Land Rover 2000-05

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Fuel system pressure
     
    Alternator
     
    Air intake hose from the plenum chamber
     
    Throttle and cruise control cables from the throttle linkage and mounting brackets
     
    Breather hose from the plenum chamber
     
    Purge hose from plenum chamber
     
    TP sensor
     
    Stepper motor electrical connector
     
    The 6 bolts securing the plenum chamber to the ram housing
     
    Coolant hoses attached to the plenum chamber and intake manifold
     
    Plenum chamber assembly
     
    Breather hoses, as necessary
     
    ECT and temperature gauge sensors
     
    The 8 fuel injector connectors
     
    Fuel temperature sensor connector
     
    Fuel supply and return lines
     
    The 6 nuts securing fuel rail and ignition coil bracket to the inlet manifold
     

  4.  
  5. Lift the fuel rail slightly to remove the ignition coil bracket from the inlet manifold studs and place aside.
  6.  
  7. Using the sequence shown, remove the 12 bolts securing the intake manifold to the cylinder heads, then remove the manifold.
  8.  
  9. Remove the bolts and clamps securing the manifold gasket to the cylinder block.
  10.  
  11. Remove the inlet manifold gasket and discard.
  12.  
  13. Remove the gasket seals and discard.

    Click image to see an enlarged view

    Fig. Intake manifold components



    Click image to see an enlarged view

    Fig. Intake manifold bolt removal sequence

  14.  

To install:

  1. Clean all gasket mating faces.
  2.  
  3. Apply a thin bead of Loctite® Superflex (black) sealant to the 4 notches between cylinder head and block.
  4.  
  5. Install a new gasket seals. Be sure the ends engage correctly in the notches.
  6.  
  7. Install a new inlet manifold gasket and tighten the manifold gasket clamps to 6 inch lbs. (0.7 Nm).
  8.  
  9. With the aid of an assistant, hold the harness and ignition coils aside, position the inlet manifold assembly.
    NOTE
    Tighten the manifold bolts in the reverse order of removal.

  10.  
  11. Install the inlet manifold bolts and tighten as follows:

    84 inch lbs. (10 Nm).
     
    37 ft. lbs. (50 Nm).
     

  12.  
  13. Tighten the gasket clamp bolts to 13 ft. lbs. (17 Nm).
  14.  
  15. Install or connect the following:

    Ignition coil bracket on the inlet manifold studs, and tighten the mounting bolts to 72 inch lbs. ( 8 Nm).
     
    Fuel lines
     
    Connectors to the fuel injectors and fuel temperature sensor
     
    ECT sensor and temperature gauge sensor
     
    Breather hoses as removed
     

  16.  
  17. Clean the mating faces of the plenum chamber.
  18.  
  19. Connect any coolant hoses that were removed.
  20.  
  21. Apply a thin, uniform coating of Loctite® 577 sealant to the mating face of the plenum chamber.
  22.  
  23. Install or connect the following:

    Plenum chamber to the ram housing and tighten to 18 ft. lbs. (24 Nm)
     
    Stepper motor and TP sensor connectors
     
    Purge hose to the plenum chamber
     
    Breather hose to the plenum chamber
     
    Throttle and cruise control cables
     
    Air intake hose to the plenum chamber and secure with clip
     
    Coolant
     
    Alternator
     
    Negative battery cable
     

  24.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Fuel system pressure
     
    Air intake hose from the plenum chamber
     
    Throttle and cruise control cables from the throttle linkage and mounting brackets
     
    Breather hose from the plenum chamber
     
    Purge hose from plenum chamber
     
    TP sensor
     
    Stepper motor electrical connector
     
    The 6 bolts securing the plenum chamber to the ram housing
     
    Coolant hoses attached to the plenum chamber and intake manifold
     
    Plenum chamber assembly
     
    Breather hoses, as necessary
     
    ECT and temperature gauge sensors
     
    The 8 fuel injector connectors
     
    Fuel temperature sensor connector
     
    Fuel supply and return lines
     
    The 6 nuts securing fuel rail and ignition coil bracket to the intake manifold
     

  4.  
  5. Lift the fuel rail slightly to remove the ignition coil bracket from the intake manifold studs and place aside.
  6.  
  7. Using the sequence shown, remove the 12 bolts securing the intake manifold to the cylinder heads, then remove the manifold.
  8.  
  9. Remove the bolts and clamps securing the manifold gasket to the cylinder block.
  10.  
  11. Remove the intake manifold gasket and discard.
  12.  
  13. Remove the gasket seals and discard.

    Click image to see an enlarged view

    Fig. Intake manifold components-Discovery (2000-02) and Range Rover (2000-02)



    Click image to see an enlarged view

    Fig. Intake manifold bolt removal sequence-Discovery II (2000-02) and Range Rover (2000-02)

  14.  

To install:

  1. Clean all gasket mating faces.
  2.  
  3. Apply a thin bead of Loctite®.Superflex (black) sealant to the 4 notches between cylinder head and block.
  4.  
  5. Install a new gasket seals. Be sure the ends engage correctly in the notches.
  6.  
  7. Install a new intake manifold gasket and tighten the manifold gasket clamps to 6 inch lbs. (0.7 Nm).
  8.  
  9. With the aid of an assistant, hold the harness and ignition coils aside, position the intake manifold assembly.
    NOTE
    Tighten the manifold bolts in the reverse order of removal.

  10.  
  11. Install the intake manifold bolts and tighten as follows:

    84 inch lbs. (10 Nm).
     
    37 ft. lbs. (50 Nm).
     

  12.  
  13. Tighten the gasket clamp bolts to 13 ft. lbs. (17 Nm).
  14.  
  15. Install or connect the following:

    Ignition coil bracket on the intake manifold studs, and tighten the mounting bolts to 72 inch lbs. (8 Nm).
     
    Fuel lines
     
    Connectors to the fuel injectors and fuel temperature sensor
     
    ECT sensor and temperature gauge sensor
     
    Breather hoses as removed
     

  16.  
  17. Clean the mating faces of the plenum chamber.
  18.  
  19. Connect any coolant hoses that were removed.
  20.  
  21. Apply a thin, uniform coating of Loctite®.577 sealant to the mating face of the plenum chamber.
  22.  
  23. Install or connect the following:

    Plenum chamber to the ram housing and tighten to 18 ft. lbs. (24 Nm)
     
    Stepper motor and TP sensor connectors
     
    Purge hose to the plenum chamber
     
    Breather hose to the plenum chamber
     
    Throttle and cruise control cables
     
    Air intake hose to the plenum chamber and secure with clip
     
    Coolant
     
    Alternator
     
    Negative battery cable
     

  24.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the air intake hose.
  10.  
  11. Remove both ignition coil covers.
  12.  
  13. Disconnect all ignition coil connectors.
  14.  
  15. Disconnect and label all intake manifold electrical connectors.
  16.  
  17. Remove 2 nuts attaching fuel injector harness to fuel rail.
  18.  
  19. On the left side, remove vacuum reservoir and mounting bracket and fuel hose and mounting bracket.
  20.  
  21. Disconnect alternator harness clip from engine cover bracket.
  22.  
  23. Disconnect all fuel injector connectors.
  24.  
  25. Disconnect main engine harness and move aside.
  26.  
  27. Disconnect charcoal canister connector.
  28.  
  29. Disconnect all vacuum and breather hoses.
  30.  
  31. Remove the secondary air solenoid valve.
  32.  
  33. Position the fuel injector harness aside.
  34.  
  35. Remove the air intake plenum.
  36.  
  37. Remove the terminal cover, attaching nuts and disconnect 2 cables from the terminal post.
  38.  
  39. Disconnect fuel feed hose from fuel rail.
  40.  
  41. Remove the oil separator.
  42.  
  43. Remove the 10 intake manifold attaching nuts.
  44.  
  45. Position aside the brake servo vacuum pipe.
  46.  
  47. Lift the intake manifold, disconnect the breather pipe and remove manifold.
  48.  

To install:

  1. Clean all gasket mating faces.
  2.  
  3. Install new o-rings to the fuel injectors.
  4.  
  5. Install 4 new intake manifold gaskets.
  6.  
  7. Place the intake manifold over the mounting position and connect the lower breather pipe.
  8.  
  9. Lower the intake manifold and install the 10 spacers and attaching nuts. Tighten the nuts to 11 ft. lbs. (15 Nm).
  10.  
  11. Install the brake servo vacuum pipe, front cover and brake vacuum hoses.
  12.  
  13. Connect the 2 breather hoses.
  14.  
  15. Clean the fuel hose connections, then connect fuel feed line to fuel rail.
  16.  
  17. Connect 2 cables to terminal post, tighten nut and install cover.
  18.  
  19. Install the air intake plenum.
  20.  
  21. Position the fuel injector harness, install the washer, place the vacuum switching valve on the right side injector mounting stud and install the 2 nuts and tighten.
  22.  
  23. Connect charcoal canister solenoid connector.
  24.  
  25. Position and secure main engine harness to mounting bracket.
  26.  
  27. Connect fuel injector connectors.
  28.  
  29. Install alternator harness on front cover mounting bracket.
  30.  
  31. Place fuel hose and mounting bracket to left side injector stud.
  32.  
  33. Install vacuum reservoir and mounting bracket to left side injector mounting stud.
  34.  
  35. Install and tighten 2 nuts to left side injector mounting stud.
  36.  
  37. Connect all labeled electrical connectors to appropriate locations.
  38.  
  39. Connect ignition coil connectors.
  40.  
  41. Install ignition coil covers.
  42.  
  43. Connect air intake hose.
  44.  
  45. Connect the negative battery cable.
  46.  
  47. Fill the engine with coolant.
  48.  
  49. Start engine and check for leaks.
  50.  

With Secondary Air Injection
Upper Intake Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect or remove the following:

    Multiplug from the MAF sensor
     
    Clip on the intake hose and release the harness
     
    IACV hose
     
    Air intake hose
     
    Vacuum hose from secondary air valve
     
    2 nuts holding hose to air valve
     
    Air manifold unions from adapters in cylinder head
     
    left side air manifold
     
    Purge valve hose from the intake manifold
     
    Purge valve and air control valve from bracket (lay it aside)
     
    Multiplug from the IACV
     
    Breather hose from the throttle housing
     
    Multiplug from TP sensor

    Click image to see an enlarged view

    Fig. Identifying the location of the purge valve, IACV, breather hose and TP sensor-Discovery (2003-04)

     
    2 coolant hoses from throttle housing
     
    Throttle and cruise control cables from throttle body (lay cables aside)
     

  6.  
  7. Depress the plastic collar and disconnect the brake servo hose from the intake manifold.
  8.  
  9. Disconnect the vacuum hose from the manifold.
  10.  
  11. Release the engine harness from the bulkhead clips and lay the harness aside.
  12.  
  13. Remove the hood seal from the rear of the engine compartment.
  14.  
  15. Remove the 2 bolts holding the air pipe and coil bracket to the manifold.
  16.  
  17. Loosen 2 lower bolts enough to allow the coil bracket to clear the manifold.
  18.  
  19. Release plug leads from upper manifold clips, near bulkhead.
  20.  
  21. Disconnect the air hose from the secondary air bypass valve.
  22.  
  23. Remove the 2 nuts securing the right side air manifold support bracket to the upper intake manifold.
  24.  
  25. Disconnect the IACV hose from the throttle housing.
  26.  
  27. Remove the 6 bolts securing the upper intake manifold and remove the manifold. Remove and discard the gasket.

    Click image to see an enlarged view

    Fig. Identifying location of upper intake manifold bolts-Discovery (2003-04)

  28.  

To install:

  1. Clean upper and lower intake manifold mating faces, dowels and dowel holes.
  2.  
  3. Using a new gasket, position the upper intake manifold into place. Install the retaining bolts. Working in a diagonal sequence, tighten bolts to 16 ft. lbs. (22 Nm).
  4.  
  5. Complete installation by reconnecting or installing components in reverse of removal procedure.
  6.  

Without Secondary Air Injection
Upper Intake Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect or remove the following:

    MAF sensor harness from clip
     
    Air intake hose
     
    Throttle and cruise control cables from throttle body (lay cables aside)
     

  6.  
  7. Disconnect the EVAP pipe from the intake manifold.
  8.  
  9. Disconnect the multiplug from the throttle body.
  10.  
  11. Remove the clip securing the breather hose to the throttle body and release the hose.
  12.  
  13. Disconnect the coolant hoses from the throttle body.
  14.  
  15. Disconnect the brake servo vacuum pipe and the breather hose from the intake chamber
  16.  
  17. Remove the bolt holding the coolant rails.
  18.  
  19. Release the engine harness from the bulkhead clips and position the harness aside.
  20.  
  21. Remove the 4 bolts securing the ignition coils. Position the coils aside.
  22.  
  23. Detach the plug leads from the upper manifold clips. Disconnect the multiplug from the IACV. Release and disconnect the IACV hose.
  24.  
  25. Remove the 6 bolts securing the upper intake manifold and remove the manifold. Remove and discard the gasket.
  26.  

To install:

  1. Clean upper and lower intake manifold mating faces, dowels and dowel holes.
  2.  
  3. Using a new gasket, position the upper intake manifold into place. Install the retaining bolts. Working in a diagonal sequence, tighten bolts to 16 ft. lbs. (22 Nm).
  4.  
  5. Complete installation by reconnecting or installing components in reverse of removal procedure.
  6.  

Lower Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground lead.
  4.  
  5. Drain cooling system.
  6.  
  7. Remove fuel rail.
  8.  
  9. Depress locking collar and release breather hose from left side intake manifold.
  10.  
  11. Release clip and disconnect coolant hose from left side intake manifold.
  12.  
  13. Progressively loosen and remove 7 bolts securing left side intake manifold to cylinder head.
  14.  
  15. Remove intake manifold and discard gasket.
  16.  

To install:

  1. Clean intake manifold and cylinder head mating faces.
  2.  
  3. Install new intake manifold gasket to cylinder head, position intake manifold, fit and tighten bolts to 18 ft. lbs. ( 25 Nm).
  4.  
  5. Connect breather hose to left side intake manifold.
  6.  
  7. Connect coolant hose to intake manifold and secure clip.
  8.  
  9. Install fuel rail.
  10.  
  11. Fill cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove both rocker arm covers.
  10.  
  11. Disconnect the left side injector harness and connectors.
  12.  
  13. Remove the upper radiator hose.
  14.  
  15. Remove the auxiliary drive belt.
  16.  
  17. Unbolt active cornering enhancement (ACE) pump and move out of the way.
  18.  
  19. Remove the alternator.
  20.  
  21. Remove the power steering pump pulley and the adjoining auxiliary drive belt pulley.
  22.  
  23. Release power steering pump high pressure pipe. Plug the pipe and pump openings immediately.
  24.  
  25. Remove the bolt holding the oil cooling pipe and release the bracket from the auxiliary housing.
  26.  
  27. Remove 2 bolts holding the power steering pump.
  28.  
  29. Remove 5 bolts and one nut securing the auxiliary housing. Pull the housing forward, remove the power steering pump and the auxiliary housing.

    Click image to see an enlarged view

    Fig. Identifying auxiliary housing and related retaining bolts-Discovery (2003-04)

  30.  
  31. Remove 4 bolts securing top cooling hose outlet and remove outlet pipe. Remove and discard the O-ring.
  32.  
  33. Disconnect the fuel pipe from the intake manifold. Plug the openings immediately. Wipe up any spilled fuel.
  34.  
  35. Using the sequence shown, remove the 12 lower intake manifold retaining bolts. Remove the lower intake manifold.
  36.  
  37. Remove the 2 bolts retaining the intake manifold gasket and collect the gasket end clamps. Remove the gasket and seals.

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt removal sequence-Discovery (2003-04)

  38.  

To install:

  1. Clean all gasket mating faces on cylinder head, block and lower intake manifold.
  2.  
  3. Apply sealant STC 50550 to cylinder head and cylinder block notches.
  4.  
  5. Install new gasket seals, making sure ends of seals engage correctly in notches.
  6.  
  7. Install a new intake manifold gasket. Position the gasket end clamps and install the bolts, but do not tighten at this stage.
  8.  
  9. Position the lower intake manifold to the engine. Install the retaining bolts. Working in the sequence shown, tighten the bolts in 2 steps:
    1. Step 1: 7 ft. lbs. (10 Nm)
    2.  
    3. Step 2: 38 ft. lbs. (51 Nm)
    4.  

  10.  
  11. Tighten the gasket end clamp bolts to 13 ft. lbs. (18 Nm).
  12.  
  13. Reconnect the fuel pipe to the intake manifold.
  14.  
  15. Clean the top hose outlet pipe mating faces, install a new O-ring, position the pipe and tighten the retaining bolts to 16 ft. lbs. (22 Nm).
  16.  
  17. Install the alternator and tighten the bolts to 33 ft. lbs. (45 Nm).
  18.  
  19. Install the power steering pump to the auxiliary housing, position the auxiliary housing on the engine, and tighten the retaining bolts to 30 ft. lbs. (40 Nm). Tighten the nut to 7 ft. lbs. (10 Nm).
  20.  
  21. Install and tighten the power steering pump bolts to 16 ft. lbs. (22 Nm).
  22.  
  23. Install the oil cooling pipe bracket bolt and tighten to 16 ft. lbs. (22 Nm).
  24.  
  25. Position the lower auxiliary drive belt pulley and tighten the bolt to 37 ft. lbs. (50 Nm).
  26.  
  27. Clean the power steering pump pulley mating faces. Install the pulley and tighten the bolts to 16 ft. lbs. (22 Nm).
  28.  
  29. Install the auxiliary drive belt.
  30.  
  31. Reconnect the injector harness and connectors.
  32.  
  33. Install the upper radiator hose.
  34.  
  35. Install the rocker covers.
  36.  
  37. Check and refill all fluids.
  38.  
  39. Reconnect the negative battery cable.

    Click image to see an enlarged view

    Fig. Lower intake manifold bolt torque sequence-Discovery (2003-04)

  40.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground lead.
  4.  
  5. Drain cooling system.
  6.  
  7. Remove fuel rail.
  8.  
  9. Release clip and disconnect coolant hose from right side intake manifold.
  10.  
  11. Depress locking collar and release breather hose from right side intake manifold.
  12.  
  13. Progressively loosen and remove 7 bolts securing right side intake manifold to cylinder head.
  14.  
  15. Remove intake manifold and gasket.
  16.  
  17. Remove bolt securing coolant breather hose mounting bracket to intake manifold and remove bracket.
  18.  

To install:

  1. Clean intake manifold and cylinder head face.
  2.  
  3. Position coolant/breather hose bracket to intake manifold, fit and tighten bolt to 7 ft. lbs. (9 Nm).
  4.  
  5. Install new intake manifold gasket to cylinder head, position intake manifold, fit and tighten bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Connect coolant hose to intake manifold and secure clip.
  8.  
  9. Connect breather hose to manifold and secure into collar.
  10.  
  11. Install fuel rail.
  12.  
  13. Fill cooling system.
  14.  
  15. Connect the negative battery cable.
  16.  

 
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