEMENT - AIR CLEANER»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation).

Scheme 24

1. Release 2 clips securing MAF/IAT sensor to upper air cleaner housing. (Scheme 25) Disconnect SAI pump air intake hose from upper air cleaner housing.
2. Release 4 clips and remove upper air cleaner housing. (Scheme 26)
3. Discard "O" ring from upper air cleaner housing.
4. Remove air cleaner element. (Scheme 27)

Scheme 25

Scheme 26

Scheme 27

1. Clean air cleaner housing.
2. Fit air cleaner element.
3. Fit "O" ring seal into upper air cleaner housing.
4. Lubricate "O" ring.
5. Fit upper air cleaner housing and secure clips.
6. Connect SAI pump hose to upper air cleaner housing.

1. Remove engine acoustic cover. See «ACOUSTIC COVER -- ENGINE»(ref-158804-S20286524212005013100000).
2. Disconnect vacuum pipes from air intake pipe. (Scheme 28)
3. Release 2 clips and disconnect air intake pipe from throttle body. (Scheme 29)
4. Remove air intake pipe.
5. Remove seal from air intake pipe, at MAF sensor connection end.
6. Remove clips from air intake pipe.

Scheme 28

Scheme 29

1. Fit seal to MAF sensor.
2. Lubricate air intake pipe mating face of throttle body seal and MAF sensor seal to aid refit.
3. Fit clips to air intake pipe.
4. Fit and secure air intake pipe.
5. Connect vacuum pipes to air intake pipe.
6. Fit engine acoustic cover. See «ACOUSTIC COVER -- ENGINE»(ref-158804-S20286524212005013100000) .
7. If a replacement sensor has been fitted, reset adaptions using TestBook/T4.

SENSOR - ACCELERATOR PEDAL POSITION (APP)

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

Note. The Accelerator Pedal Position (APP) sensor is not serviced separately from the throttle pedal.

1. Disconnect battery earth lead.
2. Remove cap from screw and remove Allen screw securing throttle pedal. (Scheme 30)
3. Release pedal from bracket, disconnect multiplug from APP sensor and remove pedal.

Scheme 30

1. Position throttle pedal and connect multiplug to APP sensor.
2. Fit pedal to bracket, tighten Allen screw to 10 Nm (7 ft. lbs) and fit cap to screw.
3. Connect battery earth lead.
4. If a replacement sensor has been fitted, re-set adaptions using TestBook/T4.

SENSOR - COMBINED MASS AIR FLOW (MAFS) & INTAKE AIR TEMPERATURE (IAT)

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation).
3. Disconnect multiplug from MAF/IAT sensor. (Scheme 31)
4. Release MAF/IAT sensor securing clips and remove sensor. (Scheme 32) NOTE: The "O" ring may become released from upper air cleaner housing during the removal of the MAF/IAT sensor.

Scheme 31

Scheme 32

1. Fit "O" ring seal into upper air cleaner housing.
2. Lubricate "O" ring with clean engine oil.
3. Fit MAF/IAT sensor into upper air cleaner housing and secure with clips.
4. Connect multiplug to MAF/IAT sensor.
5. Connect air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation) .
6. Connect battery earth lead.
7. If a replacement sensor has been fitted, re-set adaptions using TestBook/T4.

1. Remove air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation).
2. Disconnect multiplug from throttle body. (Scheme 33)
3. Remove 4 bolts securing throttle body to inlet manifold and remove throttle body. (Scheme 34)
4. Discard 2 throttle body seals.

Scheme 33

Scheme 34

1. Clean mating faces of throttle housing and inlet manifold.
2. Fit 2 new throttle body seals.
3. Fit throttle housing to inlet manifold and tighten 4 bolts to 10 Nm (7 ft. lbs).
4. Connect multiplug to throttle body.
5. Connect air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation) .
6. If fitting a new throttle body, reset adaptions using TestBook/T4.

FUEL RAIL - REMOVE FOR ACCESS & REFIT

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation).
3. Remove LH ignition coil cover. See «COVER - IGNITION COILS - LH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-lh).
4. Remove RH ignition coil cover. See «COVER - IGNITION COILS - RH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-rh).
5. Disconnect multiplugs from ignition coils. (Scheme 35)
6. Disconnect multiplugs from throttle body, thermostat heater, CMP sensor and ECT sensor. (Scheme 36)
7. Cut 2 cable ties and release engine harness.
8. Disconnect multiplugs from VCC solenoids. (Scheme 37)
9. Release VCC multiplug harness from clip.
10. Disconnect multiplug from charcoal canister purge solenoid valve. (Scheme 38)
11. Disconnect alternator multiplug. (Scheme 39)
12. Release alternator harness from 4 clips.
13. Disconnect multiplugs from KS and CMP sensor. (Scheme 40)
14. Remove 2 nuts securing fuel injector harness to fuel rail. (Scheme 41)
15. Release vacuum reservoir and mounting bracket from LH fuel injector harness securing stud.
16. Remove fuel hose and mounting bracket from LH fuel injector harness securing stud.
17. Release alternator harness from 2 clips on engine cover mounting brackets. (Scheme 42)
18. Disconnect multiplugs from LH fuel injectors. (Scheme 43)
19. Release engine harness from clips and move clear of camshaft cover. (Scheme 44)
20. Remove 2 nuts securing engine harness to induction manifold. (Scheme 45)
21. If fitted: Disconnect multiplug from SAI solenoid. (Scheme 46)
22. If fitted: Remove SAI solenoid valve from RH fuel injector harness securing stud.
23. Remove washer from fuel injector harness securing stud. (Scheme 47)
24. Disconnect multiplug from RH KS.
25. Disconnect multiplugs from RH fuel injectors. (Scheme 48)
26. Reposition injector harness.
27. Remove air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(/land-rover/range-rover/l322-2002-2005/remont/heater/#heating-and-ventilation-removal-installation).
28. Depressurize fuel system. See «FUEL SYSTEM -- DEPRESSURIZE»(/land-rover/range-rover/l322-2002-2005/remont/fuel-system/#fuel-delivery-system__fuel-system-depressurize).
29. Disconnect fuel feed hose from fuel rail. (Scheme 49) CAUTION: ALWAYS fit plugs to open connections to prevent contamination.
30. Release clip and disconnect breather hose from camshaft cover.
31. Remove clip and disconnect purge solenoid valve vacuum hose. (Scheme 50)
32. If fitted: Disconnect SAI vacuum pipe.
33. Remove 4 bolts securing engine cover brackets and remove brackets from induction manifold. (Scheme 51)
34. Remove bolt securing fuel rail to induction manifold and remove fuel rail with injectors.

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. Clean injectors and recesses in inlet manifold.
2. Fit fuel rail with injectors to induction manifold and fit bolt.
3. Fit 2 new brackets to manifold and tighten 5 bolts to 10 Nm (7 ft. lbs).
4. Fit solenoid valve and connect vacuum pipe.
5. Reposition brake servo vacuum pipe.
6. Connect brake vacuum hose and secure with clip.
7. Connect breather hose to camshaft cover and secure with clip.
8. Clean fuel hose connections.
9. Connect fuel feed hose to fuel rail.
10. Fit air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(/land-rover/range-rover/l322-2002-2005/remont/heater/#heating-and-ventilation-removal-installation) .
11. Reposition injector harness.
12. Connect multiplugs to RH fuel injectors.
13. Connect KS multiplug.
14. Fit washer to fuel injector harness securing stud.
15. If fitted: Fit SAI solenoid valve to RH fuel injector securing stud.
16. Fit 2 nuts securing fuel injector harness to induction manifold and tighten.
17. If fitted: Connect multiplug to SAI solenoid.
18. Position and secure engine harness to brackets with clips.
19. Connect multiplugs to LH fuel injectors.
20. Connect alternator harness to 2 clips on engine cover mounting brackets.
21. Fit fuel hose and mounting bracket to LH fuel injector harness securing stud.
22. Fit vacuum reservoir and mounting bracket to LH fuel injector harness securing stud.
23. Fit 2 nuts securing fuel injector harness to induction manifold and tighten.
24. Connect KS multiplug.
25. Connect multiplug to CMP sensor.
26. Connect alternator harness to 4 clips.
27. Connect alternator multiplug.
28. Connect multiplug to charcoal canister purge solenoid valve.
29. Connect VCC multiplug harness to clip.
30. Connect multiplugs to VCC solenoids.
31. Fit new cable ties, align and secure harness.
32. Connect multiplug to CMP sensor.
33. Connect multiplug to throttle body.
34. Connect multiplugs to ECT sensors.
35. Connect multiplugs to ignition coils.
36. Fit LH ignition coil cover. See «COVER - IGNITION COILS - RH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-rh) .
37. Fit RH ignition coil cover. See «COVER - IGNITION COILS - LH»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__cover-ignition-coils-lh) .
38. Connect air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation) .
39. If a new fuel rail has been fitted, reset adaptions using TestBook/T4.

1. Remove fuel rail. See «FUEL RAIL - REMOVE FOR ACCESS & REFIT»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__fuel-rail-remove-for-access).
2. Remove spring clips securing injectors to fuel rail and remove injectors. Discard 2 "O" rings from each injector. (Scheme 52)

Scheme 52

1. Lubricate new "O" rings with silicone grease and fit to each end of injectors.
2. Fit injectors to fuel rail and secure with spring clips.
3. Fit fuel rail. See «FUEL RAIL - REMOVE FOR ACCESS & REFIT»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation__fuel-rail-remove-for-access) .
4. If new injector(s) has been fitted, then TestBook/T4 must be connected and the adaptions reset: System Diagnostics Engine Management Vehicle Maintenance Reset Adaptions

1. Release brake pedal position sensor from holder, disconnect multiplug and remove sensor. (Scheme 53)
2. Remove holder from pedal bracket.

Scheme 53

1. Fit holder to pedal bracket.
2. Position brake pedal position sensor, connect multiplug and secure to holder.
3. With brake pedal released, ensure brake pedal position sensor is in contact with operating tang on brake pedal.
4. If a replacement sensor has been fitted, re-set adaptions using TestBook/T4.

SOLENOID - CANISTER PURGE

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Disconnect multiplug from charcoal canister purge solenoid valve. (Scheme 54)
3. Disconnect 2 pipes from charcoal canister purge solenoid valve. (Scheme 55)
4. Remove charcoal canister purge solenoid valve from securing bracket.

Scheme 54

Scheme 55

1. Fit charcoal canister purge solenoid valve to securing bracket.
2. Connect 2 pipes to charcoal canister purge solenoid valve.
3. Connect multiplug to charcoal canister purge solenoid valve.
4. Connect battery earth lead.

CHARCOAL CANISTER

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Remove rear propeller (drive) shaft. See «REAR DRIVE SHAFT»(/land-rover/range-rover/l322-2002-2005/remont/driveshaft-universal-joints/#driveshafts-universal-joints).
4. Remove 8 bolts and 2 nuts securing RH fuel tank shield. (Scheme 56)
5. Disconnect 3 pipes from charcoal canister, remove 2 Torx bolts and remove charcoal canister. (Scheme 57)

Scheme 56

Scheme 57

1. Fit charcoal canister, tighten 2 bolts and connect 3 pipes to charcoal canister.
2. Fit bolts and nuts securing RH fuel tank shield and tighten to 25 Nm (18 ft. lbs).
3. Fit rear propeller (drive) shaft. See «REAR DRIVE SHAFT»(/land-rover/range-rover/l322-2002-2005/remont/driveshaft-universal-joints/#driveshafts-universal-joints) .
4. Connect battery earth lead.

VALVE - VACUUM ACTIVATION - SECONDARY AIR INJECTION (SAI)

Note. This procedure is also applicable to the gasket.

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Remove air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation).
4. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/accessory-drive-belts/#specifications-drive-belt-routing__draining-refilling-cooling-system).
5. Release clip, disconnect radiator bottom hose from thermostat housing and remove bolt securing "P" clip. (Scheme 58)
6. Disconnect vacuum pipe and pressure pipe from vacuum activation valve. (Scheme 59)
7. Remove 2 nuts, remove vacuum activation valve and discard gasket.

Scheme 58

Scheme 59

1. Clean SAI pipe and vacuum activation valve mating faces.
2. Fit new gasket to SAI pipe.
3. Fit vacuum activation valve to SAI pipe. Fit and tighten 2 nuts.
4. Fit vacuum pipe and pressure pipe to vacuum activation valve.
5. Connect radiator bottom hose to thermostat housing and secure with clip.
6. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/accessory-drive-belts/#specifications-drive-belt-routing__draining-refilling-cooling-system) .
7. Connect air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation) .
8. Connect battery earth lead.

RELAY - SECONDARY AIR INJECTION PUMP (SAI)

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove 10 Allen screws securing E-box cover and remove cover. (Scheme 1)
3. Release SAI relay from E-box and disconnect multiplug. (Scheme 60)

Scheme 60

1. Position SAI relay, connect multiplug and fit relay to E-box.
2. Fit E-box cover and tighten Allen screws to 2 Nm (1.5 ft. lbs).
3. Connect battery earth lead.

1. Position vehicle on lift.
2. Remove air cleaner housing. See «HOUSING - AIR CLEANER»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation).
3. Release clip and disconnect air intake hose from SAI pump, discard clip. (Scheme 61)
4. Depress clip and disconnect air outlet hose from SAI pump.
5. Remove SAI pump upper securing bolts. (Scheme 62)
6. Remove undertray. See «76.11.81 UNDERTRAY -- FRONT»(ref-208059-S32217400672005120200000).
7. Remove screw securing RH front wheel arch liner to wing. (Scheme 63)
8. Release front valance panel from front bumper and position aside for access. (Scheme 64)
9. Disconnect multiplug from SAI pump, remove bolt securing SAI pump and remove SAI pump. (Scheme 65)

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

1. Fit SAI pump and loosely fit lower securing bolt.
2. Fit SAI pump upper securing bolts and tighten to 22 Nm (16 ft. lbs).
3. Tighten SAI pump lower securing bolt to 5 Nm (4 ft. lbs).
4. Connect multiplug to SAI pump.
5. Align front valance panel to front bumper.
6. Fit and tighten screw securing RH front wheel arch liner to wing.
7. Fit undertray. See «76.11.81 UNDERTRAY -- FRONT»(ref-208059-S32217400672005120200000) .
8. Connect SAI pump air outlet hose to SAI pump.
9. Fit new clip and connect air intake hose to SAI pump.
10. Fit air cleaner housing. See «HOUSING - AIR CLEANER»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation) .

MODULE - TANK LEAKAGE DIAGNOSTIC (DMTL)

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Remove RH rear wheel arch liner. See «76.10.49 LINER -- REAR WHEEL ARCH -- SINGLE»(ref-208059-S38337152322005120200000).
3. Disconnect multiplug from DMTL. (Scheme 66)
4. Remove bolt securing DMTL to body and release from clips.
5. Position DMTL beneath fuel tank filler neck for access. Remove and discard clip securing vent pipe to DMTL. (Scheme 67) CAUTION: Before disconnecting any part of the fuel system, it is imperative that all dust, dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system.
6. Release vent pipe and remove DMTL assembly.
7. Plug all connections. NOTE: DO NOT carry out further dismantling if component is removed for access only.
8. Release air filter pipe from DMTL.
9. Remove 3 Torx screws securing DMTL to bracket and remove DMTL.

Scheme 66

Scheme 67

1. Position DMTL to bracket and secure with screws. Connect air filter pipe.
2. Fit vent pipe to DMTL assembly and secure with new clip.
3. Position DMTL to body, fit bolt and tighten to 10 Nm (7 ft. lbs).
4. Connect multiplug to DMTL.
5. Fit RH rear wheel arch liner. See «76.10.49 LINER -- REAR WHEEL ARCH -- SINGLE»(ref-208059-S38337152322005120200000) .
6. Connect the battery earth lead.

CATALYTIC CONVERTER

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Remove exhaust system. See «EXHAUST SYSTEM & MOUNTINGS»(/land-rover/range-rover/l322-2002-2005/remont/exhaust/#manifold-exhaust-system__exhaust-system-mountings).
4. Remove HO2S sensors from exhaust assembly and discard sealing washers.
5. Using LRT-99-027, cut pipe at point indicated by depression in pipe and remove front pipe section. (Scheme 68)

Scheme 68

1. Fit new sealing washers and apply anti seize compound to threads of HO2S. Fit and tighten HO2S to 50 Nm (37 ft. lbs). CAUTION: Ensure anti-seize compound does not contact sensor tip.
2. Clean front pipe and mating face.
3. Fit front pipe and align flange, fit nuts but do not tighten at this stage.
4. Clean front pipe and intermediate pipe, fit joining sleeve.
5. Fit exhaust system. See «EXHAUST SYSTEM & MOUNTINGS»(/land-rover/range-rover/l322-2002-2005/remont/exhaust/#manifold-exhaust-system__exhaust-system-mountings) .
6. Centralize connecting sleeve over joint, align intermediate pipe with front pipes and tighten sleeve clamp nuts to 48 Nm (35 ft. lbs).
7. Check exhaust for correct alignment.
8. Connect battery earth lead.

1. Raise vehicle on lift.
2. Release HO2S harness from clip. (Scheme 69)
3. Release HO2S multiplug from support bracket.
4. Disconnect HO2S multiplug from harness.
5. Remove HO2S.
6. Remove and discard HO2S sealing washer.

Scheme 69

1. Clean HO2S and front pipe mating face.
2. Fit new sealing washer and apply anti-seize compound to thread of HO2S. Fit and tighten to 50 Nm (37 ft. lbs). CAUTION: Ensure anti-seize compound does not contact sensor tip.
3. Connect HO2S multiplug and secure to support bracket.
4. Secure harness in clip.

1. Raise vehicle on lift.
2. Release HO2S harness from clips. (Scheme 70)
3. Release HO2S multiplug from support bracket.
4. Disconnect HO2S multiplug from harness.
5. Remove HO2S and discard sealing washer.

Scheme 70

1. Clean HO2S and front pipe mating face.
2. Fit new sealing washer and apply anti seize compound to thread of HO2S. Fit and tighten HO2S to 50 Nm (37 ft. lbs). CAUTION: Ensure anti-seize compound does not contact sensor tip.
3. Connect HO2S multiplug to sensor and secure to support bracket.
4. Secure harness in clips.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• ELECTRICAL PRECAUTIONS
• DRAINING & REFILLING COOLING SYSTEM
• 80.15.62 PLENUM -- AIR INTAKE
• FUEL SYSTEM -- DEPRESSURIZE
• REAR DRIVE SHAFT
• EXHAUST SYSTEM & MOUNTINGS
• IGNITION COILS - MULTIPLE - SET
• COVER - IGNITION COILS - LH
• COVER - IGNITION COILS - RH
• HOSE - AIR FLOW METER TO THROTTLE BODY
• FUEL RAIL - REMOVE FOR ACCESS & REFIT