oil LAND ROVER DISCOVERY 2002 Workshop Manual

AIR CONDITIONING
REPAIRS 82-45
7.Disconnect A/C harness multiplugs from body
harness.
8.Remove 2 clips securing ducting to A/C
assembly and release ducting. 9.Remove 4 bolts securing evaporator assembly
and remove assembly.
Refit
1.Position evaporator assembly to body fit bolts
and tighten to 16 Nm (12 lbf.ft).
2.Position ducting to evaporator assembly and
secure with clips.
3.Connect harness multiplugs.
4.Position seat support bracket, fit bolts and
tighten to 24 Nm (18 lbf.ft).
5.Fit LH rear lower trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
6.Position grommet flange and tighten bolts.
7.Lubricate new 'O' rings with clean refrigerant oil
and fit to high and low pressure pipes.
8.Position high and low pressure pipes, fit bolts
and tighten to 10 Nm (7 lbf.ft).
9. V8 models: Position exhaust heat shield and
secure with clips.
10.Repressurise air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.

WIPERS AND WASHERS
DESCRIPTION AND OPERATION 84-9
The wiper blades are attached to the wiper arms with a clips that allow the blade to pivot. Each wiper blade comprises
a number of levers and yokes to which the rubber wiper is attached. The levers and yokes ensure that the pressure
applied by the arm spring is distributed evenly along the full length of the blade. The rubber wiper is held in the yokes
by a pair of stainless steel strips which also contribute to the even distribution of spring pressure along the blade. The
driver's side wiper blade is fitted with an aerofoil which presses the blade onto the screen at high speed. This prevents
the blade from lifting off the screen and maintains the wiping performance.
Front wash/ wipe switch
The front wash/ wipe switch is located on a stalk on the RH side of the steering column and allows the driver to control
the operation of the front wipers and the front washer pump.
Operating the washer switch provides battery voltage from fuse 19 in the passenger compartment fusebox to the
washer pump motor.
Operating the flick wipe function provides battery voltage from fuse 19 in the passenger compartment fuse box to the
high-speed brushes of the wiper motor.
Operating the intermittent function provides a battery voltage signal to the BCU. The BCU determines the wipe
interval from the variable delay switch and signals the IDM to activate the front wiper relay, which provides battery
voltage to the wiper motor.
Operating the low-speed function provides battery voltage from fuse 19 in the passenger compartment fuse box to
the low-speed brushes of the wiper motor.
Operating the high-speed function provides battery voltage from fuse 19 in the passenger compartment fuse box to
the high-speed brushes of the wiper motor

WIPERS AND WASHERS
DESCRIPTION AND OPERATION 84-15
Headlamp powerwash pump
The headlamp power wash pump consists of a DC motor with an impeller. It is located on the front of the washer fluid
reservoir.
The BCU controls operation of the headlamp power wash relay, which supplies battery voltage from fuse 4 located in
the engine compartment fuse box to the headlamp power wash pump. When the BCU determines headlamp power
wash is to be activated, it provides a ground path for the coil of the headlamp power wash relay. The auxiliary relay
located in the engine compartment fuse box supplies the headlamp power wash relay coil with battery voltage.

WIPERS AND WASHERS
REPAIRS 84-23
6.Remove nut securing linkage connecting rod to
wiper motor spindle.
7.Release link from motor spindle.
8.Remove 3 bolts securing motor to mounting
plate and remove motor.
Refit
1.Fit new wiper motor to mounting plate and
secure with bolts.
2.Connect link to motor spindle and tighten nut to
7 Nm (5.2 lbf.ft).
3.Fit motor and linkage to body, connect
multiplug. Tighten all fixings to 2.5 Nm (1.8
lbf.ft).
4.Fit plenum air intake.

+ HEATING AND VENTILATION,
REPAIRS, Plenum Air Intake.
Switch - wiper and washer - windscreen
$% 84.15.34
WARNING: It is imperative that before any work
is undertaken on the SRS system the appropriate
information is read thoroughly.
Remove
1.Remove rotary coupler.

+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler.
2.Release passive coil from steering column lock
and lower the coil without disconnecting the
harness.
3.Release front wiper delay multiplug from
column switch mounting bracket and
disconnect from harness.
4.Disconnect harness multiplug from wiper
switch.
5.Remove 2 screws securing switch, carefully
raise edge of switch bracket to clear location
peg and remove switch.
Refit
1.Fit new switch to bracket and secure with
screws.
2.Connect harness multiplug to switch.

WIPERS AND WASHERS
84-24 REPAIRS
3.Connect front wiper delay multiplug and fit
multiplug to switch bracket.
4.Fit passive coil to column lock.
5.Fit rotary coupler.

+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler.
Jet - washer - headlamp
$% 84.20.08
The procedure to remove the headlamp washer jet
on 03MY vehicles is detailed in the front bumper
finisher job.

+ EXTERIOR FITTINGS, REPAIRS, Trim
finisher - bumper - front - from 03MY.
Remove
1.Remove retaining screw cover from jet
housing.
2.Remove screw securing jet to bumper.
3.Release jet and withdraw sufficiently to gain
access to washer tube. Disconnect tube from
jet and remove jet.
Refit
1.Connect jet to washer tube, ensuring it is
pushed fully home.
2.Locate jet in bumper, retain with screw and fit
screw cover.

CHARGING AND STARTING
REPAIRS 86-1-1
CHARGING AND STARTING REPAIRS
Alternator - diesel
$% 86.10.02
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Release cover and remove nut securing lead
to alternator.
3.Disconnect alternator multiplug.
4.Remove bolt (LH thread) and remove auxiliary
drive belt tensioner. 5.Remove bolt securing support stay to
alternator.
6.Release clip and disconnect oil drain hose from
vacuum pump.
7.Disconnect vacuum pump oil supply pipe from
cylinder head and discard 'O' ring.
8.Remove bolt securing alternator and release
from mounting bracket.
9.Disconnect vacuum hose from vacuum pump.
10.Remove alternator. Take care not to damage
radiator cooling fins.
11.Remove 4 bolts, and remove vacuum pump
from alternator.
CAUTION: Always fit plugs to open
connections to prevent contamination.

CHARGING AND STARTING
86-1-2 REPAIRS
Refit
1.Clean mating faces of alternator and vacuum
pump.
2.Fit vacuum pump to alternator and tighten
bolts to 8 Nm (6 lbf.ft).
3.Position alternator to engine and connect
multiplug.
4.Connect vacuum hose and oil drain hose to
vacuum pump and secure clips.
5.With assistance align alternator to mounting
bracket and fit but do not tighten bolt.
6.Fit bolt securing support stay to alternator and
tighten to 25 Nm (18 lbf.ft) .
7.Tighten bolt securing alternator to mounting
bracket to 45 Nm (33 lbf.ft).
8.Using new 'O' ring, connect oil supply pipe to
cylinder head and tighten to 10 Nm (7 lbf.ft).
9.Connect lead to alternator and tighten nut to 6
Nm (4.4 lbf.ft).
10.Fit auxiliary drive belt tensioner and tighten bolt
to 50 Nm (37 lbf.ft).
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
Alternator - V8
$% 86.10.02
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Remove 2 bolts securing alternator to
mounting bracket.
3.Release alternator from mounting bracket
4.Remove nuts securing alternator cables, and
release cables.

BODY CONTROL UNIT
86-3-2 DESCRIPTION AND OPERATION
Power supply
Battery supply to the BCU and the IDM is provided through a 10 A fuse located in the engine compartment fuse box.
The BCU unit receives an ignition switched power supply (ignition switch position II) input via a 10 A fuse in the
passenger compartment fuse box.
The BCU receives a signal when the ignition switch is turned to the crank position, it then supplies an earth path to
the starter relay coil, to enable the crank operation by supplying power through the starter relay contacts to the starter
motor.
Battery voltage is monitored and BCU operation will function normally between 8 and 18 volts. Between 5.7 and 8
volts the BCU is in the 'under volts' state. The status of the battery is used to determine which outputs may be driven.
If a voltage supply above 18 volts is experienced, outputs will not normally be driven except for those functions which
are required during cranking (robust immobilisation, antenna coil, crank enable relay and feed to gear position switch
contacts W, X, Y, Z). In the over voltage state the vehicle can be driven, but all other functions are disabled and
outputs are switched off (power windows, heated screen, direction indicators etc.).
All functions are disabled on power up until communications between the BCU and IDM have been established. If
communications cannot be established, operation will commence with degraded functionality.
Battery supply to the IDM is provided through the inertia switch and a 10 A fuse in the engine compartment fuse box.
If the inertia switch contacts are closed battery voltage is available at the IDM; if the inertia switch contacts are open
there is no battery supply to the IDM. The supply condition of the IDM is signalled to the BCU via the serial bus. If the
inertia switch is operated (contacts open) the change in state is detected by the BCU which unlocks the doors if the
ignition switch is in position II and the alarm is not set.
The BCU is earthed through a hard-wire connection.
Inputs and outputs
The BCU and IDM process inputs and provide the necessary outputs for control and operation of the vehicle's 'body'
systems.
BCU inputs
The BCU processes signals received from the following components:
lDoor latch switches.
lDriver's door key lock/ unlock switches.
lBonnet activated security system.
lVolumetric sensors.
lCentral Door Locking (CDL) switches.
lRemote transmitter (via receiver unit).
lInertia fuel cut-off switch.
lIgnition switch.
lFuel flap release switch.
The input voltages (V
in) for BCU digital signals are defined as follows:
lLogic 1 when V
in ≥ 6V.
lLogic 0 when V
in ≤ 2V.
BCU input voltages between 2 and 6 volts are indeterminate and cannot be guaranteed.
Analogue input voltages are measured as a ratio with respect to battery voltage.

BODY CONTROL UNIT
DESCRIPTION AND OPERATION 86-3-3
BCU outputs
The BCU processes the input signals it receives and uses the information to determine the control outputs that need
to be established for any given set of conditions. The BCU provides controlled outputs for the following systems:
lInterior courtesy lamps.
lFuel flap release actuator.
lAnti-theft status LED.
lEngine Control Module.
lDoor lock actuators.
lDirection indicators and hazard warning lamps.
lHeadlamps.
lAlarm sounder.
lVehicle horns.
lBattery backed sounder.
lStarter relay.
lPassive re-mobilisation exciter coil.
Simultaneous switching of outputs in different units is limited by the bus transfer time, but the skew is no longer than
100 ms for either the BCU or the IDM. When the processor is reset, all outputs are switched off until the inputs have
been read for the first time to check current condition.
BCU to harness connectors
1Connector C0661
2Connector C0662
3Connector C0663
4Connector C0660
5Connector C0664

BODY CONTROL UNIT
DESCRIPTION AND OPERATION 86-3-5
C0661 connector pin details
Pin No. Description Input/Output
1 Serial bus to instrument pack and IDM Input/Output
2 Not used-
3 Battery backed up sounder code (AL) Output
4 Diagnostic bi-directional 'K'-line Input/Output
5 RF regulated power supply Output
6 RF receiver input Input
7 Brake switch activated Input
8 Reverse gear selected Input
9 Sunroof enable line Output
10 Robust immobilisation Output
11 Front washer pump Input
12 Heated front screen relay Output
13 Heated front screen active Output
14 Battery backed up sounder code (ST) Output
15 Heated rear screen active Output
16 'N' or 'R' or 'P' or brake selected Output
17 Not used-
18 Passive remobilisation exciter coil Output
19 RF battery supply from fuse 20 in passenger compartment fusebox Input
20 Security status LED Output
21 Front intermittent wiper Input
22 Driver's door key unlock Input