Contemplating spark plug wire replacement. Really don't want to pull the intake. Lots of fragile parts that could get ruined, bum gasket joints that end up leaking, ECU codes where there were none. Doesn't seem smart to tear apart perfectly functioning components for maintenance of another. I've read that it is possible to do the job without pulling the intake, but I've pulled enough wires only to have the connector stay on the plug or in the coil tower to know that the "Intake in Place" method will be heavily influenced by Murphy and his Laws.

So, I'm looking to develop a new process that makes maintenance easier. Has anyone contemplated removing the coils with the wires attached? Is there enough clearance to remove the two electrical connectors, coil mounting bolts and slide the coil assembly laterally and out? Repopulate the coils with new wires and reinstall.

Another thought is to abandon the existing coils all together and mount new ones in a better location with adapter harnesses attached to the engine harness. Anyone know where to source electrical connectors that would be used to make such a harness? I design stainless sheetmetal parts and have access to a cnc laser and lots of stainless so very nice brackets are a piece of cake. Wouldn't it be nice to have coils where you can get to them? I say $100 worth of parts beats several hours of risky wrenching any day.

Any thoughts?

 

You cannot get the coils out without taking the upper half of the intake off! Secondly you cannot unplug the coil plugs without taking the intake off as well. To me sounds too risky on what you are planning on doing. Taking off the upper part of the intake is easy and it doesn't take much time. Personally.......I wouldn't do it. But that's just my opinion.
Also you need to place new coils in the middle of the engine so the cables can reach both sides. Having said that........are you going to mount the new coils on top of the intake???? Can't close the hood then!
Electrical connections are a totally different topic and liability that goes with messing with one of the most important electrical systems on the vehicle.
I don't know.......I wouldn't do anything like this. But again that's just a Mech. Engineer talking.....
Please don't take offense to my reply.

 

I can remove the upper intake on my non-SAI 1999 in about an hour, and there really isn't much that can break. I think I do recall someone suggesting unbolting the engine mounts and lowering the engine with a floor jack. Not sure if it's been tried and to what result.

 

changed my plugs and wires in about 1 and 1/2 hours including the taking off and putting back on the plenium..some have done the wires without removing anything.. smaller hands are required. What you are talking about doing would take sooooooo much more effort than worth as you really do not need to change wires, plugs, coil packs all that often.... why dont you do all at the same time and not worry about if for a a few years.. as long as nothing else breaks on you.

 

I replaced my wires w/ out taking all that stuff off, It did work out fine.It took me about 2 hrs, Scared hands and blood every where.Take it from me just take every thing off.Somtimes short cuts und up being the long way.

 

Looks like I'm on my own on this one. Thanks for the replies. I personally don't see the risk in extending the harness and making a bracket.

Boris, you don't work at WEP by any chance do you?

 

No I don't.

 

I just replaced "without" taking out the Intake in the last 2 days. I am not in hurry so I am taking my time. I printed out pic, diagrams, cautions from others on this board, Posted on the Garage wall right on front of me. Taking out was hard, but once I understood it was not difficult to replace. I bought these strange pliers from HF (3 Piece Long Reach Hose Grip Pliers) It helped.

Careful on the Flimsy pipe goes from intake to Master Cylinder with red ring around.

I have yet to finish the rest. Hope this helps.

 

Please post how things went after completion. The pliers look like they would work well and give great leverage. Thanks for the tip.

 

@trp34.

Between end of the year work load and unusual temp drop in Austin I'm running out of time for play time! I will take some pic before all done. and email you if you like.

Follow this 2 and the job should be clear. 2 wires in the middle/bottom are the diff one to get to.

Plug wires 1999 Disco II pictures by adraintaylor - Photobucket

https://landroverforums.com/forum/di...im-9657/#64762