Land Rover 2000-05

Removal & Installation 2

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Discovery (2000-04)



  1. Disconnect the negative (() battery cable, then disconnect the positive (+) battery cable.
    NOTE
    Remove the key from the ignition switch and wait 10 minutes before starting work to allow system airbags to fully discharge.

  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Discharge and recover the air conditioning system refrigerant.
  6.  
  7. Detach the heater hoses from the firewall connections.
  8.  
  9. Disconnect A/C refrigerant pipes from the evaporator fittings at the firewall and discard the O-rings.
  10.  
  11. Remove the dash panel assembly by performing the following procedure:
    1. Remove the stereo (radio/cassette/CD) player, using special tools as shown.
    2.  
    3. Remove the steering wheel.
    4.  
    5. Remove the steering column cover.
    6.  
    7. Remove the center console assembly.
    8.  
    9. Remove the A-pillar trim panels.
    10.  
    11. Remove the passenger and driver side lower trim panels.
    12.  
    13. Disconnect the connectors from the switches in the instrument cowl and remove the cowl.
    14.  
    15. Remove the instrument cluster.
    16.  
    17. Remove the glove box.
    18.  
    19. Disconnect the multiplug from the heater controls.
    20.  
    21. From the glove box opening, separate the Blue multiplug and release the coaxial cables from the dash panel.
    22.  
    23. Disconnect the multiplug from the passenger air bag.
    24.  
    25. Disconnect the blower motor.
    26.  
    27. Through the glove box opening, remove the passenger air bag assembly.
    28.  
    29. Remove bolts holding the dash panel at the transmission tunnel and at the A-pillars.
    30.  
    31. With an assistant, carefully remove the dash panel from the vehicle.
    32.  

  12.  
  13. Remove the 4 screws securing the rear heater ducting and remove the ducting from along the center.
  14.  
  15. Remove the 2 blower motor housing nuts and bolt and remove the blower motor from the heater housing.
  16.  
  17. Remove the 2 center console front mounting bracket-to-chassis bolts and remove the center console front mounting bracket.
  18.  
  19. Remove the 2 nuts holding the right dash panel support bracket and remove the bracket.
  20.  
  21. Disconnect both drain tubes.
  22.  
  23. Remove the front heater ducting.
  24.  
  25. Remove the 4 nuts and bolt holding the heater assembly. Remove the heater by detaching it from the bulkhead grommet.

    Click image to see an enlarged view

    Fig. Removing stereo system from dash-Discovery



    Click image to see an enlarged view

    Fig. Disconnecting blue multiplug and coaxial cables-Discovery

  26.  

To install:

  1. Position the heater assembly to bulkhead, fixing the heater tubes into the bulkhead grommet.
  2.  
  3. Install the heater assembly nuts and bolt and torque to 12 ft. lbs. (16 Nm).
  4.  
  5. Position right dash panel support bracket and install and tighten nuts.
  6.  
  7. Install the front heater ducting.
  8.  
  9. Position the center console support bracket and tighten retaining screws.
  10.  
  11. Connect both drain tubes.
  12.  
  13. Install the heater motor to its casing. Install and tighten the nuts and bolt to 14 ft. lbs. (19 Nm).
  14.  
  15. Connect the multiplug for the heater motor.
  16.  
  17. Install the rear heater ducting and secure with screws.
  18.  
  19. Install the dash panel assembly by performing the following procedure:
    1. Using an assistant, install the dash panel assembly to the vehicle. Install and tighten the lower edge bolts to 19 ft. lbs. (26 Nm).
    2.  
    3. Install and tighten the bolts retaining the instrument panel to the frame to 19 ft. lbs. (26 Nm).
    4.  
    5. Install the instrument panel-to-steering column bracket nuts and tighten to 8 ft. lbs. (11 Nm).
    6.  
    7. Secure the coaxial cables to the instrument panel and secure the blue multiplug to the main ICE multiplug, working through the glove box opening.
    8.  
    9. Connect the heater control multiplug connector.
    10.  
    11. Connect the connectors for the blower motor and for the passenger air bag.
    12.  
    13. Install the glove box and secure with bolts.
    14.  
    15. Connect the dash connectors to the main harness and to the fuse box.
    16.  
    17. Position to instrument cluster and connect the connectors, then install the cluster assembly with its screws.
    18.  
    19. Install the instrument cluster cowl, connecting the connectors to the cowl switches.
    20.  
    21. Working below the steering column, install the driver-s side access panel.
    22.  
    23. Install both lower closing panels and secure with their clips.
    24.  
    25. Install both dash panel mats.
    26.  
    27. Install the center console assembly.
    28.  
    29. Install the steering column covers, then install the steering wheel, using a new self-locking nut torqued to 32 ft. lbs. (43 Nm).
    30.  
    31. Install the radio assembly.
    32.  

  20.  
  21. Use new O-rings and insert the A/C pipes into the evaporator. Tighten the bolts to 2.7 ft. lbs. (5 Nm).
  22.  
  23. Connect the heater hoses and install the clamps at the firewall.
  24.  
  25. Evacuate and charge the air conditioning system.
  26.  
  27. Refill the cooling system.
  28.  
  29. Connect the positive (+) battery cable and then the negative (() battery cable.
  30.  
  31. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  32.  

Range Rover (2003-04)



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative (() battery cable; then the positive (+) battery cable.
    NOTE
    Wait at least 20 minutes for the air bag(s) to discharge before performing any work on the system(s).


    NOTE
    The instrument panel fascia is released from the passenger side and swung out for access with the main harness still attached.

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Discharge and recover the air conditioning refrigerant.
  8.  
  9. Remove the air intake plenum.
  10.  
  11. Release the driver side air bag by inserting a 2 inch (50 mm) rod through the steering wheel access hole on each side and push on the rod until the air bag clips are released.
  12.  
  13. Disconnect the electrical connectors and remove air bag.
  14.  
  15. With the front wheels in the straight ahead position, note the position of the steering wheel to column alignment marks, then remove the steering wheel.
  16.  
  17. Remove the passenger side air bag.
  18.  
  19. Remove the front seat belt anchor bolts.
  20.  
  21. Remove the front seats.
  22.  
  23. Remove the center console footwell panels.
  24.  
  25. Remove the driver side upper finish panel.
  26.  
  27. Remove the passenger side lower finish panel.
  28.  
  29. Remove 7 screws attaching the glove box.
  30.  
  31. Disconnect lamp connector, glove box latch cable and 2 screws attaching CD player to glove box.
  32.  
  33. Remove CD player and glove box assembly.
  34.  
  35. Remove center console finish panel.
  36.  
  37. Remove center console side panels.
  38.  
  39. Remove storage box from center console, along with 2 screws and washer at base of storage box opening.
  40.  
  41. Remove 2 screws attaching ignition switch to center console.
  42.  
  43. Remove 1 screw attaching center console to instrument panel.
  44.  
  45. Remove center console rear closing panel.
  46.  
  47. Raise the rear of the center console and disconnect 3 electrical connectors and air duct.
  48.  
  49. Remove 3 connectors from the accessory power socket and then remove center console.
  50.  
  51. Release 4 clips attaching the heater control panel, and remove the control panel.
  52.  
  53. Remove the air suspension control panel, located below the heater control panel.
  54.  
  55. Remove the parking brake lever assembly.
  56.  
  57. Remove the air ducts from the heater-A/C assembly.
  58.  
  59. Remove the driver-s foot rest.
  60.  
  61. Remove the upper and lower A pillar finish panels.
  62.  
  63. Remove instrument panel side fascia from both sides.
  64.  
  65. Remove the gearshift selector assembly.
  66.  
  67. Remove 4 nuts attaching the gearshift selector assembly carrier and remove the carrier.
    NOTE
    Cover the selector assembly mounting studs to prevent damage to the instrument panel.

  68.  
  69. Remove 4 bolts attaching the parking brake mounting bracket and remove the bracket.
  70.  
  71. Remove 4 bolts attaching the center console mounting bracket and remove the bracket.
  72.  
  73. Mark the location of the steering column lower shaft to the intermediate shaft, then remove the clamp securing them together.
  74.  
  75. Remove 2 nuts attaching steering support bearing to the body, release the bearing and disconnect the shaft.
  76.  
  77. Remove the wiper arm, disconnect the wiper motor and position aside.
  78.  
  79. From inside the engine compartment, remove 2 bolts attaching the instrument panel to the firewall.
  80.  
  81. Disconnect the A/C lines from the firewall, discard the o-rings and cap the line openings.
  82.  
  83. Disconnect the heater hoses at the firewall.
  84.  
  85. Remove 3 nuts attaching the heater assembly to the firewall.
  86.  
  87. From inside the vehicle, remove 4 nuts and 2 bolts attaching the instrument panel to the body.

    Click image to see an enlarged view

    Fig. Instrument panel mounting-Range Rover (2003-04)

  88.  
  89. Disconnect electrical connectors and release wiring harnesses from both A pillars.
  90.  
  91. Pull out instrument panel enough to disconnect airbag connectors.
  92.  
  93. Remove the transfer case Electronic Control Unit (ECU).
  94.  
  95. From inside the engine compartment, disconnect the power lead, relay and connector from firewall fuse box.
  96.  
  97. Disconnect headlight check control module from A pillar and position aside.
  98.  
  99. Remove door harness connector block from A pillar.
  100.  
  101. Remove ground header from A pillar.
  102.  
  103. Raise carpet and remove 3 bolts attaching wiring harness cover panel and remove panel.
  104.  
  105. Disconnect wiring harness connector block from Body Control Unit (BCU) carrier.
  106.  
  107. Remove 2 nuts and position BCU carrier aside.
  108.  
  109. Release the main wiring harness from the channel and withdraw the harness through the firewall.
  110.  
  111. With the aid of an assistant, rotate the instrument panel outward and support it on suitable stands to protect trim and carpet.
  112.  
  113. Disconnect air blend motor connector and remove motor.
  114.  
  115. Disconnect screws and nut from rear of instrument panel tray and release clip to allow wiring harness to move.
  116.  
  117. Remove 2 nuts attaching HVAC assembly.
  118.  
  119. With an assistant, remove the HVAC assembly from vehicle.

    Click image to see an enlarged view

    Fig. Rear of instrument panel wiring harness mounting-Range Rover (2003-04)



    Click image to see an enlarged view

    Fig. HVAC assembly mounting bolts-Range Rover (2003-04)

  120.  
  121. Turn HVAC assembly upside down and remove left side heat duct.
  122.  
  123. Remove heater pipes from assembly and discard o-rings.
  124.  
  125. Remove right side heat duct.
  126.  
  127. Disconnect all electrical connectors.
  128.  
  129. Remove rear air vent motor.
  130.  
  131. Remove thermal expansion valve cover.
  132.  
  133. Remove 7 screws and 3 clips from lower HVAC access panel and remove panel.
  134.  
  135. Remove heater core from HVAC assembly.

    Click image to see an enlarged view

    Fig. Removing HVAC lower access panel-Range Rover (2003-04)

  136.  

To install:

  1. Install heater core to HVAC assembly.
  2.  
  3. Install lower access panel.
  4.  
  5. Install thermal expansion valve cover.
  6.  
  7. Install rear air vent motor.
  8.  
  9. Connect all electrical connectors.
  10.  
  11. Install right side heat duct
  12.  
  13. Install heater pipes to HVAC assembly using NEW o-rings
  14.  
  15. Install left side heat duct.
  16.  
  17. With an assistant, install the HVAC assembly into the vehicle and tighten the nuts.
  18.  
  19. Place wiring harness into position in rear of instrument panel tray and clips and screws.
  20.  
  21. Connect air blend motor connector and install motor.
  22.  
  23. With the aid of an assistant, rotate the instrument panel inward and place it in position.
  24.  
  25. Feed the main wiring harness through the firewall.
  26.  
  27. Raise carpet and place the main harness in the channel and install wiring harness cover panel.
  28.  
  29. Install the BCU carrier.
  30.  
  31. Connect wiring harness connector block to BCU carrier.
  32.  
  33. Install ground header to A pillar.
  34.  
  35. Install door harness connector block to A pillar.
  36.  
  37. Install headlight check control module to A pillar.
  38.  
  39. From inside the engine compartment, install the power lead, relay and connector to firewall fuse box.
  40.  
  41. Install the transfer case Electronic Control Unit (ECU).
  42.  
  43. Pull out instrument panel enough to reconnect airbag connectors.
  44.  
  45. Connect electrical connectors and attach wiring harnesses to both A pillars.
  46.  
  47. From inside the vehicle, install 4 nuts and 2 bolts attaching the instrument panel to the body. Tighten the fasteners to 18 ft. lbs. (25 Nm).
  48.  
  49. Install 3 nuts attaching the heater assembly to the firewall and tighten to 7 ft. lbs. (10 Nm).
  50.  
  51. Connect the heater hoses at the firewall.
  52.  
  53. Connect the A/C lines to the firewall, using NEW the o-rings.
  54.  
  55. From inside the engine compartment, install 2 bolts attaching the instrument panel to the firewall. Tighten the bolts to 18 ft. lbs. (25 Nm).
  56.  
  57. Install the wiper motor and tighten to 7 ft. lbs. (10 Nm).
  58.  
  59. Install the wiper arm and tighten to 18 ft. lbs. (25 Nm).
  60.  
  61. Install 2 nuts attaching steering support bearing to the body, and tighten to 18 ft. lbs. (25 Nm).
  62.  
  63. Using marks made on removal, position the steering column lower shaft to the intermediate shaft, and tighten the bolt to 18 ft. lbs. (25 Nm).
  64.  
  65. Install 4 bolts attaching the center console mounting bracket and tighten to 7 ft. lbs. (10 Nm).
  66.  
  67. Install 4 bolts attaching the parking brake mounting bracket and tighten to 18 ft. lbs. (25 Nm).
  68.  
  69. Install 4 nuts attaching the gearshift selector assembly carrier and tighten to 18 ft. lbs. (25 Nm).
  70.  
  71. Install the gearshift selector assembly.
  72.  
  73. Install instrument panel side fascia to both sides.
  74.  
  75. Install the upper and lower A pillar finish panels.
  76.  
  77. Install the driver-s foot rest.
  78.  
  79. Install the air ducts to the heater-A/C assembly.
  80.  
  81. Install the parking brake lever assembly.
  82.  
  83. Install the air suspension control panel.
  84.  
  85. Install the heater control panel.
  86.  
  87. Install the center console.
  88.  
  89. Connect 3 connectors to accessory power socket.
  90.  
  91. Raise the rear of the center console and connect 3 electrical connectors and air duct.
  92.  
  93. Install center console rear closing panel.
  94.  
  95. Install 1 screw attaching center console to instrument panel.
  96.  
  97. Install 2 screws attaching ignition switch to center console.
  98.  
  99. Install 2 screws and washer at base of storage box opening.
  100.  
  101. Install storage box.
  102.  
  103. Install center console side panels.
  104.  
  105. Install center console finish panel.
  106.  
  107. Install CD player and glove box assembly.
  108.  
  109. Install the passenger side lower finish panel.
  110.  
  111. Install the driver side upper finish panel.
  112.  
  113. Install the center console footwell panels.
  114.  
  115. Install the front seats and tighten the bolts to 33 ft. lbs. (45 Nm).
  116.  
  117. Install the seal belt anchor bolts and tighten to 35 ft. lbs. (48 Nm).
  118.  
  119. Install the passenger side air bag and tighten the bolts to 16 ft. lbs. (22 Nm).
  120.  
  121. Noting the position of the steering wheel to column alignment marks, install the steering wheel and tighten the bolt to 46 ft. lbs. (63 Nm).
  122.  
  123. Release the driver side air bag by inserting a 2 inch (50 mm) rod through the steering wheel access hole on each side and push on the rod until the air bag clips are released.
  124.  
  125. Connect the electrical connectors and install driver side air bag. Tighten the screws to 22 inch lbs. (2.5 Nm).
  126.  
  127. Install the air intake plenum.
  128.  
  129. Charge the air conditioning refrigerant.
  130.  
  131. Fill the cooling system.
  132.  
  133. Connect the battery cables.
  134.  
  135. Start the vehicle and check for leaks and proper heater operation.
  136.  

 
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