LAND ROVER DISCOVERY 2002 Workshop Manual

PAINTING
77-5-2 PROCEDURES
Paint preparation
Paint refinishing
The following process must be adhered to for paint refinishing operations.
1Seal required exterior and interior seams with an approved seam sealer

+ BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.
2Repair any damage to underbody sealers

+ CORROSION PREVENTION AND SEALING, CORROSION PREVENTION, Corrosion prevention.
3Apply a two-pack paint refinishing system
4Apply cavity wax to all interior surfaces which have not received refinish paint
Paint repairs
Before carrying out paintwork repairs, clean the vehicle thoroughly using either a steam cleaner or high-pressure
washer.
Wash locally repaired areas using a mild water-mixable detergent and wipe them clean with solvent, immediately
before paint application.
Ensure that damaged paintwork which has led to exposed metal is abraded until the metal is clean, extending beyond
the area of the original damage. Treat the bare metal with an etch phosphate to remove all traces of rust and to provide
a key for new paint coats. Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer
or an integrated etch primer/filler, and follow with a two-pack paint system. Treat those surfaces not receiving paint
using an approved cavity wax, following paint operations.
aTwo-pack top coat
bTwo-pack primer filler and etch primer
cEtch phosphate
When heat curing paint repairs, the temperature must not exceed 65
°C (149°F). Temperatures above this
figure will cause the reflective elements within the headlamps and taillamps to distort.

HEATING AND VENTILATION
DESCRIPTION AND OPERATION 80-1
HEATING A ND VENT ILATION DESCRIPTION AND OPERAT ION
Heating and ventilation component
layout
RH drive shown, LH drive similar
1Control panel
2Outlet vent
3Rear footwell ducts
4Front footwell duct
5Air inlet duct
6Heater assembly

HEATING AND VENTILATION
80-2DESCRIPTION AND OPERATION
Fuel burning heater component layout
RH drive shown, LH drive similar
1FBH fuel line connection
2FBH unit
3Air temperature sensor
4FBH pump

HEATING AND VENTILATION
DESCRIPTION AND OPERATION 80-3
Description
General
The heating and ventilation system controls the temperature and distribution of air supplied to the vehicle interior. The
system consists of an air inlet duct, heater assembly, distribution ducts and a control panel. An outlet vent is
incorporated at the rear of the cabin. Some diesel models also incorporate a fuel burning heater (FBH) system in the
engine coolant supply to the heater assembly.
Fresh or recirculated air flows into the heater assembly from the inlet duct. An electrical variable speed blower in the
inlet duct, and/or ram effect, forces the air through the system. Depending on the settings on the control panel, the air
is then heated and supplied through the distribution ducts to fascia and floor level outlets.

HEATING AND VENTILATION
80-4DESCRIPTION AND OPERATION
Air inlet duct
RH drive shown, LH drive similar
1Air outlet
2Resistor pack
3Wiring harness
4Blower
5Blower relay6Recirculated air servo motor
7Recirculated air inlet
8Recirculated air inlet
9Fresh air inlet
10Control flap operating mechanism
The air inlet duct is installed behind the fascia, on the passenger's side. The air inlet duct is connected to the plenum
to provide the fresh air inlet. Two grilles in the air inlet duct provide recirculated air inlets from the cabin. Two control
flaps, operated by a servo motor, open and close the fresh and recirculated air inlets to control the source of incoming
air. Operation of the servo motor is controlled by a switch on the control panel.
The blower is installed between the air inlets and the outlet to the heater assembly, and consists of an open hub,
centrifugal fan powered by an electric motor. Operation of the blower is controlled by a slider switch on the control
panel, via a blower relay mounted on the air inlet duct and a resistor pack. The resistor pack is installed in the air outlet
from the blower fan, so that any heat generated is dissipated by the air flow. A wiring harness on the air inlet duct
connects the servo motor, blower motor, blower relay and resistor pack to the vehicle wiring.

HEATING AND VENTILATION
DESCRIPTION AND OPERATION 80-5
Heater assembly
1Windscreen and side window air outlet
2Face level air outlet
3Casing
4Rear footwell air outlet
5Front footwell air outlet
6Drain outlet
7Air inlet8Engine coolant return
9Engine coolant feed
10Heater matrix
11RH temperature control cable
12Distribution control cable
13LH temperature control cable
The heater assembly heats and distributes air as directed by selections made on the control panel. The assembly is
installed on the vehicle centre-line, between the fascia and the engine bulkhead. The heater assembly consists of a
casing, formed from a series of plastic moldings, which contains a heater matrix and control flaps. Internal passages
integrated into the casing guide the air through the casing and separate it into two flows, one for the LH outlets and
one for the RH outlets. Two drain outlets at the bottom of the casing connect to overboard drain tubes installed in the
sides of the transmission tunnel.
Heater matrix
The heater matrix provides the heat source to warm the air being supplied to the distribution outlets. The heater matrix
is an aluminium two pass, fin and tube heat exchanger, installed in the RH side of the casing. Two aluminium tubes
attached to the heater matrix extend through the engine bulkhead to connect the heater assembly to the engine
coolant system. When the engine is running, coolant is constantly circulated through the heater matrix by the engine
coolant pump. On diesel models, the coolant flow is assisted by an electric pump while the FBH system is active.

HEATING AND VENTILATION
80-6DESCRIPTION AND OPERATION
Control flaps
Control flaps are installed in the heater assembly to control the temperature and distribution of air. Blend flaps control
the temperature and distribution flaps control the distribution.
Temperature and distribution control
Figure shows flaps set for medium heat to face level and footwell outlets
1Windscreen/Side windows outlet
2Heater assembly casing
3Air inlet
4Heater matrix5Front footwells outlet
6Rear footwells outlet
7Face level outlet
Blend flaps:Two sets of three blend flaps, one LH and one RH, regulate the flow of air through the heater matrix and
a heater matrix bypass, to control the temperature of the air leaving the heater assembly. The two sets of blend flaps
operate independently to allow different temperatures to be set for the LH and RH outlets.
Each blend flap is attached to a spindle. The end of each spindle extends through the side of the heater casing and
is attached to a common lever mechanism on the related side of the casing. A control cable is installed between the
lever mechanism and the related temperature knob on the control panel. When the flow is split between the bypass
and the heater matrix, the two flows mix downstream of the heater matrix to produce an even air temperature at the
individual outlets.
Distribution flaps: Separate distribution flaps are installed to control the flow of air to the footwells, windscreen/side
windows and the LH and RH face level outlets. The distribution flaps are attached to spindles that extend through the
RH side of the heater casing and are attached to a common lever mechanism. A control cable is installed between
the lever mechanism and the distribution knob on the control panel.

HEATING AND VENTILATION
DESCRIPTION AND OPERATION 80-7
Distribution ducts
Separate distribution ducts are installed for the front and rear footwell outlets. Distribution ducts for the face level,
windscreen and side windows outlets are integrated into the fascia. The front footwell ducts are attached to ports at
the sides of the heater assembly. The rear footwell ducts locate in ports at the rear of the heater assembly and extend
along each side of the centre console to vent into the rear footwells from below the cubby box.
Vent assemblies in the fascia allow occupants to control the flow and direction of face level air. Each vent assembly
incorporates a thumbwheel to regulate flow and moveable vanes to control direction.

HEATING AND VENTILATION
80-8DESCRIPTION AND OPERATION
Control panel
The controls for heating and ventilation are installed on a control panel in the centre of the fascia, below the radio.
Three rotary knobs control the LH and RH outlet temperatures and distribution. A slider switch controls blower speed.
A latching pushswitch controls the selection of fresh/recirculated air; an amber LED in the switch illuminates when
recirculated air is selected.
Graphics on the panel and the controls indicate the function and operating positions of the controls.
Outlet vent
The outlet vent promotes the free flow of heating and ventilation air through the cabin. The outlet vent is installed in
the RH rear quarter body panel and vents cabin air into the sheltered area between the rear quarter body panel and
the outer body side panel. The vent consists of a grille covered by soft rubber flaps and is effectively a non-return
valve. The flap opens and closes automatically depending on the differential between cabin and outside air pressures.
FBH system (diesel models only)
The FBH system is an auxiliary heating system that compensates for the relatively low coolant temperatures inherent
in the diesel engine. At low ambient temperatures, the FBH system heats the coolant supply to the heater assembly,
and maintains it within the temperature range required for good in-car heating performance. Operation is fully
automatic, with no intervention required by the driver.
The system consists of an air temperature sensor, a FBH fuel pump and a FBH unit. Fuel for the FBH system is taken
from the fuel tank, through a line attached to the fuel tank's fuel pump, and supplied via the FBH fuel pump to the FBH
unit. The connection on the fuel tank's fuel pump incorporates a tube which extends down into the tank. At the FBH
unit connection, the fuel line incorporates a self-sealing, quick disconnect coupling. In the FBH unit, the fuel delivered
by the FBH fuel pump is burned and the resultant heat output is used to heat the coolant. An ECU integrated into the
FBH unit controls the operation of the system at one of two heat output levels, 2.5 kW at part load and 5 kW at full load
Ambient temperature sensor
The ambient temperature sensor controls a power supply from the alternator to the FBH unit. The sensor is installed
on the RH support strut of the bonnet closing panel and contains a temperature sensitive switch that is closed at
temperatures below 5
°C (41 °F) and open at temperatures of 5 °C (41 °F) and above.

HEATING AND VENTILATION
DESCRIPTION AND OPERATION 80-9
FBH fuel pump
The FBH fuel pump regulates the fuel supply to the FBH unit. The FBH fuel pump is installed in a rubber mounting on
the chassis crossmember immediately in front of the fuel tank. The pump is a self priming, solenoid operated plunger
pump, with a fixed displacement of 0.063 ml/Hz. The ECU in the FBH unit outputs a pulse width modulated signal to
control the operation of the pump. When the pump is de-energised, it provides a positive shut-off of the fuel supply to
the FBH unit.
FBH fuel pump nominal operating speeds/outputs
Sectioned view of FBH fuel pump
1Solenoid coil
2Plunger
3Filter insert
4Fuel line connector
5'O' ring seal6Spring
7Piston
8Bush
9Fuel line connector
10Non return valve
The solenoid coil of the FBH fuel pump is installed around a housing which contains a plunger and piston. The piston
locates in a bush, and a spring is installed on the piston between the bush and the plunger. A filter insert and a fuel
line connector are installed in the inlet end of the housing. A non return valve and a fuel line connector are installed
in the fuel outlet end of the housing.
While the solenoid coil is de-energised, the spring holds the piston and plunger in the 'closed' position at the inlet end
of the housing. An 'O' ring seal on the plunger provides a fuel tight seal between the plunger and the filter insert,
preventing any flow through the pump. When the solenoid coil is energised, the piston and plunger move towards the
outlet end of the housing, until the plunger contacts the bush, and draw fuel in through the inlet connection and filter.
The initial movement of the piston also closes transverse drillings in the bush and isolates the pumping chamber at
the outlet end of the housing. Subsequent movement of the piston then forces fuel from the pumping chamber through
the non return valve and into the line to the FBH unit. When the solenoid coil de-energises, the spring moves the piston
and plunger back towards the closed position. As the piston and plunger move towards the closed position, fuel flows
passed the plunger and through the annular gaps and transverse holes in the bush to replenish the pumping chamber.
Operating phase Speed, Hz Output, l/h (US galls/h)
Start sequence 0.70 0.159 (0.042)
Part load 1.35 0.306 (0.081)
Full load 2.70 0.612 (0.163)