fuel pump LAND ROVER DISCOVERY 2002 Owners Manual

HEATING AND VENTILATION
80-10DESCRIPTION AND OPERATION
FBH unit
1Air inlet hose
2Electrical connectors
3Exhaust pipe
4Quick disconnect coupling5Coolant inlet hose
6Fuel supply line
7Circulation pump
8Coolant outlet hose
The FBH unit is installed on the bulkhead in the engine compartment, on the side opposite the brake servo, and is
connected in series in the coolant supply to the heater assembly. Two electrical connectors on the top of the FBH unit
connect to the vehicle wiring.
FBH unit connector pin details
Connector/Pin
No.Description Input/Output
C0925
2 K line (diagnostics) Input/Output
3 Alternator power supply Input
6 FBH fuel pump Output
C0926
1 Battery power supply Input
2Earth -

HEATING AND VENTILATION
DESCRIPTION AND OPERATION 80-11
Sectioned view of FBH unit
1Combustion air fan
2Burner housing
3ECU
4Heat exchanger
5Burner insert
6Exhaust
7Glow plug/flame sensor8Evaporator
9Coolant inlet
10Circulation pump
11Fuel inlet
12Coolant outlet
13Air inlet
The FBH unit consists of:
lA circulation pump.
lA combustion air fan.
lA burner housing.
lAn ECU/heat exchanger.
lAn air inlet hose.
lAn exhaust pipe.

HEATING AND VENTILATION
80-12DESCRIPTION AND OPERATION
Circulation pump. The circulation pump is installed at the coolant inlet to the FBH unit to assist the coolant flow through
the FBH unit and the heater assembly. The pump runs continuously while the FBH unit is in standby or active
operating modes. While the FBH unit is inactive, coolant flow is reliant on the engine coolant pump.
Combustion air fan. The combustion air fan regulates the flow of air into the unit to support combustion of the fuel
supplied by the FBH pump. It also supplies the air required to purge and cool the FBH unit. Ambient air is supplied to
the combustion air fan through an air inlet hose containing a sound deadening foam ring.
Burner housing. The burner housing contains the burner insert and also incorporates connections for the exhaust
pipe, the coolant inlet from the circulation pump and the coolant outlet to the heater assembly. The exhaust pipe
directs exhaust combustion gases to atmosphere at the bottom of the engine compartment.
The burner insert incorporates the fuel combustion chamber, an evaporator and a glow plug/flame sensor. Fuel from
the FBH fuel pump is supplied to the evaporator, where it evaporates and enters the combustion chamber to mix with
air from the combustion air fan. The glow plug/flame sensor provides the ignition source of the fuel:air mixture and,
once combustion is established, monitors the flame.
ECU/heat exchanger. The ECU controls and monitors operation of the FBH system. Ventilation of the ECU is
provided by an internal flow of air from the combustion air fan. The heat exchanger transfers heat generated by
combustion to the coolant. A sensor in the heat exchanger provides the ECU with an input of heat exchanger casing
temperature, which the ECU relates to coolant temperature and uses to control system operation. The temperature
settings in the ECU are calibrated to compensate for the difference between coolant temperature and the heat
exchanger casing temperature detected by the sensor. Typically: as the coolant temperature increases, the coolant
will be approximately 7
°C (12.6 °F) hotter than the temperature detected by the sensor; as the coolant temperature
decreases, the coolant will be approximately 2
°C (3.6 °F) cooler than the temperature detected by the sensor.

HEATING AND VENTILATION
DESCRIPTION AND OPERATION 80-13
Operation
Air distribution
Turning the distribution knob on the control panel turns the control flaps in the heater assembly to direct air to the
corresponding fascia and footwell outlets.
Air temperature
Turning the LH or RH temperature knob on the control panel turns the related blend flaps in the heater assembly. The
blend flaps vary the proportion of air going through the cold air bypass and the heater matrix. The proportion varies,
between full bypass no heat and no bypass full heat, to correspond with the position of the temperature knob.
Blower speed
The blower can be selected off or to run at one of four speeds. While the ignition is on, when the blower switch is set
to positions 1, 2, 3, or 4, ignition power energises the blower relay, which supplies battery power to the blower. At
switch positions 1, 2 and 3, the blower switch also connects the blower to different earth paths through the resistor
pack, to produce corresponding differences of blower operating voltage and speed. At position 4, the blower switch
connects an earth direct to the blower, bypassing the resistor pack, and full battery voltage drives the blower at
maximum speed.
Fresh/Recirculated inlet air
When the recirculated air switch is latched in, the amber indicator LED in the switch illuminates and an earth is
connected to the recirculated air side of the fresh/recirculated air servo motor. The fresh/recirculated air servo motor
then turns the control flaps in the air inlet duct to close the fresh air inlet and open the recirculated air inlets.
When the latch of the recirculated air switch is released, the amber indicator LED in the switch extinguishes and the
earth is switched from the recirculated air side to the fresh air side of the fresh/recirculated air servo motor. The fresh/
recirculated air servo motor then turns the control flaps in the air inlet duct to open the fresh air inlet and close the
recirculated air inlets.
FBH system (where fitted)
The FBH system operates only while the engine is running and the ambient temperature is less than 5
°C (41 °F).
With the engine running and the ambient temperature below 5
°C (41 °F), the air temperature sensor connects the
alternator power supply to the ECU in the FBH unit. On receipt of the alternator power supply, the ECU starts the
circulation pump and, depending on the input from the temperature sensor in the heat exchanger, enters either a
standby or active mode of operation. If the heat exchanger casing temperature is 65
°C (149 °F) or above, the ECU
enters a standby mode of operation. If the heat exchanger casing temperature is below 65
°C (149 °F), the ECU enters
an active mode of operation. In the standby mode, the ECU monitors the heat exchanger casing temperature and
enters the active mode if it drops below 65
°C (149 °F). In the active mode, the ECU initiates a start sequence and
then operates the system at full or part load combustion to provide the required heat input to the coolant.
Start sequence
At the beginning of the start sequence the ECU energises the glow plug function of the glow plug/flame sensor, to
preheat the combustion chamber, and starts the combustion air fan at slow speed. After 30 seconds, the ECU
energises the FBH fuel pump at the starting sequence speed. The fuel delivered by the FBH fuel pump evaporates in
the combustion chamber, mixes with air from the combustion air fan and is ignited by the glow plug/flame sensor. The
ECU then progressively increases the speed of the FBH fuel pump and the combustion air fan to either part or full
load speed, as required by the system. Once full or part load speed is achieved, the ECU switches the glow plug/flame
sensor from the glow plug function to the flame sensing function to monitor combustion. From the beginning of the
start sequence to stable combustion takes approximately 90 seconds for a start to part load combustion and 150
seconds for a start to full load combustion.

HEATING AND VENTILATION
80-14DESCRIPTION AND OPERATION
Coolant temperature control
When the ECU first enters the active mode, it initiates a start to full load combustion. Full load combustion continues
until the heat exchanger casing temperature reaches 60
°C (140 °F), when the ECU decreases the speed of the FBH
fuel pump and the combustion air fan to half speed, to produce part load combustion. The ECU maintains part load
combustion while the heat exchanger casing temperature remains between 54 and 65
°C (129 and 149 °F). If the heat
exchanger casing temperature decreases to 54
°C (129 °F), the ECU switches the system to full load combustion
again. If the heat exchanger casing temperature increases to 65
°C (149 °F), the ECU enters a control idle phase of
operation.
On entering the control idle phase, the ECU immediately switches the FBH fuel pump off, to stop combustion, and
starts a timer for the combustion air fan. After a 2 minute cooldown period, the ECU switches the combustion air fan
off and then remains in the control idle phase while the heat exchanger casing temperature remains above 59
°C (138
°F). If the heat exchanger casing temperature decreases to 59 °C (138 °F), within 15 minutes of the ECU entering the
control idle phase, the ECU initiates a start to part load combustion. If more than 15 minutes elapse before the heat
exchanger casing temperature decreases to 59
°C (138 °F), the ECU initiates a start to full load combustion.
In order to limit the build-up of carbon deposits on the glow plug/flame sensor, the ECU also enters the control idle
phase if the continuous part and/or full load combustion time exceeds 72 minutes. After the cooldown period, if the
heat exchanger casing is still in the temperature range that requires additional heat, the ECU initiates an immediate
restart to part or full load combustion, as appropriate.
Shutdown
The FBH system is de-activated when the alternator power supply to the FBH unit is disconnected, either by the
engine stopping or, if the ambient temperature increases to 5
°C (41 °F) or above, by the contacts in the air
temperature sensor opening. If the system is active when the alternator power supply is disconnected, the ECU de-
energises the FBH fuel pump to stop combustion, but continues operation of the combustion air fan and the circulation
pump to cool down the FBH unit. The cool down time depends on the combustion load at the time the alternator power
input is disconnected.
Cool down times
Diagnostics
The ECU in the FBH unit monitors the system for faults. Any faults detected are stored in a volatile memory in the the
ECU, which can be interrogated by Testbook. A maximum of three faults and associated freeze frame data can be
stored at any one time. If a further fault is detected, the oldest fault is overwritten by the new fault.
The ECU also incorporates an error lockout mode of operation that inhibits system operation to prevent serious faults
from causing further damage to the system. In the error lockout mode, the ECU immediately stops the FBH fuel pump,
and stops the combustion air fan and circulation pump after a cool down time of approximately 2 minutes. Error lockout
occurs for start sequence failures and/or combustion flameouts, heat exchanger casing overheat and out of limit input
voltage. The error lockout mode can be cleared using Testbook, or by disconnecting the battery power supply for a
minimum of 10 seconds.
Start failure/flameout. If a start sequence fails to establish combustion, or a flameout occurs after combustion is
established, the ECU immediately initiates another start sequence. The start failure or flameout is also recorded by
an event timer in the ECU. The event timer is increased by one after each start failure or flameout, and decreased by
one if a subsequent start is successful. If the event timer increases to three (over any number of drive cycles), the
ECU enters the error lockout mode.
Heat exchanger casing overheat. To protect the system from excessive temperatures, the ECU enters the error
lockout mode if the heat exchanger casing temperature exceeds 105
°C (221 °F).
Out of limit voltage. The ECU enters the error lockout mode if the battery or alternator power input is less than 10.5
±
0.3 V for more than 20 seconds, or more than 15.5
± 0.5 V for more than 6 seconds.
Combustion load Cool down time, seconds
Part 100
Full 175

ALARM SYSTEM AND HORN
86-4-16 DESCRIPTION AND OPERATION
Operation
Standard system functions
All vehicles have the following functions as standard.
lLocking.
lUnlocking.
lFuel cut off switch unlocking.
lInternal locking.
lElectric fuel flap release.
Locking
The doors are locked by pressing the lock button on the handset or by locking the vehicle from the driver's door with
the key.
In order to lock the vehicle, the following conditions must be met:
lThe driver's door is closed.
lThe ignition is off.
lThe fuel cut off switch is not tripped.
lThe bonnet is closed.
lThe vehicle is not super locked.
Depending on system configuration a mislock occurs if these conditions are not met. The doors may lock (depending
on condition not met) and the system may not fully arm, depending on configuration of the system. If a mislock occurs
an audible warning is emitted and the vehicle becomes partially armed.
Unlocking
The doors are unlocked by pressing the unlock button on the handset or by unlocking the vehicle from the driver's
door with the key. This may unlock only the driver's door or it may unlock all doors depending on system configuration.
Fuel cut off switch unlocking
In the event that the vehicle experiences a force strong enough to actuate the switch, all the doors on the vehicle
immediately unlock. The following conditions must be met for this to occur:
lThe security system is not armed.
lThe ignition is on.
This same action causes the fuel pump to shut off and disables the Engine Control Module (ECM). In some markets,
this action may also cause the direction indicators lights to flash.

INSTRUMENTS
88-10 DESCRIPTION AND OPERATION
Fuel tank sender unit
The fuel tank sender unit is combined with the pump. It contains a variable resistor with change in resistance
proportional to the change in level of fuel in the tank.
The resistance of the fuel tank sender unit in relation to tank contents and gauge display is shown in the table below:
The fuel tank sender unit input voltage feed is supplied from the fuel gauge. The earth path return circuit of the sender
unit is connected to the instrument pack.
Tank contents Sender resistance, ohms Gauge display
Empty 245 0
Full 19 1

INSTRUMENTS
88-30 DESCRIPTION AND OPERATION
Water sensor
On vehicles with diesel engines a water sensor is located in the bottom of the fuel filter. The sensor utilises the
different resistance properties between water and diesel fuel to determines the presence of water in the fuel.
The sensor receives a battery voltage supply from the fuel pump relay. The sensor output is supplied to the instrument
pack. The water sensor provides the earth path to illuminate the warning lamp.
l< 1.8 volts = warning lamp on.
l> 7.7 volts = warning lamp off.