Discovery I (LJ) V8-4.0L (1996)
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9.
Install coolant pipes to intake manifold and tighten bolts.
10.
Install spark plug wires to spark plugs and retaining clips.
11.
Connect purge pipe from charcoal canister at plenum.
Left Side Valve Cover Procedure
Left Side Valve Cover Gasket and Valve Cover Bolt Repair
Air Flow Sensor Removal
1.
Loosen intake hose clamp, disconnect from air flow sensor.
2.
Disconnect multi-plug from air flow sensor.
3.
Release two clips securing air cleaner to air flow sensor.
4.
Remove sensor from engine compartment.
Plenum Chamber Removal (94-95 MY)
1.
Disconnect vacuum hose adjacent to bypass air valve.
2.
Mark an identification line on throttle cable outer housing to assist in assembly.
3.
Remove clevis pin and clip from throttle cable.
4.
Pry adjustment thumbwheel from throttle bracket. Lay cable aside.
5.
Apply adhesive tape behind rear adjustment nut on kick down cable to prevent nut moving.
6.
Remove front lock nut. Remove cable and lay aside.
7.
Remove PCV hose.
8.
Remove cruise control vacuum hose.
9.
Remove intake hose from neck of plenum chamber.
10.
Disconnect throttle position sensor multi-plug.
11.
Disconnect two coolant hoses and identify for later assembly.
12.
Disconnect fuel feed pipe.
13.
Disconnect distributor vacuum hose.
14.
Remove six screws securing plenum chamber and remove plenum chamber.
15.
Remove idle air control valve hose.
Plenum Chamber Removal (96 MY)
1.
Loosen clip securing intake hose to plenum chamber and remove hose.
2.
Remove split pin from throttle cable clevis pin and remove clevis pin.
3.
Unhook and remove kick down cable clevis pin.
4.
Disconnect vacuum hose from cruise actuator.
5.
Remove throttle cable from abutment bracket.
6.
Remove front lock nut from kick down cable.
7.
Remove cable from bracket.
8.
Disconnect breather hose from plenum.
9.
Press release clip and disconnect multiplug from throttle position sensor (TP sensor).
10.
Disconnect multiplug from idle air control (IAC) valve.
11.
Remove six bolts securing plenum chamber.
12.
Remove plenum chamber from ram pipe housing.
13.
Clamp water jacket coolant hoses.
14.
Place cloth in position to absorb coolant spillage.
15.
Loosen clamps securing coolant hoses to plenum.
16.
Remove coolant hoses from water jacket and remove plenum chamber.
Valve Cover Removal and Inspection
1.
Remove dipstick.
2.
Remove spark plug wires from spark plugs and retaining clips.
3.
Disconnect coil wire.
4.
Remove alternator heat shield securing nut from valve cover.
5.
Remove air flow meter harness clip.
6.
Remove bolt securing dipstick tube clip.
