Battery connection box (BJB) 4.0L (Discovery 3)

Removing

All cars

1. Disconnect the wire "masses" from the battery. For more information refer to Specification.

2. Place the SRS system in safe mode. For more information, refer to Standard Techniques Used in a Service Station.

3. Remove both internal ignition coils. For more information refer to Ignition Coil (18.20.32)

4. Remove the grille. For more information refer to Radiator Grille (76.55.03)

5. Remove the air filter assembly. For more information refer to Air Filter (19.10.01)

6. Remove the block of management of the full drive. For more information refer to Four Wheel Drive Control Module (4WD) (41.30.01)

7. Remove the battery tray. For more information, refer to Battery Mounting Shelf (76.10.30)

8. Remove the extra battery tray. For more information, refer to Additional Battery Shelf (76.10.31)

9. Remove the ECM cover.

• Disconnect 2 electrical connectors to gain access.
• Disconnect the 2 electrical connectors from the ECM.
• Remove 4 Torx head screws.

10. Remove the ECM. Remove the ECM top cover.



11. Remove the BJB cover. Release the clamp.


12. Disconnect the positive battery cable from the BJB. Loosen the nut.



13. Remove both panels of finishing of a doorway. For more information refer to Front Doorway Trim Panel (76.13.27)

14. Remove CJB. For more information refer to Central Junction Box (CJB) (86.70.56)

15. Release the CJB bracket.

• Release the 3 upper cable harness clips.
• Turn out 2 bolts.

16. Remove the CJB bracket.

• Disconnect the two electrical connectors.
• Release the 3 bottom cable harness clips.
• Loosen 2 nuts.

17. Disconnect 2 cables "masses" from the bottom of the rack "A". Loosen the nut.




18. Disconnect an electric socket of the electric motor of a heater.



19. Remove the BJB from the bracket. Turn out a bolt.



20. Disconnect the wire "masses" from the battery.

• Loosen the nut.
• Release the extra cable "masses".

21. Remove BJB wiring harness from bulkhead.

• Disconnect 6 electrical connectors.
• Release the sealing sleeve.

22. Raise and support the vehicle.

23. Remove the mudguards of both front fenders. For more information refer to Fender Mudguard (76.10.48)

24. Remove both headlamps. For more information refer to headlight assembly (86.40.49)

25. Passenger side: Disconnect the engine wiring harness electrical connector.

26. Passenger side: Disconnect the transfer case electrical connector.



27. Left side: Disconnect the washer hose.



28. Left side: Disconnect the adaptive headlamp controller electrical connector.




Vehicles with optional climate control

29. Left side: Remove the A/C lines from the body panel. Loosen the nut.

All cars

30. Left side: Disconnect the 3 body panel electrical connectors.



31. Left side: Remove cables "masses" three body panels. Loosen the nut.



32. Left side: Release the 2 air suspension pipes from the wiring harness. Release 7 clips.

33. Left side: Disconnect the ABS electrical connectors.



34. Left side: Loosen 3 cables "masses" engine compartment.

• Loosen 3 nuts.
• Release 2 clips.

35. Left side: Remove the washer reservoir harness.

• Disconnect 2 electrical connectors.
• Disconnect the 2 washer nozzle hoses.

36. Left side: Disconnect the electrical connector of the coolant level sensor in the expansion tank.



37. Left side: Disconnect the brake pad wear sensor electrical connector.

38. Left side: Remove the wiring harness.

• Release the sealing sleeve.
• Release 4 clips.

39. Remove the windshield wiper motor. For more information, refer to Windshield Wiper Motor (84.15.12)

40. Remove the hood trim. Remove 11 clips.



41. Remove the hood wiring harness.

• Disconnect the 2 washer nozzle hoses.
• Disconnect the two electrical connectors.
• Release 10 clips.
• Remove the wiring harness cover.
• Release the sealing sleeve.

42. Disconnect the brake booster vacuum pump electrical connector.



43. Disconnect the electrical connector for the A/C pressure sensor.



44. Disconnect the electrical connector of the wiring harness going from the battery to the engine compartment.



45. Remove the wiring harness from the manifold.

• Release 2 clips.
• Loosen 3 nuts.

46. Disconnect the electrical connector of the brake fluid reservoir.

47. Disconnect the ABS block electrical connector.



48. Remove the air suspension control unit. For more information refer to Air Suspension Control Module (60.50.04)

49. Driver's side: Disconnect 2 electrical connectors from the bottom of the pillar "A".



50. Driver side: Remove the wiring harness from the bulkhead. Release the sealing sleeve.



Vehicles with auxiliary heater

51. Right side: Remove the heater pipes from the body panel. Loosen the nut.

All cars

52. Right side: Disconnect 3 body panel electrical connectors.



53. Right side: Remove cables "masses" three body panels. Loosen the nut.



54. Right side: Disconnect the ABS electrical connectors.

55. Right side: Remove the air suspension line from the wiring harness clamp.



56. Right side: Release 2 cables "masses" engine compartment. Loosen 2 nuts.



57. Disconnect the electrical connector of the ambient air temperature sensor.


58. Disconnect both electrical connectors of the front impact sensor. Release 3 clips.



59. Right side: Remove the wiring harness. Release 9 clips.



60. Disconnect the hood switch electrical connector.

61. Disconnect both electric sockets of a sound signal.



62. Disconnect the electrical connector of the cruise control unit, if available.

63. Disconnect the contamination sensor electrical connector, if equipped.

• Release the clamp.
• Release the sealing sleeve.

64. Release the hood opening cable. Release from 3 clips.



65. Disconnect the front bumper wiring harness electrical connector.



66. With assistance, remove the BJB and wiring harness.

Installation

All cars
1. With assistance, install the BJB and wiring harness.

2. Connect the front bumper wiring harness electrical connector.

3. Attach the hood release cable. Fasten with clips.

4. Connect the contamination sensor electrical connector, if equipped.

• Install the sealing sleeve.
• Fasten the clamp.

5. Connect the electrical connector of the cruise control unit, if equipped.

6. Connect electric sockets of a sound signal.

7. Connect the hood switch electrical connector.

8. Right side: Fix the wiring harness. Fasten the clamps.

9. Connect both front impact sensor electrical connectors. Fasten the clamps.

10. Right side: Connect the air suspension pipe.

11. Connect an electric socket of the gauge of temperature of air.

12. Right side: Connect cables "masses" engine compartment. Tighten nuts (tightening torque 25 Nm).

13. Right side: Connect the ABS electrical connector.

14. Right side: Connect the cables "masses" three body panels. tighten the nut (tightening torque 25 Nm).

15. Right side: Connect body panel electrical connectors.

Vehicles with auxiliary heater

16. Right side: Attach the heater lines to the body panel. tighten the nut (tightening torque 10 Nm).

All cars

17. Driver's side: Connect the wiring harness to the bulkhead. Install the sealing sleeve.

18. Driver's side: Connect the electrical connectors on the bottom of the rack "A".

19. Install the air suspension control unit. For more information refer to Air Suspension Control Module (60.50.04)

20. Connect an electric socket of block ABS.

21. Connect the electrical connector of the brake fluid reservoir.
22. Attach the wiring harness to the manifold.

• Fasten the clamps.
• Tighten nuts (tightening torque 4 Nm).

23. Connect the electrical connector of the wiring harness coming from the battery to the engine compartment.

24. Connect an electric socket of the gauge of pressure of the conditioner.

25. Connect an electric socket of the vacuum pump of the brake booster.

26. Attach the hood wiring harness.

• Install the sealing sleeve.
• Install the cover.
• Fasten with clips.
• Connect electrical connectors.
• Connect the washer nozzle hoses.

27. Install the hood trim. Install clamps.

28. Install the windshield wiper motor. For more information, refer to Windshield Wiper Motor (84.15.12)

29. Left side: Attach the wiring harness.

• Install the sealing sleeve.
• Fasten the clamps.

30. Left side: Connect the brake pad wear sensor electrical connector.

31. Left side: Connect the electrical connector of the coolant level sensor in the expansion tank.

32. Left side: Connect the washer reservoir harness.

• Connect the washer nozzle hoses.
• Connect electrical connectors.

33. Left side: Connect cables "masses" engine compartment.

• Fasten the clamps.
• Tighten nuts (tightening torque 25 Nm).

34. Left side: Connect the ABS electrical connector.

35. Left side: Connect the air suspension pipes. Fasten the clamps.

36. Left side: Connect cables "masses" three body panels. tighten the nut (tightening torque 25 Nm).

37. Left side: Connect body panel electrical connectors.

Vehicles with optional climate control

38. Left side: Attach the A/C lines to the body panel. tighten the nut (tightening torque 10 Nm).

All cars

39. Left side: Connect the adaptive headlamp controller electrical connector.

40. Left side: Connect the washer nozzle hose.

41. Passenger side: Connect the transfer case electrical connector.

42. Passenger side: Connect the engine wiring harness electrical connector.

43. Install the headlights. For more information refer to headlight assembly (86.40.49)

44. Install the front fender mudguards. For more information refer to Fender Mudguard (76.10.48)

45. Attach the BJB wiring harness to the bulkhead.

• Connect electrical connectors.
• Install the sealing sleeve.

46. Connect the wire "masses" to the battery.

• Connect an additional cable "masses".
• tighten the nut (tightening torque 25 Nm).

47. Attach the BJB to the bracket. tighten bolt (tightening torque 6 Nm).

48. Connect an electric socket of the electric motor of a heater.

49. Connect cables "masses" to the bottom of the rack "A". tighten the nut (tightening torque 10 Nm).

50. Install the CJB bracket.

• Tighten nuts (tightening torque 10 Nm).
• Fasten the clamps.
• Connect electrical connectors.
• Tighten the bolts (tightening torque 25 Nm).

51. Install CJB. For more information refer to Central Junction Box (CJB) (86.70.56)

52. Connect the positive battery cable to the BJB. tighten the nut (tightening torque 25 Nm).

53. Install the BJB cover. Fasten the clamp.

54. Install the ECM. Install the ECM top cover.

55. Install the ECM cover.

• Tighten the Torx screws.
• Connect electrical connectors.

56. Install the extra battery tray. For more information, refer to Additional Battery Shelf (76.10.31)

57. Install the battery tray. For more information, refer to Battery Mounting Shelf (76.10.30)

58. Install the four-wheel drive control unit. For more information refer to Four Wheel Drive Control Module (4WD) (41.30.01)

59. Install the air filter assembly. For more information refer to Air Filter (19.10.01)

60. Install the grille. For more information refer to Radiator Grille (76.55.03)

61. Install ignition coils. For more information refer to Ignition Coil (18.20.32)

62. Connect the wire "masses" to the battery. For more information refer to Specification.

63. Check up correctness of adjustment of a light bunch of headlights. For more information refer to Headlight adjustment (86.40.17)