wheel LAND ROVER DISCOVERY 2002 Workshop Manual

AIR CONDITIONING
82-26DESCRIPTION AND OPERATION
The rear evaporator/blower assembly cools and dehumidifies air from the cabin and supplies it to the rear distribution
system. The unit is installed on the left side of the loadspace, behind the quarter trim. A grille in the quarter trim allows
air to flow from the loadspace into the evaporator/blower. Refrigerant lines for the evaporator and a condensate drain
tube are attached to the rear floor.
The evaporator and blower are installed in a common housing, which also incorporates the resistor pack for the
blower. A thermostatic expansion valve is integrated into the inlet refrigerant line. A rear blower relay is attached to
the top of the housing.
Evaporator
The evaporator absorbs heat from the recirculated air being supplied to the distribution ducts.
Thermostatic expansion valve
The thermostatic expansion valve meters the flow of refrigerant into the evaporator to match the heat load of the air
passing through the evaporator matrix. A capillary tube, attached to the outlet pipe of the evaporator and connected
to the thermostatic expansion valve, automatically adjusts the valve opening in relation to the refrigerant temperature
at the evaporator outlet.
Blower
The blower controls the volume of air being supplied to the distribution outlets. The blower is an open hub, centrifugal
fan powered by an electric motor. A dust filter is installed over the fan inlet. The blower switch on the control panel
and the resistor pack control the operation of the blower, which can be selected to run at one of four speeds.
Resistor pack
The resistor pack supplies reduced voltages to the blower motor for blower speeds 1, 2 and 3. For blower speed 4,
the resistor pack is bypassed and battery voltage drives the motor at full speed. The pack is installed in the air outlet
from the blower fan, so that any heat generated is dissipated by the air flow.
Distribution system
Air ducts
Ducts connected to the rear evaporator/blower motor assembly distribute air to five vent assemblies in the roof.
Vent assemblies
The vent assemblies allow occupants to control the flow and direction of air. Each vent assembly incorporates a
thumbwheel to regulate flow and moveable vanes to control direction.
Rear control system
The control system operates the blower to control the operation of the rear A/C. The control system consists of two
control switches and a rear blower relay.
Control switches
A rear A/C switch and a blower speed switch are installed on a control panel in the roof lining. The A/C switch is a
latching pushswitch with an amber indicator lamp which illuminates when rear A/C is selected on. The blower speed
switch is a slide switch with a positive detent at each of four speed positions (there is no off position).
Rear blower relay
The rear blower relay controls the electrical supply to the blower.

WIPERS AND WASHERS
84-2 DESCRIPTION AND OPERATION
Front wiper components
1Linkage assembly
2Wiper motor
3Stud plate
4Gasket
5Wheel box 2 off
6Bolt 2 off
7Earth strap
8Cover plate9Bolt 3 off
10Lock washer
11Nut
12Flanged nut 5 off
13Wiper blade 2 off
14Cover
15Nut
16Wiper arm 2 off

WIPERS AND WASHERS
84-8 DESCRIPTION AND OPERATION
Description
General
All markets have a common wiper system with headlamp powerwash as an option.
The wipers system comprises two front wipers and one rear wiper which are powered by electric motors. A washer
reservoir is located in the front left hand wheel arch and is fitted with two electric pumps. Each pump supplies washer
fluid to either the front or rear screens. On certain models, a third pump can be fitted to operate a headlamp power
wash function. Operation of the front and rear wipers and washers is controlled by the driver using switches located
on a steering column stalk and push button switches on the fascia.
Control of the wipers and washers is achieved by the following components:
lBCU.
lIDM.
lFront wiper relay.
lFront wash/ wipe switch.
lVariable delay switch.
lFront wiper motor assembly.
lFront washer pump motor.
lRear wiper relay.
lRear wiper switch.
lRear washer switch.
lRear wiper motor.
lRear washer pump motor.
Both the Body Control Unit (BCU) and the Intelligent Driver Module (IDM) control the wiper system. The BCU controls
the time delay function of the wiper system and is located below and behind the passenger glovebox. During engine
cranking the BCU prevents wiper functions. Two relays are located in the passenger compartment fusebox. The
relays control the delay operation of the front and rear wipers. The relays are an integral part of the fusebox and
cannot be renewed separately.
Power for the wiper system is supplied by the IDM, which is integral with the passenger fusebox and cannot be
renewed as a component. A serial communication link allows communication between the IDM and the BCU.
The system has diagnostic capabilities through TestBook.
Front wipers
The two front windscreen wipers are operated by a linkage assembly and an electric motor located under the plenum
grill below the windscreen. The linkage and motor assembly is handed for left and right hand drive vehicles. The motor
is an integral part of the linkage and cannot be replaced separately.
The linkage comprises a pressed steel mounting plate which provides for the attachment of a wheel box at each end.
The mounting plate is secured to the bulkhead with flanged nuts which attach to a stud plate located behind the
bulkhead. A link arm is attached to each wheel box by a short link and secured with circlips. The link arm has an
attachment hole centrally located along its length for the electric motor drive link.
The electric motor is mounted in a recess in the bulkhead below a sealed cover plate. The drive spindle of the motor
protrudes through the cover plate and is fitted with a link. The link is attached to a tapered spline on the motor spindle
and is secured with a lock washer and nut. The opposite end of the link is attached to the central attachment point on
the link arm and secured with a circlip.
Each wheel box has a taper splined shaft which allows for the attachment of the wiper arm which is secured with a
washer and nut. The shaft of each wheel box is passed through a rubber sealed aperture in the plenum. The wiper
arm attachment to the splined shaft has a pivot to which the remainder of the arm is attached. The two parts of the
arm are connected by a spring which controls the pressure of the blade on the screen to a predetermined amount.

WIPERS AND WASHERS
84-12 DESCRIPTION AND OPERATION
Rear wiper motor
The DC motor contains two permanent magnets and a park switch. An earth braid attached between the motor casing
and the brush pack is utilised to minimise radio interference during wiper functions.
The rear wiper switch provides an earth signal to the BCU, which determines the delay interval, if appropriate. The
BCU then signals the IDM to activate the rear wiper motor relay, which provides power to the rear wiper motor.
To allow the rear wiper to park when the rear wiper is switched off, power flows through the park switch until a cam
in the wiper motor assembly breaks the contact of the park switch. Triggering the park switch grounds the positive
side of the wiper motor causing it to stop abruptly
Washers
The washer system comprises a reservoir, washer pumps, hoses and washer jets. The front washers are controlled
from a stalk switch on the steering column and the rear washers are operated by a non-latching pushbutton switch on
the fascia adjacent to the instrument pack.
Reservoir
The reservoir is located behind the front bumper in the inner wheel arch and has a capacity of 6.0 litres (12.5 US pints).
A filler neck tube is connected to the reservoir with a seal and extends into the engine compartment on the front left
hand side. The filler neck tube contains a removable filter to prevent particle contamination and a yellow float to show
reservoir contents. The washer filler neck tube is sealed with a cap which is coloured blue for identification.
Two electric washer pumps are located on the rear face of the reservoir and supply washer fluid to the front
windscreen and the tail door window. Each pump is sealed to the reservoir with a rubber sealing grommet.
On vehicles with headlamp powerwash fitted, a third pump is fitted with a sealing grommet to the front face of the
reservoir.
The reservoir and filler neck tube are manufactured from moulded opaque nylon. The reservoir has moulded lugs for
attachment to the vehicle body. A bracket is attached to the top of the filler neck tube and locates in a hole in the body
to secure the top of the tube.

WIPERS AND WASHERS
REPAIRS 84-21
Jet - washer - windscreen
$% 84.10.08
Remove
1.Carefully pull the elbow from the washer jet.
2.Place a protective covering around the washer
jet, then release and remove washer jet.
Refit
1.Fit washer jet to its location in the bonnet, and
remove the protective material.
2.Connect the washer tube, ensuring that it is
pushed fully onto the stub pipe.
Pump - washer - screen and headlamp
$% 84.10.21
The following procedure also covers removal of the
rear screen washer pump and the headlamp washer
pump.
Remove
1. Headlamp washer pump: Remove front
bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
2. Front and rear screen washer pumps:
Remove 7 screws securing LH front wheel arch
liner extension to liner and bumper valance and
remove liner extension.
3.Position container under washer reservoir to
collect fluid spillage.

WIPERS AND WASHERS
84-22 REPAIRS
4.Disconnect multiplug from washer pump.
5.Release clip and disconnect washer hose from
washer pump.
6.Remove washer pump from reservoir and
remove and discard pump seal.
Refit
1.Use a new seal and fit pump to reservoir.
2.Connect hose to pump and secure with clip.
3.Connect multiplug to pump.
4. Front and rear screen washer pumps:Fit
wheel arch liner extension, secure to bumper
valance and liner with screws.
5. Headlamp washer pump:Fit front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
6.Fill reservoir with washer fluid.
Motor and linkage - wiper - windscreen
$% 84.15.11
Remove
1.Remove plenum air intake.

+ HEATING AND VENTILATION,
REPAIRS, Plenum Air Intake.
2.Remove 4 nuts and one bolt securing motor
mounting plate to body.
3.Remove nut and bolt securing linkage to body.
4.Release motor and linkage from body and
disconnect multiplug from windscreen wiper
motor.
5.Remove motor and linkage.

WIPERS AND WASHERS
REPAIRS 84-25
Jet - washer - rear screen
$% 84.30.09
Remove
1.Remove spare wheel.
2.Remove rear screen wiper blade.
3.Release washer jet and washer jet tube from
wiper arm.
4.Release washer jet from washer jet tube and
remove jet.
Refit
1.Fit new washer jet to washer jet tube and fit to
wiper arm.
2.Fit rear screen wiper blade.
3.Fit spare wheel.
Switch - rear wash
$% 84.30.27
Remove
1.Carefully remove switch from instrument cowl.
2.Disconnect multiplug and remove switch.
Refit
1.Position new switch and connect multiplug.
2.Carefully push switch into instrument cowl.

WIPERS AND WASHERS
84-26 REPAIRS
Motor - wiper - rear screen
$% 84.35.12
Remove
1.Remove spare wheel from taildoor.
2.Remove tail door trim casing.

+ DOORS, REPAIRS, Trim casing - tail
door.
3.Remove tail door water shedder.
4.Disconnect washer tube
5.Raise nut cover, remove nut and release wiper
arm.
6.Remove spindle nut and flat washer and
discard rubber seal.
7.Disconnect taildoor harness multiplug from
wiper motor.
8.Remove 2 bolts securing wiper motor to tail
door.
9.Remove wiper motor. Refit
1.Position wiper motor to door and secure with
bolts.
2.Connect tail door harness multiplug to wiper
motor.
3.Fit rubber seal, flat washer and spindle nut.
Tighten spindle nut to 3 Nm (2.2 lbf.ft).
4.Position wiper arm to tail door and connect
washer tube.
5.Tighten wiper arm nut to 20 Nm (15 lbf.ft) and
fit nut cover.
6.Fit tail door water shedder.
7.Fit tail door trim casing.

+ DOORS, REPAIRS, Trim casing - tail
door.
8.Fit spare wheel to tail door.

LIGHTING
86-2-6 REPAIRS
Lamp - tail
$% 86.40.70
Remove
1.Remove 4 screws securing tail lamp to body.
2.Disconnect multiplug from tail lamp.
3.Remove tail lamp.
Refit
1.Position tail lamp to body and connect
multiplug.
2.Secure tail lamp to body with screws.
Lamp - front fog up to 03MY
$% 86.40.95
Remove
1.Raise front of vehicle, one side.
2. For RH lamp: Remove 7 screws securing
wheel arch liner extension to liner and bumper
valance and remove liner extension.
Disconnect lamp multiplug from harness.
3. For LH lamp:Remove front bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.

LIGHTING
REPAIRS 86-2-7
4.Remove 4 screws and remove lamp.
Refit
1.Fit new lamp and secure with screws.
2. For LH lamp:Fit front bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
3. For RH lamp: Connect multiplug to harness.
Fit wheel arch liner extension, secure to
bumper valance and liner with screws.
4.Lower vehicle.
Lamp - front fog from 03MY
$% 86.40.96
Remove
1.Remove the front bumper finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Trim finisher - bumper - front - from 03MY.
2.Remove 3 screws securing the fog lamp to the
bumper.
3.Disconnect the fog lamp multiplug and remove
the fog lamp.
Refit
1.Position the fog lamp to the bumper, connect
the multiplug and secure with screws.
2.Fit the front bumper finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Trim finisher - bumper - front - from 03MY.