ECU LAND ROVER DISCOVERY 2002 Workshop Manual

EMISSION CONTROL - V8
17-2-48 REPAIRS
Sensor - heated oxygen (HO2S) - post-
catalytic converter
$% 19.22.17
Remove
1.Raise vehicle on ramp.
2.Release HO
2S multiplug from support bracket.
3.Disconnect HO
2S multiplug from harness.
4.Using a 22 mm crowsfoot spanner, remove
HO
2S.
CAUTION: HO2 sensors are easily damaged
by dropping, excessive heat or
contamination. Care must be taken not to
damage the sensor housing or tip.Refit
1.Clean sensor and exhaust pipe mating
surfaces.
2.If refitting existing sensor, apply anti-seize
compound to sensor threads.
WARNING: Some types of anti-seize
compound used in service are a health
hazard. Avoid skin contact.
NOTE: A new HO2 sensor is supplied pre-
treated with anti-seize compound.
3.Fit a new sealing washer to HO
2S
4.Fit HO
2S and tighten to 45 Nm (33 lbf.ft).
5. Connect HO
2S multiplug to harness and fit
harness to bracket.
6.Secure harness to clip.
7.Lower vehicle.

EMISSION CONTROL - V8
REPAIRS 17-2-49
Control Valve - Secondary Air Injection
(SAI)
$% 17.25.02
Remove
1.Release clip and disconnect air hose from
valve.
2.Disconnect vacuum hose from valve.
3.Remove 2 bolts securing valve to air manifold.
4.Remove valve and discard gasket.
Refit
1.Clean SAI control valve and mating face on
manifold.
2.Fit new gasket and fit valve. Tighten bolts to 10
Nm (7 lbf.ft).
3.Connect vacuum hose.
4.Connect air hose and secure with clip.
Reservoir - Vacuum - Secondary Air
Injection (SAI) - up to 03MY
$% 17.25.04
Remove
1.Disconnect 2 vacuum hoses from reservoir.
2.Remove bolt securing reservoir to mounting
bracket and collect reservoir.
Refit
1.Position reservoir to mounting bracket and
tighten bolt to 10 Nm.
2.Connect vacuum hoses to reservoir.
M17 0222
1
2
3
4
M17 0227
2
1
1

EMISSION CONTROL - V8
17-2-50 REPAIRS
Reservoir - vacuum - Secondary Air
Injection (SAI) - from 03MY
$% 17.25.04
Remove
1.Disconnect 2 vacuum pipes from air reservoir.
2.Remove bolt securing air reservoir to air pump
and remove the reservoir.
Refit
1.Position air reservoir to air pump, fit bolt and
tighten to 10 Nm (7 lbf.ft).
2.Connect vacuum pipes to the air reservoir.
Pump - Air - Secondary Air Injection
(SAI)
$% 17.25.07
Remove
1.Disconnect multiplug from air pump.
2.Release clip and disconnect air hose from air
pump.
3.Remove bolt securing air pump bracket to
body.
4.Remove air pump and bracket assembly.
5.Remove 3 nuts securing bracket to air pump
and collect bracket.
6.Remove 3 mountings from air pump.
Refit
1.Fit mountings to air pump and tighten to 10
Nm.
2.Fit bracket to air pump mountings and tighten
nuts to 10 Nm.
3.Position air pump assembly and tighten bolt to
20 Nm.
4.Connect air hose to SAI pump.
5.Connect multiplug to air pump.
M17 0225
2
1
3
4
M17 0226
5
5
6

EMISSION CONTROL - V8
REPAIRS 17-2-51
Air Manifold - LH - Secondary Air
Injection (SAI)
$% 17.25.17
Remove
1.Remove SAI control valve.

+ EMISSION CONTROL - V8,
REPAIRS, Control Valve - Secondary Air
Injection (SAI).
2.Loosen 2 union nuts securing air manifold to
cylinder head adaptors.
3.Remove 2 nuts securing air manifold bracket to
inlet manifold.
4.Remove air manifold.
Refit
1.Clean air manifold and cylinder head adaptors.
2.Fit air manifold and start union nuts.
3.Fit nuts securing air manifold to inlet manifold.
4.Tighten air manifold unions to 25 Nm.
5.Fit SAI control valve.

+ EMISSION CONTROL - V8,
REPAIRS, Control Valve - Secondary Air
Injection (SAI).
Air Manifold - RH - Secondary Air
Injection (SAI)
$% 17.25.18
Remove
1.Remove SAI control valve.

+ EMISSION CONTROL - V8,
REPAIRS, Control Valve - Secondary Air
Injection (SAI).
2.Remove heater feed pipe.

+ HEATING AND VENTILATION,
REPAIRS, Pipe - Heater - Feed.
3.Loosen 2 union nuts securing air manifold to
cylinder head adaptors.
4.Remove nut securing air manifold bracket to
inlet manifold.
5.Remove air manifold.
Refit
1.Clean air manifold and cylinder head adaptors.
2.Fit air manifold and start union nuts.
3.Fit nut securing air manifold to inlet manifold.
4.Tighten air manifold unions to 25 Nm.
5.Fit heater feed pipe.

+ HEATING AND VENTILATION,
REPAIRS, Pipe - Heater - Feed.
6.Fit SAI control valve.

+ EMISSION CONTROL - V8,
REPAIRS, Control Valve - Secondary Air
Injection (SAI).
M17 0234
4
3
2
2
M17 0223
43
3
5

EMISSION CONTROL - V8
17-2-52 REPAIRS
Solenoid - Vacuum - Secondary Air
Injection (SAI)
$% 17.25.47
Remove
1.Release multiplug from solenoid.
2.Disconnect 2 vacuum hoses from solenoid.
3.Release solenoid from mounting bracket and
remove.
Refit
1.Secure solenoid to mounting bracket.
2.Connect vacuum hoses and multiplug to
solenoid.
Pipe - Secondary Air Injection (SAI)
$% 17.25.59
Remove
1.Loosen clip securing RH SAI control valve hose
to air injection pipe.
2.Release hose from air injection pipe.
3.Loosen clip securing SAI pump hose to air
injection pipe.
4.Release hose from air injection pipe.
5.Loosen clip securing LH SAI control valve hose
to air injection pipe.
6.Release hose from air injection pipe.
7.Disconnect multiplug from SAI vacuum
solenoid.
M17 0236
1
2
2
3
M17 0230

EMISSION CONTROL - V8
REPAIRS 17-2-53
8.Remove 2 nuts securing air injection pipe to air
intake plenum.
9.Release pipe from clip on rear of air intake
plenum.
10.Release 3 clips securing harness to engine bay
bulkhead.
11.Position container to collect any coolant
spillage.
12.Release clips securing heater hoses to heater.
13.Release hoses from heater.
14.With assistance, manoeuvre air injection pipe
from engine bay.Refit
1.With assistance, manoeuvre air injection pipe
into engine bay and secure onto clip at rear of
air intake plenum.
2.Connect heater hoses to heater and secure
with clips.
3.Reposition harness along engine bay bulkhead
and secure with clips.
4.Fit and tighten nuts securing air injection pipe to
air intake plenum.
5.Connect multiplug to SAI vacuum solenoid.
6.Connect air pump hose to air injection pipe and
secure with clip.
7.Connect LH and RH SAI control valve hoses to
air injection pipe and secure with clips.
8.Remove container.
9.Top up engine coolant.

+ MAINTENANCE, PROCEDURES,
Cooling system.
M17 0231
M17 0232
M17 0233

EMISSION CONTROL - V8
17-2-54 REPAIRS
Pump - Fuel Leak Detection - up to 03MY
$% 17.45.41
Remove
1.Raise the vehicle on lift.
2.Disconnect multiplug from fuel leak detection
pump.
3.Release leak detection air filter hose from top of
pump.
4.Remove 3 Torx screws securing pump to
mounting bracket.
5.Remove clip securing EVAP canister hose to
pump.
6.Release EVAP canister hose from pump.
7.Remove pump.
Refit
1.Connect EVAP canister hose to pump and
secure with clip.
2.Position pump to mounting bracket and secure
with Torx screws.
3.Connect leak detection air filter hose to top of
leak detection pump.
4.Connect multiplug to pump.
5.Lower vehicle.
Pump - fuel leak detection - from 03MY
$% 17.45.41
Remove
1.Raise the vehicle on lift.
2.Disconnect multiplug from the fuel leak
detection pump.
3.Remove 3 screws securing the fuel leak
detection pump to the chassis mounting
bracket.
4.Position absorbent cloth around fuel hoses to
collect any fuel spillage.
5.Disconnect the fuel leak detection filter pipe
from the fuel leak detection pump.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove and discard clip securing EVAP pipe
to the fuel leak detection pump and disconnect
the pipe.
7.Remove the fuel leak detection pump.
Refit
1.Connect the EVAP pipe to the fuel leak
detection pump and secure with a new clip.
2.Connect the fuel leak detection filter pipe to the
fuel leak detection pump.
3.Remove absorbent cloth.
4.Fit and tighten 3 screws securing the fuel leak
detection pump to the chassis mounting
bracket.
5.Connect multiplug to the fuel leak detection
pump.
6.Lower the vehicle lift.
M17 0235
2
3
4
57

EMISSION CONTROL - V8
REPAIRS 17-2-55
Filter - fuel leak detection pump - up to
03MY
$% 17.45.42
Remove
1.Remove bolt securing air filter to mounting
bracket and collect nut.
2.Remove clip securing hose to air filter.
3.Release hose from air filter.
4.Remove air filter.
Refit
1.Connect hose to air filter and secure with clip.
2.Position air filter to mounting bracket and
secure with nut and bolt.
Filter - fuel leak detection pump - from
03MY
$% 17.45.42
Remove
1.Remove Allen bolt securing fuel leak detection
pump filter to the mounting bracket.
2.Remove and discard clip securing fuel pipe to
the fuel leak detection pump filter and
disconnect the pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
3.Remove the fuel leak detection pump filter.
Refit
1.Connect fuel pipe to the fuel leak detection
pump and secure with a new clip.
2.Position fuel leak detection pump filter to
mounting bracket, fit Allen bolt and tighten to 3
Nm (2.2 lbf.ft).
17M 0224

ENGINE MANAGEMENT SYSTEM - TD5
DESCRIPTION AND OPERATION 18-1-5
1Mass air flow sensor
2Ambient air pressure sensor
3Manifold absolute pressure/ inlet air
temperature sensor
4Engine coolant temperature sensor
5Crankshaft speed and position sensor
6Throttle position sensor
7Fuel temperature sensor
8Brake pedal switch
9Clutch switch
10High/ Low ratio switch
11Main relay
12Malfunction indicator lamp
13Fuel pump relay
14Glow plug warning lamp
15Glow plugs16Electronic unit injectors
17Turbocharger wastegate modulator
18EGR modulator
19Diagnostic connector
20Engine control module
21Cruise control master switch
22Cruise control SET+ switch
23Cruise control RES switch
24Air conditioning clutch relay
25Air conditioning cooling fan relay
26Electronic automatic transmission ECU
27Self levelling and anti-lock brakes ECU
28Instrument cluster
29Body control unit

ENGINE MANAGEMENT SYSTEM - TD5
DESCRIPTION AND OPERATION 18-1-9
Connector C0658
Pin No. Input/Output Function Signal type Value Interfaces
B1 Input Earth 1 0 volts 0 volts
B2 Input Earth 4 0 volts 0 volts
B3 Input Supply battery voltage 12 volts 12 volts
B4 Output Cooling fan relay Switch 12-0 volts A/C ECU
B5 Output Fuel pump relay Switch 12-0 volts
B6 Output MIL Switch 12-0 volts Instruments
B7 Output Temperature gauge Digital 0-12 volts Instruments
B8 Not used
B9 Input A/C clutch request Switch 12-0 volts A/C ECU
B10 Input Normally closed brake
switchSwitch 12-0 volts
B11 Input Cruise control SET+ switch Switch 12-0 volts
B12 Input TP sensor 1 Analogue 0- 5 volts
B13 Input Vehicle speed Digital 0-12 volts
B14 Input TP sensor supply 5 volts 5 volts
B15 Input Cruise control master switch Switch 12-0 volts
B16 Input Normally open brake switch Switch 0-12 volts
B17 Input Cruise control RES switch Switch 12-0 volts
B18 Input/Output Serial communication link Digital 0-12 volts All ECU's
B19 Output Tachometer engine speed Digital 0-12 volts Instrument
Cluster
B20 Not used
B21 Output Main relay Switch 0-12 volts
B22 Input Supply battery voltage 12 volts 12 volts
B23 Input A/C fan request Switch 12-0 volts
B24 Input Earth 3 0 volts 0 volt
B25 Input Earth 2 0 volts 0 volts
B26 Input TP sensor earth 0 volts 0 volts
B27 Input Supply 2 12 volts 12 volts
B28 Not used
B29 Output A/C relay Switch 12-0 volts
B30 Output Glow plug warning light Switch 12-0 volts Instrument
Cluster
B31 Not used
B32 Output ABS digital 0-5 volts SLABS
B33 Input Ignition Switch 0-12 volts
B34 Input Security code digital 0-5 volts
B35 Input Clutch switch Switch 12-0 volts
B36 Input TP sensor 2 Analogue 5-0 volts