sensor LAND ROVER DISCOVERY 1999 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 1999Pages: 1529, PDF Size: 34.8 MB
Page 6 of 1529
CONTENTS
CONTENTS 3
MAINTENANCE ........................................................................................ 10-1
PROCEDURES
V8 engine underbonnet view .......................................................................................................... 10-1
Diesel underbonnet view ................................................................................................................. 10-2
Seats and seat belts ...................................................................................................................... 10-3
Lamps, horns and warning indicators ............................................................................................. 10-5
Wipers and washers ...................................................................................................................... 10-5
Handbrake .................................................................................................................................. 10-6
Alarm handset battery ..................................................................................................................... 10-6
Road wheels ................................................................................................................................... 10-6
Tyres .............................................................................................................................................. 10-6
Brake pads, discs and calipers ....................................................................................................... 10-6
Road wheel speed sensors ............................................................................................................. 10-7
Brake fluid ....................................................................................................................................... 10-7
Fuel filter - diesel engine ................................................................................................................. 10-7
Fuel filter sedimenter ...................................................................................................................... 10-7
Road wheels ................................................................................................................................... 10-8
Radiator/Intercooler ........................................................................................................................ 10-8
Ambient air Temperature and pressure sensor .............................................................................. 10-8
Doors, bonnet and fuel filler flap ..................................................................................................... 10-8
Air suspension intake filter .............................................................................................................. 10-9
Anti-freeze....................................................................................................................................... 10-9
Cooling system ............................................................................................................................... 10-9
Spark plugs - V8 engine.................................................................................................................. 10-10
Air cleaner - V8 engine ................................................................................................................... 10-10
Air cleaner and dump valve - diesel engine .................................................................................... 10-10
Auxiliary drive belt ........................................................................................................................... 10-11
Auxiliary drive belt - V8 engine ....................................................................................................... 10-11
Auxiliary drive belt - diesel engine .................................................................................................. 10-11
Fluid reservoirs ............................................................................................................................... 10-12
Steering box .................................................................................................................................... 10-13
Battery ............................................................................................................................................. 10-13
Intercooler - diesel engine............................................................................................................... 10-14
Engine oil - V8 engine ..................................................................................................................... 10-14
Engine oil - diesel engine ................................................................................................................ 10-15
Centrifuge rotor – diesel engine ...................................................................................................... 10-15
Engine oil filter - diesel engine ........................................................................................................ 10-16
Engine oil filter – V8 engine ............................................................................................................ 10-16
Manual gearbox .............................................................................................................................. 10-17
Automatic gearbox ......................................................................................................................... 10-18
Transfer box .................................................................................................................................... 10-19
Front and rear axle .......................................................................................................................... 10-20
Propeller shafts ............................................................................................................................... 10-20
Anti-roll bar links ............................................................................................................................. 10-22
ACE actuators ................................................................................................................................. 10-23
ACE filter ......................................................................................................................................... 10-23
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CONTENTS
4CONTENTS
Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ 10-24
Engine, gearbox, transfer box and axles ........................................................................................ 10-25
Exhaust system .............................................................................................................................. 10-25
Steering box and front suspension ................................................................................................. 10-25
Steering rod ball joints ................................................................................................................... 10-27
Dampers and SLS height sensors .................................................................................................. 10-27
Front and rear axle suspension links .............................................................................................. 10-28
Towing bracket ............................................................................................................................... 10-29
Engine mountings - V8 engine........................................................................................................ 10-30
Road/roller test ............................................................................................................................... 10-31
Page 9 of 1529
CONTENTS
6CONTENTS
EMISSION CONTROL - V8 ....................................................................... 17-2-1
DESCRIPTION AND OPERATION
Crankcase emission control system ............................................................................................... 17-2-1
Exhaust emission control ................................................................................................................ 17-2-2
Evaporative emission system component layout ............................................................................ 17-2-3
Evaporative emission system (with positive pressure leak detection) component layout (NAS only) 17-2-4
Evaporative emission system control diagram ............................................................................... 17-2-5
Secondary air injection system component layout.......................................................................... 17-2-6
Secondary air injection system control diagram ............................................................................. 17-2-8
Emission Control Systems .............................................................................................................. 17-2-9
Crankcase Emission Control System ............................................................................................. 17-2-10
Exhaust Emission Control System.................................................................................................. 17-2-11
Evaporative Emission Control System............................................................................................ 17-2-15
Secondary Air Injection System ...................................................................................................... 17-2-26
Crankcase Emission Control Operation.......................................................................................... 17-2-34
Exhaust Emission Control Operation .............................................................................................. 17-2-35
Evaporative Emission Control Operation ........................................................................................ 17-2-39
Secondary Air Injection System Operation ..................................................................................... 17-2-43
SAI System Fault Finding and Check Malfunctions ........................................................................ 17-2-44
REPAIRS
Canister - EVAP ............................................................................................................................ 17-2-51
Canister - EVAP - Models with Fuel Leak Detection Pump - up to 03MY ...................................... 17-2-52
Canister - EVAP - Models with Fuel Leak Detection Pump - from 03MY ....................................... 17-2-53
Valve - purge control ..................................................................................................................... 17-2-54
Solenoid - evap canister vent solenoid (CVS) valve ..................................................................... 17-2-55
Sensor - heated oxygen (HO2S) - pre-catalytic converter .............................................................. 17-2-56
Sensor - heated oxygen (HO2S) - post-catalytic converter ............................................................ 17-2-57
Control Valve - Secondary Air Injection (SAI) ............................................................................... 17-2-58
Reservoir - Vacuum - Secondary Air Injection (SAI) - up to 03MY ................................................. 17-2-58
Reservoir - vacuum - Secondary Air Injection (SAI) - from 03MY .................................................. 17-2-59
Pump - Air - Secondary Air Injection (SAI) ..................................................................................... 17-2-59
Air Manifold - LH - Secondary Air Injection (SAI) ........................................................................... 17-2-60
Air Manifold - RH - Secondary Air Injection (SAI) .......................................................................... 17-2-61
Solenoid - Vacuum - Secondary Air Injection (SAI) ...................................................................... 17-2-62
Pipe - Secondary Air Injection (SAI) .............................................................................................. 17-2-62
Pump - Fuel Leak Detection - up to 03MY...................................................................................... 17-2-64
Pump - fuel leak detection - from 03MY ......................................................................................... 17-2-64
Filter - fuel leak detection pump - up to 03MY ................................................................................ 17-2-65
Filter - fuel leak detection pump - from 03MY ................................................................................. 17-2-65
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CONTENTS
CONTENTS 7
ENGINE MANAGEMENT SYSTEM - V8 .................................................. 18-2-1
DESCRIPTION AND OPERATION
Engine management component location - Passenger compartment ............................................ 18-2-1
Engine management component location - Engine compartment .................................................. 18-2-2
Engine management block diagram ............................................................................................... 18-2-4
Description - engine management .................................................................................................. 18-2-6
Operation - engine management .................................................................................................... 18-2-49
DESCRIPTION AND OPERATION
Cruise control component layout .................................................................................................... 18-2-61
Cruise control block diagram .......................................................................................................... 18-2-62
Description - cruise control ............................................................................................................. 18-2-63
Operation - cruise control................................................................................................................ 18-2-74
ADJUSTMENTS
Cable - throttle ............................................................................................................................. 18-2-77
Cable - cruise control .................................................................................................................... 18-2-77
REPAIRS
Spark plugs .................................................................................................................................. 18-2-79
Coil - ignition ................................................................................................................................. 18-2-80
Engine control module (ECM) ......................................................................................................... 18-2-81
Sensor - engine coolant temperature (ECT) ................................................................................ 18-2-82
Sensor - crankshaft position (CKP) ............................................................................................... 18-2-83
Sensor - radiator temperature ....................................................................................................... 18-2-84
Sensor - camshaft position (CMP) ................................................................................................. 18-2-84
Knock sensor (KS) .......................................................................................................................... 18-2-85
Air cleaner assembly ..................................................................................................................... 18-2-86
Element - air filter .......................................................................................................................... 18-2-87
Cable - throttle ................................................................................................................................ 18-2-88
Sensor - Mass Air Flow (MAF) ...................................................................................................... 18-2-89
Throttle Body................................................................................................................................... 18-2-90
Plenum chamber ............................................................................................................................. 18-2-91
Sensor - throttle position (TP) ....................................................................................................... 18-2-91
Valve - idle air control (IACV) ........................................................................................................ 18-2-92
Injectors ......................................................................................................................................... 18-2-92
Actuator - cruise control ................................................................................................................ 18-2-94
Vacuum control unit - up to 03MY................................................................................................... 18-2-94
Vacuum control unit - from 03MY ................................................................................................... 18-2-95
Cable - cruise control ..................................................................................................................... 18-2-96
Switch - cruise control (on/off) ........................................................................................................ 18-2-96
Switch - cruise control (set/resume) ............................................................................................... 18-2-97
Switch - clutch pedal - cruise control ............................................................................................ 18-2-97
ECU - Cruise control ..................................................................................................................... 18-2-98
Page 14 of 1529
CONTENTS
CONTENTS 11
TRANSFER BOX - LT230SE .................................................................... 41-1
DESCRIPTION AND OPERATION
LT230SE transfer box ..................................................................................................................... 41-1
Transfer box cross section .............................................................................................................. 41-2
Main casing components – Vehicles up to 03 model year .............................................................. 41-4
Main casing components – Vehicles from 03 model year ............................................................... 41-5
Differential components – Vehicles up to 03 model year ................................................................ 41-6
Differential components – Vehicles from 03 model year ................................................................. 41-7
Front output housing components – Vehicles up to 03 model year ................................................ 41-8
Front output housing components – Vehicles from 03 model year ................................................. 41-10
Rear output housing components ................................................................................................... 41-12
Description ...................................................................................................................................... 41-13
Operation ........................................................................................................................................ 41-18
ADJUSTMENTS
Cable - selector - differential lock - adjust ...................................................................................... 41-21
Cable - high/low selector ................................................................................................................. 41-21
REPAIRS
Bottom cover - transfer box .......................................................................................................... 41-23
Cable - selector - differential lock .................................................................................................... 41-24
Transfer box - Diesel....................................................................................................................... 41-25
Transfer box - V8 ............................................................................................................................ 41-29
Gasket - rear cover plate ................................................................................................................ 41-33
Switch - differential lock - Up to 03 MY ........................................................................................... 41-34
Cable - high/low selector ................................................................................................................. 41-35
Oil seal - input shaft ...................................................................................................................... 41-36
Seal - front output shaft................................................................................................................... 41-36
Seal - rear output shaft ................................................................................................................... 41-38
Gasket - rear output shaft housing.................................................................................................. 41-39
Solenoid - interlock - Up to 03 MY .................................................................................................. 41-40
Solenoid - interlock - from 03 MY .................................................................................................... 41-40
Sensor - neutral ........................................................................................................................... 41-41
Sensor - oil temperature - If fitted ................................................................................................... 41-41
Switch - high low - warning ........................................................................................................... 41-42
Switch(es) - differential lock warning From 03 MY .......................................................................... 41-42
OVERHAUL
Intermediate gear assembly .......................................................................................................... 41-43
Differential assembly .................................................................................................................... 41-46
Dog clutch - differential lock .......................................................................................................... 41-64
Input gear/bearing .......................................................................................................................... 41-68
Low gear - differential ................................................................................................................... 41-70
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CONTENTS
16 CONTENTS
REAR SUSPENSION ................................................................................ 64-1
DESCRIPTION AND OPERATION
Rear suspension component layout (vehicles with SLS) ............................................................... 64-2
Rear suspension component layout (vehicles without SLS) .......................................................... 64-3
Rear suspension components ........................................................................................................ 64-4
Description ...................................................................................................................................... 64-6
DESCRIPTION AND OPERATION
SLS component layout.................................................................................................................... 64-9
SLS system control diagram ........................................................................................................... 64-10
Description - SLS ............................................................................................................................ 64-12
Operation ........................................................................................................................................ 64-21
ADJUSTMENTS
SLS calibration blocks .................................................................................................................... 64-25
REPAIRS
Wheel hub....................................................................................................................................... 64-27
Road spring - rear ........................................................................................................................... 64-29
Air spring - SLS............................................................................................................................... 64-30
Damper - rear ............................................................................................................................... 64-31
Bushes - radius arm ....................................................................................................................... 64-31
Bushes - Watts linkage ................................................................................................................. 64-34
Sensor - height - SLS ..................................................................................................................... 64-35
Compressor unit - air - SLS ............................................................................................................ 64-35
Filter - intake - SLS ......................................................................................................................... 64-37
Switch - ride height ......................................................................................................................... 64-37
Air valve - SLS ................................................................................................................................ 64-38
Actuator - rear - ACE ...................................................................................................................... 64-39
Bushes - rear long arm - ACE......................................................................................................... 64-41
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CONTENTS
CONTENTS 17
BRAKES ................................................................................................... 70-1
DESCRIPTION AND OPERATION
Brake system control component layout ......................................................................................... 70-1
Brake system control diagram ........................................................................................................ 70-2
Brake system hydraulic component layout ..................................................................................... 70-4
Description ...................................................................................................................................... 70-5
Operation ........................................................................................................................................ 70-20
DESCRIPTION AND OPERATION
Handbrake component layout ......................................................................................................... 70-25
Description ...................................................................................................................................... 70-26
ADJUSTMENTS
Handbrake .................................................................................................................................... 70-29
Brake system bleeding ................................................................................................................... 70-30
REPAIRS
Brake disc - front .......................................................................................................................... 70-33
Brake disc - rear ............................................................................................................................ 70-34
Master cylinder - brake ................................................................................................................. 70-35
Cable - handbrake ........................................................................................................................ 70-36
Switch - brake light ........................................................................................................................ 70-37
Brake pads - front ......................................................................................................................... 70-38
Brake pads - rear .......................................................................................................................... 70-39
Brake shoes - handbrake ................................................................................................................ 70-40
Servo - brake .................................................................................................................................. 70-42
Vacuum pump - servo ..................................................................................................................... 70-43
Housing - caliper - front ................................................................................................................. 70-45
Housing - caliper - rear ................................................................................................................. 70-46
ECU - Self levelling and anti locking brakes (SLABS) ................................................................. 70-47
Sensor – ABS – front ..................................................................................................................... 70-48
Sensor – ABS – rear ....................................................................................................................... 70-48
Modulator unit - ABS ...................................................................................................................... 70-49
Switch - Hill descent control ............................................................................................................ 70-50
Switch - handbrake ....................................................................................................................... 70-50
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CONTENTS
24 CONTENTS
AIR CONDITIONING ................................................................................. 82-1
DESCRIPTION AND OPERATION
A/C refrigerant system component layout....................................................................................... 82-1
A/C control system component layout ............................................................................................ 82-2
Description ...................................................................................................................................... 82-3
Operation ........................................................................................................................................ 82-16
DESCRIPTION AND OPERATION
Rear A/C refrigerant system component layout .............................................................................. 82-21
Rear A/C distribution and control component layout ...................................................................... 82-22
Description ...................................................................................................................................... 82-23
Operation ........................................................................................................................................ 82-26
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Refrigerant recovery, recycling and recharging .............................................................................. 82-27
REPAIRS
Compressor - diesel........................................................................................................................ 82-29
Compressor - V8............................................................................................................................. 82-30
Fan - condenser ............................................................................................................................ 82-31
Condenser .................................................................................................................................... 82-31
Receiver drier and dual pressure switch......................................................................................... 82-33
ECU - air temperature control ......................................................................................................... 82-35
Sensor - ambient air temperature ................................................................................................ 82-35
Sensor - solar light ........................................................................................................................ 82-36
Sensor - air temperature ............................................................................................................. 82-37
Evaporator, evaporator thermistor and thermal expansion valve (TXV) ........................................ 82-38
Expansion valve - (TXV) - rear ....................................................................................................... 82-41
Evaporator - rear............................................................................................................................. 82-42
Evaporator and motor assembly - rear ........................................................................................... 82-43
Blower motor assembly - rear ......................................................................................................... 82-44
Resistor - blower motor ................................................................................................................. 82-45
Duct - centre - rear.......................................................................................................................... 82-45
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CONTENTS
28 CONTENTS
DRIVING AIDS .......................................................................................... 86-8-1
DESCRIPTION AND OPERATION
Park Distance Control – Component Location................................................................................ 86-8-1
Park Distance Control – Control Diagram....................................................................................... 86-8-2
Description ...................................................................................................................................... 86-8-4
Operation ........................................................................................................................................ 86-8-11
REPAIRS
Control unit (ECU) - park distance control (PDC) ........................................................................... 86-8-13
Sounder - parking aid rear ............................................................................................................. 86-8-14
Sensor - parking aid - rear - inner ................................................................................................... 86-8-15
Sensor - parking aid - rear - outer .................................................................................................. 86-8-16
NAVIGATION SYSTEM ............................................................................ 87-1
DESCRIPTION AND OPERATION
Harman/Becker Navigation System Component Location.............................................................. 87-1
Description ...................................................................................................................................... 87-2
DESCRIPTION AND OPERATION
CARiN III Navigation and Trafficmaster System Component Location........................................... 87-12
Description ...................................................................................................................................... 87-14
Operation ........................................................................................................................................ 87-20
REPAIRS
Interface electronic control unit (ECU) - remote control ................................................................. 87-29
Display unit .................................................................................................................................... 87-30
INSTRUMENTS ......................................................................................... 88-1
DESCRIPTION AND OPERATION
Instrument pack .............................................................................................................................. 88-1
Instrument component location - Engine compartment / underneath vehicle ................................. 88-2
Instrument component location - Passenger compartment ............................................................ 88-3
Instrument block diagram ............................................................................................................... 88-4
Description ...................................................................................................................................... 88-5
Interior rear view mirror with compass (where fitted) ..................................................................... 88-42
REPAIRS
Clock ............................................................................................................................................... 88-45
Instrument pack ............................................................................................................................ 88-45
Page 34 of 1529
INTRODUCTION
01-3
Abbreviations and Symbols
A Amperes
AAP Ambient Air Pressure
ABDC After Bottom Dead Centre
ABS Anti-Lock Brake System
ac Alternating current
A/C Air Conditioning
ACE Active Cornering Enhancement
ACEA Association of Constructors of
European Automobiles
AFR Air Fuel Ratio
AP Ambient Pressure
ASC Anti-shunt Control
ATC Air Temperature Control
ATDC After Top Dead Centre
BBDC Before Bottom Dead Centre
BBUS Battery Backed Up Sounder
BCU Body Control Unit
BDC Bottom Dead Centre
bhp Brake Horse Power
BP Boost Pressure
BPP Brake Pedal Position
BS British Standard
BTDC Before Top Dead Centre
C Celsius
CAN Controller Area Network
CD Compact Disc
CDC Centre Differential Control
CDL Central Door Locking
CD - ROM Compact Disc - Read Only
Memory
CFC Chlorofluorocarbon
CHMSL Centre High Mounted Stop Lamp
CKP Crankshaft Position
CLV Calculated Load Value
cm Centimetre
cm
2Square centimetre
cm3Cubic centimetre
CMP Camshaft Position
CPP Clutch Pedal Position
CO Carbon Monoxide
CO
2Carbon Dioxide
CR Common Rail
CVS Canister Vent Solenoid
deg. Degree, angle or temperature
dia. Diameter
DIN Deutsche Industrie Normen
(German Industrial Standards)
dc Direct current
DCV Directional Control Valve
DOHC Double Overhead Camshaft
DTI Dial Test Indicator
DFM Dual Mass Flywheel
DVD Digital Versatile Disc
EACV Electronic Air Control Valve EAT Electronic Automatic
Transmission
EBD Electronic Brake pressure
Distribution
ECD European Community Directive
ECM Engine Control Module
ECT Engine Coolant Temperature
ECU Electronic Control Unit
EDC Electronic Diesel Control
EEPROM Electronic Erasable
Programmable Read Only
Memory
EGR Exhaust Gas Recirculation
EKA Emergency Key Access
EN European Norm
EOBD European On Board Diagnostics
ETC Electronic Traction Control
EUI Electronic Unit Injector
EVAP Evaporative Emission
EVR Electronic Vacuum Regulator
F Fahrenheit
FBH Fuel Burning Heater
FIP Fuel Injection Pump
FTC Fast Throttle Control
g Gramme or Gravity
hHour
hc High compression
HC Hydro Carbons
HDC Hill Descent Control
HDPE High Density Polyethylene
HFS Heated Front Screen
Hg Mercury
HO2S Heated Oxygen Sensor
HMW High Molecular Weight
HRW Heated Rear Window
ht/HT High tension
IACV Idle Air Control Valve
IAT Intake Air Temperature
ICE In-Car Entertainment
i.dia. Internal diameter
IDM Intelligent Driver Module
in3Cubic inch
ILT Inlet Throttle
ISO International Organisation for
Standardisation
k Thousand
kg Kilogramme
km Kilometre
km/h Kilometres per hour
kPa KiloPascal
KS Knock Sensor
lLitre
lbf.in Pounds force inches
lbf/in
2Pounds per square inch
lbf.ft Pounds force feet