I searched the forums looking for a quick how-to on reaching the coil pack end of my spark plug wires and after reading what I did and then attempting to reach or even see the packs, I've become quite dismayed. Do I really need to pull my intake plenum? Anything I should look out for if/when I do specific to a 2003 disco? The pictures attached show the black hole my wires disappear into...

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I was able to reach mine in my 99 D2. But it did take me about 1.5 hrs to change out the wires. Plus, it looks like you might have a few more hosesback there than on my 99 (not really sure). You should see if any of your friends have smaller hands than you.

 

You also have the secondary air emission system, one more thing to try and get around.
I would say you should pull the plenum, which is not a big job, then you can do your wires very easily.
Mike

 

Well I went at the plenum today and spent an hour or so pulling bolts and trying to get the damned thing off to no avail. From what I could tell the only thing holding the bastard on is two oil breathers. Is it safe to pull these off? Also, at the front of the plenum there appears to be another aluminum piece which is separate (throttle body attaches to this). Should I separate the plenum from this or take them both off together?

If anyone has done this job and is in southern california and wants some free pizza and beer I could use an extra set of hands. Thanks!

 

Anybody have any ideas?

 

I pulled the plenum on my 03 (not easy),but then getting the coil packs out past the A/C pipes was a beeyotch. I am 115 miles from the nearest dealer, so plug wires are another story. I cannot find an equivalent locally. Any suggestions there?

 

Here is a link for really good wires at a good price.

http://lrrforums.com/store/index.php...at&catId=9

I am sure they can overnight them to you if needed.

 

Thanks. Next time I'll check first.

 

I'm going to tackle this project when my magnacor wires arrive. Thanks Mike for the advice. Does anyone have a step-by step procedure for removing the plenum?

Thanks

 

Here is some inst for upper intake w/sec air. I removed mine a while back to replace some valve cover gaskets, it wasn't too bad but not too easy either. I did not have too drain my coolant or make any adjustments to the throttle cable. When I disc the block hose I did not let it drain and the throttle cables at the TB come out at the TB turnbuckle w/o loosening the jam nuts. Hope this helps a lil. I do not have sec air so can't give any tips on that, sorry.

Gasket - inlet manifold - upper - With
Secondary Air Injection

Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove bonnet.
4. Disconnect multiplug from MAF sensor.
5. Release clip on intake hose and release
harness.
Note: Pre 03 MY air intake hose illustrated.
6. Release and disconnect IACV hose.
7. Loosen clip securing air intake hose to throttle
body.
8. Release 2 clips securing MAF sensor.
9. Release and remove air intake hose.
10. Disconnect vacuum hose from air valve.
11. Loosen clip securing air valve hose to air valve.
12. Remove 2 nuts securing air manifold support
bracket to upper inlet manifold.
13. Disconnect 2 air manifold unions from adapters
in cylinder head.
14. Remove LH air manifold.
15. Disconnect purge valve hose from inlet
manifold.
16. Release purge valve from clips and air control
valve from bracket and lay aside.
17. Disconnect multiplug from IACV.
18. Release clip and disconnect breather hose
from throttle housing.
19. Disconnect multiplug from TP sensor.
20. Position container to collect spillage.
21. Release clips and disconnect 2 coolant hoses
from throttle housing.
22. Loosen outer cable locknuts and release
throttle and cruise control cables from
abutment.
23. Release throttle and cruise control cables from
clips and throttle cams and position aside.
24. Depress plastic collar and disconnect brake
servo hose from inlet manifold.
25. Release clip and disconnect breather hose
from manifold.
26. Disconnect vacuum hose from manifold.
27. Release engine harness from bulkhead clips
and position aside.
28. Release and remove bonnet seal from rear of
engine bay.
29. Remove 2 bolts securing air pipe and coil
bracket to manifold.
30. Loosen 2 lower bolts securing coil bracket
sufficiently to allow bracket to clear manifold.
31. Release plug leads from upper manifold clips.
32. Loosen clip and disconnect air hose from air
valve.
33. Remove 2 nuts securing RH air manifold
support bracket to upper inlet manifold.
34. Release clip and disconnect IACV hose.
35. Remove 6 bolts securing upper manifold and
remove manifold.
36. Collect upper manifold gasket.
Refit
1. Clean upper and lower inlet manifold mating
faces, dowels and dowel holes.
2. Using a new gasket, position upper inlet
manifold. Fit bolts and, working in a diagonal
sequence, tighten to 22 Nm (16 lbf.ft).
3. Connect IACV hose and secure clip.
4. Connect hose to air valve and tighten clip.
5. Secure plug leads to clips.
6. Fit and tighten nuts securing RH air manifold
support bracket.
7. Align air pipe and coil bracket, fit bolts and
tighten to 8 Nm (6 lbf.ft).
8. Tighten 2 lower bolts securing coil bracket to 8
Nm (6 lbf.ft).
9. Fit bonnet seal.
10. Secure engine harness in bulkhead clips.
11. Connect breather hose to manifold and secure
clip.
12. Connect vacuum hose to inlet manifold.
13. Connect brake servo hose to inlet manifold.
14. Connect throttle and cruise control cables.
15. Adjust throttle cable.
16. Adjust cruise control cable.
17. Connect coolant hoses to throttle housing and
secure clips.
18. Connect multiplug to TP sensor.
19. Connect breather hose to throttle housing and
secure with clip.
20. Connect multiplug to IACV.
21. Secure purge valve and air control valve to clips
and bracket.
22. Connect purge hose to manifold.
23. Clean air manifold unions, position manifold
and start union nuts.
24. Fit and tighten nuts securing air manifold
support bracket.
25. Tighten air manifold union nuts to 25 Nm (18
lbf.ft)
26. Connect hose to air valve and tighten clip.
27. Connect vacuum hose to air valve.
28. Fit air intake hose.
29. Connect multiplug to MAF sensor.
30. Secure harness to clip.
31. Connect battery earth lead.
32. Fit battery cover and secure with fixings.
33. Top up cooling system.
34. Fit bonnet.