Fuel system LAND ROVER DISCOVERY 2002 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2002, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 2002Pages: 1672, PDF Size: 46.1 MB
Page 702 of 1672
MANUAL GEARBOX - R380
REPAIRS 37-19
32.Remove 8 bolts securing gearbox to engine.
33.With assistance, remove gearbox from engine.
Refit
1.Clean gearbox to engine mating faces, dowels
and dowel holes.
2.With assistance raise gearbox on jack and
align to clutch and engine.
3.Fit bolts securing gearbox to engine and
tighten to 50 Nm (37 lbf.ft).
4.Clean oil cooling pipe housing mating faces.
5.Lubricate and fit new 'O' rings to oil cooling
pipe housing.
6.Position cooling pipe housing, fit bolts and
tighten to 25 Nm (18 lbf.ft).
7. If fitted: Secure harness in retaining clips,
connect Lucars to differential lock warning
switch and multiplug to transfer box neutral
switch.
8.Position breather pipes and secure 'P' clip with
bolt.
9.Using new sealing washers fit breather pipe
banjo bolts and tighten to 15 Nm (11 lbf.ft).
10.Connect oil temperature sensor Lucars and
reverse lamp switch multiplug.
11.Position low ratio selector cable to housing and
secure with 'C' washer and clevis pin.
12.Secure cable to fuel pipes with new cable ties. 13.Raise gearbox, ensuring gear change lever is
located in grommet.
14.Fit gearbox mountings and tighten bolts to 85
Nm (63 lbf.ft).
15.Fit nuts to gearbox mountings and tighten to 48
Nm (37 lbf.ft).
16.Remove 3 bolts securing support plate to
gearbox.
17.Position clutch slave cylinder and heat shield,
fit bolts and tighten to 25 Nm (18 lbf.ft).
18.Clean handbrake back plate and mating face.
19.Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
20.Clean handbrake drum.
21.Fit handbrake drum and tighten retaining
screw.
22.Fit front propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front..
23.Fit rear propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
24.Clean exhaust silencer and tail pipe mating
faces.
25.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
26.Fit exhaust front pipe.
+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
27.Refit starter motor.
+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
28.Refill gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Manual gearbox.
29.Refill transfer gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fit gear lever extension, fit clamp bolt and
tighten to 25 Nm (18 lbf.ft).
31.Fit gear lever trim and gear change knob.
32.Connect battery earth lead.
33.Fit cooling fan cowl and battery cover and
secure fixings.
Page 748 of 1672
TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-15
High/low detect switch
A high/low detect switch is fitted in the front output housing and connects to earth when low is selected. The switch is
connected to the engine ECM, the SLABS ECU and the EAT ECU. The purpose of the switch is to enable selection
of the hill descent feature and to modify the engine fuelling and automatic gearbox gearshift maps stored within the
respective ECM's and ECU's.
Differential lock - Fitted to certain vehicles only
The differential lock selector housing is bolted to the top of the front output housing, the selector finger passes through
the housing, locating in a slot in the differential lock selector shaft. The differential lock selector shaft passes through
the selector fork which is located beneath a plate bolted to the side of the output housing. The selector fork engages
the dog clutch sleeve with the differential rear shaft when the splines of the sleeve and differential rear shaft are
aligned. A spring loaded detent ball fitted in the output housing locates in grooves in the shaft.
Functionality – Vehicles up to 03 model year only
The function of the differential lock used in previous applications is performed on this vehicle by the Electronic Traction
Control System. However, for the purposes of 2 wheel rolling road testing , the differential lock components are
retained. For all driving conditions however, the differential lock must be set in the unlocked position.
Up to 03 model year specification shown
The differential lock must only be engaged for 2 wheel rolling road testing as engagement of the lock disables the
traction control feature and inhibits correct operation of the electronic brake distribution and hill descent features. It
will also be necessary to disconnect the propeller shaft from the transfer box output shaft driving the axle whose
wheels are NOT on the rolling road. The lock may be engaged/disengaged by using a 10 mm open ended spanner
on the flats (arrowed) machined on the differential lock selector shaft.
Vehicles not fitted with a differential lock may be identified by there being no cover or selector shaft (arrowed) on the
front output housing.
WARNING: VEHICLES NOT FITTED WITH A DIFFERENTIAL LOCK MUST NOT BE TESTED ON A ROLLING
ROAD WHERE THE ROLLERS ARE DRIVEN BY THE VEHICLE.
Page 762 of 1672
TRANSFER BOX - LT230SE
REPAIRS 41-29
22.Remove 4 bolts and nut securing RH mounting
to body and transfer box.
23.Remove nut securing LH mounting to body.
24.Raise gearbox and remove RH mounting.
25.With assistance, remove transfer box from
gearbox.
26.Remove input shaft oil seal.
+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.
Refit
1.Fit new input shaft oil seal.
+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.
2.Clean transfer box to gearbox mating faces.
3.Raise transfer box on jack and align to guide
studs LRT-41-009.
4.Clean transfer box to gearbox bolt threads.
5.Apply Loctite 290 to bolt and stud threads.
6.Fit and lightly tighten 2 bolts and nut securing
transfer box to gearbox. If new stud is to be
fitted apply Loctite 290 to threads of stud
and tighten to 45 Nm (33 lbf.ft)
7.Remove guide studs, fit and lightly tighten 3
bolts.
8.Tighten bolts and nut by diagonal selection to
45 Nm (33 lbf.ft.
9.Position gearbox RH mounting and tighten
bolts to 85 Nm (63 lbf.ft).
10.Tighten gearbox RH mounting nut to 48 Nm
(35 lbf.ft).
11.Fit nut to LH mounting and tighten to 48 Nm (35
lbf.ft).
12.Remove 4 bolts securing support plate to
gearbox jack.
13.Remove 4 bolts securing support plate LRT-99-
010 to transfer box and remove plate.
14.Clean threads of bottom plate bolts.
15.Apply Loctite 290 to threads of bolts.
16.Fit 4 bolts securing bottom plate and tighten to
25 Nm (18 lbf.ft).
17.Using new washers position breather pipe and
tighten banjo bolt.
18.Connect multiplug to transfer box neutral switch
and secure harness. 19. If fitted - Connect Lucars to differential lock
switch.
20.Connect multiplug and Lucars to reverse lamp
switch and oil temperature sensor.
21.Position high/low ratio selector cable and
secure with 'C' washer and clevis pin.
22.Secure cable to fuel pipes with new cable ties.
23.Clean handbrake back plate and mating face.
24.Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
25.Clean handbrake drum.
26.Fit handbrake drum and tighten retaining
screw.
27.Fit front propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
28.Fit rear propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
29.Clean exhaust silencer and tail pipe mating
faces.
30.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
31.Position rear cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
32.Refill transfer box with oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
33.Fit front exhaust pipe.
+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
Page 1051 of 1672
BRAKES
70-6 DESCRIPTION AND OPERATION
For all control functions, the ABS modulator regulates the hydraulic pressure to the brakes to control the speed of all
four wheels, either individually or in axle pairs. Operation of the ABS modulator is controlled by the Self Levelling and
Anti-lock Braking Systems (SLABS) ECU. The SLABS ECU also operates warning indications in the instrument pack
to provide the driver with status information on each function.
Brake servo assembly
The brake servo assembly provides power assistance to reduce the pedal load when braking. If the brake servo
assembly fails, the hydraulic system still functions but will require greater brake pedal effort due to the lack of vacuum
assistance.
Two integral tie bolts attach the brake servo assembly to the pedal and bracket assembly on the engine bulkhead.
The master cylinder assembly is attached to the forward ends of the tie bolts.
The brake servo assembly consists of a circular housing which contains two diaphragms, a central plate, a control
valve assembly, input and output push rods and a filter. The input push rod is connected to the brake pedal. The output
push rod locates in the primary piston of the master cylinder. A protective gaiter is installed on the control valve
assembly where it extends from the rear of the housing. A non return valve, installed in a port in the front face of the
housing, is connected to a vacuum line from the engine.
The control valve assembly consists of a valve body containing a valve, a piston, a valve spring and an input rod
spring. The valve controls a vacuum port in the valve body. The piston controls an air inlet port between the valve and
the piston. A reaction disc and a ratio disc separate the piston from the output push rod. A guide tube on the front of
the valve body is attached to the front diaphragm and supported in a bush in the central plate. A return spring locates
in the open end of the guide tube.
The two diaphragms and the central plate separate the interior of the housing into four sealed chambers. The
chambers at the front of the diaphragms are connected together through fixed passages in the valve assembly. The
chambers at the rear of the diaphragms are connected together through the interior of minor diaphragms on the tie
bolts.
Brakes off
With the brake pedal released, the piston in the control valve assembly positions the valve so that the vacuum port is
open and the two pairs of chambers are connected together. When the engine is running air is evacuated through the
vacuum line and non return valve, creating a partial vacuum in all four chambers. When the engine stops, the non
return valve closes to maintain the partial vacuum and, on V8 models, prevent fuel vapour entering the brake servo.
Page 1289 of 1672
PANEL REPAIRS
77-2-40 REPAIRS
13.Fit front door striker to B/C post, fit Torx bolts
and tighten to 26 Nm (19 lbf.ft).
14.Fit rear door.
+ DOORS, REPAIRS, Door - rear.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
Panel body side assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove loadspace side trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
4.Remove head lining rear trim finisher.
5.Remove rear head rests, if fitted.
6.Remove body side rear glass.
+ SCREENS, REPAIRS, Glass - body
side - rear.
7.Remove rear bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - rear - up to 03MY.
8.Remove rear bumper finisher.
9.Remove rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - rear.
10.Remove mud flap.
11.Remove tread plate from rear door aperture.
12.Remove rear door aperture seal.
13.Remove rear door striker from 'D' post.
14.Remove 'D' post outer trim finisher.
15.Remove wheel arch trim finisher.
16.Remove side drip rail finisher.
17. RH side: Remove tail door.
18. LH side: Remove tail door striker and setting
block from 'E' post.
19.Remove tail door tread plate.
20.Remove loadspace carpet retainer.
21.Remove tail door aperture seal.
22.Remove tail lamp.
+ LIGHTING, REPAIRS, Lamp - tail.
23. RH side: Remove fuel filler flap.
24. RH side: Remove fuel filler tube.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
25.Remove aerial amplifier.
26.Remove relevant wiring from body side area.
Page 1290 of 1672
PANEL REPAIRS
REPAIRS 77-2-41
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. The panel
body side assembly does not require any
welding, as it is bolted into position.
Refit
1.Position and secure wiring.
2.Fit aerial amplifier.
3. RH side: Fit fuel filler tube.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
4. RH side: Fit fuel filler flap.
5.Fit tail lamp.
+ LIGHTING, REPAIRS, Lamp - tail.
6.Fit tail door aperture seal.
7.Fit loadspace carpet retainer.
8.Fit tail door tread plate.
9. LH side: Fit tail door striker and setting block to
'E' post, fit Torx bolts and tighten to 26 Nm (19
lbf.ft).
10. RH side: Fit tail door.
11.Fit side drip rail finisher.
12.Fit wheel arch trim finisher.
13.Fit 'D' post outer trim finisher.
14.Fit rear door striker.
15.Fit rear door aperture seal.
16.Fit tread plate to rear door aperture.
17.Fit mud flap.18.Fit rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - rear.
19.Fit rear bumper finisher.
20.Fit rear bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - rear - up to 03MY.
21.Fit body side rear glass.
+ SCREENS, REPAIRS, Glass - body
side - rear.
22.Fit rear head rests, if fitted.
23.Fit head lining rear trim finisher.
24.Fit loadspace side trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
25.Connect leads/multiplug to alternator.
26.Connect battery leads, negative lead last.
M77 0000
Page 1291 of 1672
PANEL REPAIRS
77-2-42 REPAIRS
Body side inner rear assembly
In this procedure, the panel body side assembly is
replaced in conjunction with the body side inner rear
assembly.
Remove
1.Disconnect battery eath lead.
2.Disconnect leads/multiplug from alternator.
3.Remove panel body side assembly.
+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
4.Remove RH or LH rear seat.
+ SEATS, REPAIRS, Seat - rear.
5.Remove loadspace carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
6.Remove rear side seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - side.
7.Remove third row seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
8.Remove fuel tank.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.
+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
9.Remove fuel filler tube.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
10. RH side: Remove fuel flap release solenoid.
+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Solenoid - fuel filler flap release.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Solenoid - fuel filler flap release.
11. RH side: Remove air extractor vent.
12.Remove relevant wiring.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit and secure wiring.
2. RH side: Fit air extractor vent.
3. RH side: Fit fuel flap release solenoid.
+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Solenoid - fuel filler flap release.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Solenoid - fuel filler flap release.
4.Fit fuel filler tube.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
5.Fit fuel tank.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.
+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
6.Fit third row seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
7.Fit rear side seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - side.
8.Fit loadspace carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
9.Fit rear seat.
+ SEATS, REPAIRS, Seat - rear.
10.Fit panel body side assembly.
+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
11.Connect leads/multiplug to alternator.
12.Connect battery leads, negative lead last.
M77 1698A
Page 1297 of 1672
PANEL REPAIRS
77-2-48 REPAIRS
Cross member outer rear panel (RH/LH
section)
In this procedure, the panel body side assembly and
the 'E' post assembly are replaced in conjunction
with either the RH or LH section of the cross member
outer rear panel.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove 'E' post assembly.
+ PANEL REPAIRS, REPAIRS, 'E' post
assembly.
4.Remove rear folding step.
+ EXTERIOR FITTINGS, REPAIRS,
Rear folding step.
5. LH side: Remove exhaust tailpipe heatshield.
6.Remove relevant wiring.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit and secure wiring.
2. LH side: Fit exhaust tailpipe heatshield.
3.Fit rear folding step.
+ EXTERIOR FITTINGS, REPAIRS,
Rear folding step.
4.Fit 'E' post assembly.
+ PANEL REPAIRS, REPAIRS, 'E' post
assembly.
5.Connect leads/multiplug to alternator.
6.Connect battery leads, negative lead last.
Cross member closing rear panel
In this procedure, the cross member outer rear panel
is replaced in conjunction with the cross member
closing rear panel. The cross member rear assembly
can also be replaced, if required.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove cross member outer rear panel.
+ PANEL REPAIRS, REPAIRS, Cross
member outer rear panel.
4.Remove fuel tank.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.
+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
5.Remove 2 rear bolts securing body rear to
chassis.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit 2 rear bolts securing body rear to chassis
and tighten to 45 Nm (33 lbf.ft).
2.Fit fuel tank.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.
+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
3.Fit cross member rear outer panel.
+ PANEL REPAIRS, REPAIRS, Cross
member outer rear panel.
4.Connect leads/multiplug to alternator.
5.Connect battery leads, negative lead last.
Page 1344 of 1672
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.
Page 1349 of 1672
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.