belt LAND ROVER DISCOVERY 2002 Owners Manual

PANEL REPAIRS
77-2-20 PROCEDURES
7.Always use MIG plug welds where excessive
metal thickness or limited access make
resistance spot welding impractical. Make plug
welds either by using holes left by the spot weld
cutter, or through holes punched and drilled for
the purpose.
8.Dress all welds using either a sander with 36
grit disc, or a belt-type sander and/or
impregnated wire brush.
NOTE: Brazing operations, if required, must be
carried out at this point.

PANEL REPAIRS
REPAIRS 77-2-37
Sill outer assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove RH or LH front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
4.Remove RH or LH front door.

+ DOORS, REPAIRS, Door - front.
5.Remove RH or LH rear door.

+ DOORS, REPAIRS, Door - rear.
6.Remove RH or LH sill finisher.
7.Remove RH or LH 'A' post inner lower
finishers.
8.Remove RH or LH front seat.

+ SEATS, REPAIRS, Seat - front.
9. LH side: Remove power amplifier and EAT
ECU.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
10. RH side: Remove CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
11.Remove rear seats.

+ SEATS, REPAIRS, Seat - rear.
12.Remove RH or LH front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
13.Remove tread plates from front and rear door
apertures.
14.Release carpet and position aside.
15.Remove front and rear door aperture seals.
16.Release relevant wiring from 'A' post, 'B/C' post
and sill areas, and position aside.
17.Remove loadspace lower trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
18. RH side: Remove lower ACE accelerometer.

+ FRONT SUSPENSION, REPAIRS,
Accelerometer - ACE - lower.
19. LH side: Remove SLS air compressor unit.

+ REAR SUSPENSION, REPAIRS,
Compressor unit - air - SLS.
20. Models with rear A/C: Recover refrigerant
from A/C system and remove A/C pipes from
LH sill.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
21.Remove 2 bolts securing body to chassis.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit 2 bolts securing body to chassis and tighten
to 45 Nm (33 lbf.ft).
2. Models with rear A/C: Fit A/C pipes to sill and
recharge A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3. LH side: Fit SLS air compressor unit.

+ REAR SUSPENSION, REPAIRS,
Compressor unit - air - SLS.
4. RH side: Fit lower ACE accelerometer.

+ FRONT SUSPENSION, REPAIRS,
Accelerometer - ACE - lower.
5.Fit loadspace lower trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
6.Fit relevant wiring to 'A' post, 'B/C' post and sill
areas.
7.Fit front and rear door door aperture seals.
8.Fit carpet and secure into position.
9.Fit tread plates to front and rear door apertures.
10.Fit front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
11.Fit rear seats.

+ SEATS, REPAIRS, Seat - rear.
12. LH side: Fit CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
13. RH side: Fit power amplifier and EAT ECU.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
14.Fit front seat.

+ SEATS, REPAIRS, Seat - front.
15.Fit 'A' post inner lower finishers.
M77 1716A

PANEL REPAIRS
REPAIRS 77-2-39
'B/C' post assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove RH or LH rear door.

+ DOORS, REPAIRS, Door - rear.
4.Remove front door striker from 'B/C' post.
5.Remove RH or LH sill finisher.
6.Remove RH or LH front seat.

+ SEATS, REPAIRS, Seat - front.
7. RH side: Remove power amplifier.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
8. LH side: Remove CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
9.Remove RH or LH front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
10.Remove RH or LH rear seat.

+ SEATS, REPAIRS, Seat - rear.
11.Remove head lining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
12.Remove tread plate from front and rear door
apertures.
13.Release carpet from fixings and position aside.
14.Remove front and rear door door aperture
seals.
15.Release relevant wiring from 'B/C' post and sill
areas and position aside.
16.Remove side drip rail finisher.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
2. Before welding 'B/C' post to roof, apply
'Heat shrink paste' to roof area to avoid heat
damage to paintwork.
Refit
1.Fit side drip rail finisher.
2.Fit wiring to 'B/C' post and sill areas.
3.Fit front and rear door door aperture seal.
4.Position carpet and secure with fixings.
5.Fit tread plates to front and rear door apertures.
6.Fit head lining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
7.Fit rear seat.

+ SEATS, REPAIRS, Seat - rear.
8.Fit front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
9. LH side: Fit CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
10. RH side: Fit power amplifier.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
11.Fit RH or LH front seat.

+ SEATS, REPAIRS, Seat - front.
12.Fit sill finisher.

PANEL REPAIRS
77-2-42 REPAIRS
Body side inner rear assembly
In this procedure, the panel body side assembly is
replaced in conjunction with the body side inner rear
assembly.
Remove
1.Disconnect battery eath lead.
2.Disconnect leads/multiplug from alternator.
3.Remove panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
4.Remove RH or LH rear seat.

+ SEATS, REPAIRS, Seat - rear.
5.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
6.Remove rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - side.
7.Remove third row seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
8.Remove fuel tank.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
9.Remove fuel filler tube.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
10. RH side: Remove fuel flap release solenoid.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Solenoid - fuel filler flap release.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Solenoid - fuel filler flap release.
11. RH side: Remove air extractor vent.
12.Remove relevant wiring.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit and secure wiring.
2. RH side: Fit air extractor vent.
3. RH side: Fit fuel flap release solenoid.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Solenoid - fuel filler flap release.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Solenoid - fuel filler flap release.
4.Fit fuel filler tube.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
5.Fit fuel tank.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
6.Fit third row seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
7.Fit rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - side.
8.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
9.Fit rear seat.

+ SEATS, REPAIRS, Seat - rear.
10.Fit panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
11.Connect leads/multiplug to alternator.
12.Connect battery leads, negative lead last.
M77 1698A

PANEL REPAIRS
REPAIRS 77-2-45
'E' post assembly
In this procedure, the panel body side assembly and
tail door are replaced in conjunction with the 'E' post
assembly. If required the 'E' post closing assembly
can also be replaced.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
4.Remove rear seats.

+ SEATS, REPAIRS, Seat - rear.
5.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
6.Remove third row seat belts.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
7.Remove relevant wiring.
8.Remove rear drip rail finisher.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.Refit
1.Fit rear drip rail finisher.
2.Fit and secure wiring.
3.Fit third row seat belts.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
4.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
5.Fit rear seats.

+ SEATS, REPAIRS, Seat - rear.
6.Fit panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
M77 1701A

CORROSION PREVENTION AND SEALING
77-4-8 CORROSION PREVENTION
After refitting mechanical components, including hoses and pipes and other fixtures, mask off the brake discs and
apply a coat of approved underbody wax.
NOTE: Where repairs include the application of finish paint coats in the areas requiring underbody wax, carry out paint
operations before applying wax.
Cavity wax injection
Areas treated with cavity wax are shown in the previous figures. After repairs, always re-treat these areas with an
approved cavity wax. In addition, treat all interior surfaces which have been disturbed during repairs whether they
have been treated in production or not. This includes all box members, cavities and door interiors. It is permissible to
drill extra holes for access where necessary, provided these are not positioned in load-bearing members. Ensure that
such holes are treated with a suitable zinc rich primer, brushed with wax and then sealed with a rubber grommet.
Before wax injection, ensure that the cavity to be treated is free from any contamination or foreign matter. Where
necessary, clear out any debris using compressed air.
Ensure that cavity wax is applied AFTER the final paint process and BEFORE refitting any trim components.
During application, ensure that the wax covers all flange and seam areas and that it is adequately applied to all
repaired areas of both new and existing panels.
It should be noted that new panel assemblies and complete body shells are supplied without wax injection treatment.
Ensure that such treatment is carried out after repairs.
Effective cavity wax protection is vital. Always observe the following points:
lComplete all paint refinish operations before wax application;
lClean body panel areas and blow-clean cavities if necessary, before treatment;
lMaintain a temperature of 18
° C (64° F) during application and drying;
lCheck the spray pattern of injection equipment;
lMask off all areas not to be wax coated and which could be contaminated by wax overspray;
lRemove body fixings, such as seat belt retractors, if contamination is at all likely;
lMove door glasses to fully closed position before treating door interiors;
lTreat body areas normally covered by trim before refitting items;
lCheck that body and door drain holes are clear after the protective wax has dried;
lKeep all equipment clean, especially wax injection nozzles.
Underbody wax
The underbody wax must be reinstated following all repairs affecting floor panels. The wax is applied over paints and
underbody sealers.
Remove old underbody wax completely from a zone extending at least 200 mm (7.874 in) beyond the area where new
underbody sealer is to be applied.
Engine bay wax
Reinstate all protective engine bay wax disturbed during repairs using an approved material.
Where repairs have involved replacement of engine bay panels, treat the entire engine compartment including all
components, clips and other fixtures with an approved underbonnet lacquer or wax.

+ BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.

AIR CONDITIONING
DESCRIPTION AND OPERATION 82-5
To accomplish the transfer of heat, the refrigerant is circulated around the system, where it passes through two
pressure/temperature regimes. In each of the pressure/temperature regimes, the refrigerant changes state, during
which process maximum heat absorption or release occurs. The low pressure/temperature regime is from the
thermostatic expansion valve, through the evaporator to the compressor; the refrigerant decreases in pressure and
temperature at the thermostatic expansion valve, then changes state from liquid to vapour in the evaporator, to absorb
heat. The high pressure/temperature regime is from the compressor, through the condenser and receiver drier to the
thermostatic expansion valve; the refrigerant increases in pressure and temperature as it passes through the
compressor, then releases heat and changes state from vapour to liquid in the condenser.
Compressor
1Pulley
2Inlet connection
3Outlet connection
4Pressure relief valve
5Clutch connector
The compressor circulates the refrigerant around the system by compressing low pressure, low temperature vapour
from the evaporator and discharging the resultant high pressure, high temperature vapour to the condenser.
The compressor is attached to a mounting bracket on the engine, and is a ten cylinder swash plate unit with a fixed
displacement of 177 ml/rev (0.19 US qt/rev). The auxiliary drive belt drives the compressor via a pulley and an
electrically actuated clutch. Operation of the clutch is controlled by the Engine Control Module (ECM).
To protect the refrigerant system from unacceptably high pressure, a pressure relief valve is installed in the outlet side
of the compressor. The pressure relief valve is set to operate at 34.3 to 41.4 bars (497 to 600 lbf.in
2) and vents excess
pressure into the engine compartment.

AIR CONDITIONING
REPAIRS 82-31
REPAIRS
Compressor - diesel
$% 82.10.20
Remove
1.Remove engine acoustic cover.
2.Depressurise air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
4.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
5.Disconnect multiplug from compressor.
6.Remove 2 bolts securing air conditioning pipes
to compressor and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
7.Release clips and disconnect top hose from
coolant elbow and heater pipe.
8.Remove 4 bolts securing compressor to
mounting bracket.
9.Remove compressor.Refit
1.Calculate the quantity of refrigerant oil required.

+ GENERAL INFORMATION, Air
Conditioning Compressor Replacement.
2.Position compressor to mounting bracket and
tighten bolts to 25 Nm (18 lbf.ft).
3.Remove caps from compressor and pipe
connections.
4.Clean compressor and pipe connections.
5.Lubricate new 'O'rings with refrigerant oil and
fit to compressor.
6.Position A/C pipes to compressor and tighten
bolts to 10 Nm (7 lbf.ft) .
7.Connect multiplug to compressor.
8.Position top hose and secure with clips.
9.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
10.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
11.Recharge air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
12.Fit engine acoustic cover.

AIR CONDITIONING
82-32REPAIRS
Compressor - V8
$% 82.10.20
Remove
1.Depressurise air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
3.Disconnect multiplug from compressor.
4.Remove 2 bolts securing air conditioning pipes
to compressor and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove 4 bolts securing compressor to
mounting bracket.
6.Remove compressor.Refit
1.Calculate the quantity of refrigerant oil required.

+ GENERAL INFORMATION, Air
Conditioning Compressor Replacement.
2.Clean compressor dowels and dowel holes.
3.Position compressor to mounting bracket and
tighten bolts to 25 Nm (18 lbf.ft).
4.Remove caps from compressor and pipe
connections.
5.Clean compressor and pipe connections.
6.Lubricate new 'O' rings with refrigerant oil and
fit to compressor.
7.Position A/C pipes to compressor and tighten
bolts to 10 Nm (7 lbf.ft).
8.Connect multiplug to compressor.
9.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
10.Recharge air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.

CHARGING AND STARTING
REPAIRS 86-1-1
CHARGING AND STARTING REPAIRS
Alternator - diesel
$% 86.10.02
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Release cover and remove nut securing lead
to alternator.
3.Disconnect alternator multiplug.
4.Remove bolt (LH thread) and remove auxiliary
drive belt tensioner. 5.Remove bolt securing support stay to
alternator.
6.Release clip and disconnect oil drain hose from
vacuum pump.
7.Disconnect vacuum pump oil supply pipe from
cylinder head and discard 'O' ring.
8.Remove bolt securing alternator and release
from mounting bracket.
9.Disconnect vacuum hose from vacuum pump.
10.Remove alternator. Take care not to damage
radiator cooling fins.
11.Remove 4 bolts, and remove vacuum pump
from alternator.
CAUTION: Always fit plugs to open
connections to prevent contamination.