oil LAND ROVER DISCOVERY 2002 Workshop Manual

HARNESSES
86-7-8 REPAIRS
35.Secure harness to LH side of body with cable
tie clips and retainers.
36.Connect and secure multiplugs to lower LH 'A'
post.
37.Feed harness through roof to centre.
38.Secure harness behind bonnet release cable.
39.Connect rear washer pipe at lower 'A' post and
secure with clip.
40.Secure harness to roof with clips.
41.Connect multiplug to interior mirror, ARC
accelerometer.
42.Position sound deadening panels and secure
with clips.
43.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
44.Fit fascia panel.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
Harness - engine - V8
$% 86.70.17
Remove
1.Remove upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
2.Disconnect injector multiplugs, release harness
from fuel rail.
3.Disconnect ignition coil multiplugs.

HARNESSES
86-7-12 REPAIRS
24.Remove bolt securing harness clip to LH side of
engine.
25.Disconnect camshaft sensor and oil pressure
switch multiplugs.
26.Remove engine harness. Refit
1.Position engine harness around engine.
2.Connect oil pressure switch and camshaft
sensor multiplugs.
3.Fit and tighten bolt securing harness to LH side
of engine.
4.Connect both knock sensor multiplugs.
5.Connect battery cable and solenoid cable to
starter motor.
6.Position starter heat shield and secure with
bolt.
7.Clean exhaust flange mating faces, using a
new gasket align exhaust fit nuts and tighten to
60 Nm (44 lbf.ft).
8.Remove stand(s) and lower vehicle.
9.Position harness into footwell and secure
grommet.
10.Connect ECM multiplugs.
11.Position toe board and secure with trim fixings.
12.Connect engine harness to main harness
multiplug and secure earth lead.
13.Connect EVAP solenoid multiplug.
14.Connect both fuse box multiplugs.
15.Position starter lead to fuse box and secure
screw.
16.Fit fuse box cover.
17.Position battery positive lead to battery and
secure nut.
18.Secure harness to coolant rail.
19.Position alternator cables and tighten terminal
B+ to 18 Nm (13 lbf.ft) and terminal D+ to 5 Nm
(3.7 lbf.ft)
20.Connect coolant temperature sensor multiplug.
21.Connect A/C compressor multiplug.
22.Secure harness clip to rear of LH cylinder head.
23.Connect CKP sensor multiplug.
24.Secure injector harness and connect injector
multiplugs.
25.Connect coil multiplugs.
26.Connect and secure HS
2O sensor multiplug
27.Fit upper inlet manifold.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
28.Connect battery earth lead.

HARNESSES
REPAIRS 86-7-13
Harness - engine - diesel
$% 86.70.17
Remove
1.Remove engine acoustic cover.
2.Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Battery carrier.
3.Remove engine compartment fuse box cover.
4.Remove bolts securing battery and alternator
leads to fuse box.
5.Remove bolt securing heater plug lead to fuse
box.
6.Disconnect 2 engine harness multiplugs from
fuse box. 7.Disconnect 2 engine harness multiplugs from
ECM and main harness.
8.Disconnect multiplug from EGR solenoid.
9.Disconnect multiplug from oil pressure switch.

HARNESSES
REPAIRS 86-7-15
15.Disconnect multiplug from MAP sensor.
16.Disconnect 4 glow plug connectors.
17.Release nut securing battery lead to alternator
and disconnect multiplug from alternator.
18.Disconnect injector multiplug.
19.Remove 2 bolts securing harness to front of
cylinder head.
20.Disconnect multiplug from ECT sensor. 21.Disconnect multiplugs from A/C compressor,
turbocharger solenoid valve, AAP sensor and
MAF sensor.
22.Release harness clips from coolant hose and
PAS hose.
23.Note the route of the engine harness, release
from underneath of inlet manifold and remove
from engine.
Refit
1.Position harness on engine.
2.Connect multiplugs to A/C compressor,
turbocharger solenoid valve, AAP and MAF
sensors.
3.Position harness clips to coolant and PAS
hoses.
4.Connect multiplug to ECT sensor.
5.Position harness to front of cylinder head and
tighten bolts to 10 Nm (7 lbf.ft).
6.Connect injector multiplug.
7.Connect multiplug and position battery cable to
alternator and tighten nut.
8.Connect multiplug to fuel temperature sensor.
9.Connect multiplug to MAP sensor.
10.Connect glow plugs.
11.Connect CKP sensor multiplug.
12.Connect Lucar to starter solenoid.
13.Connect battery lead to starter solenoid and
tighten nut to 10 Nm (7 lbf.ft).
14.Position harness clip to coolant pipe.
15.Locate harness over bell housing and connect
multiplug to oil pressure switch.
16.Connect 2 multiplugs to EGR solenoids.
17.Connect engine harness multiplug to ECM and
main harness.
18.Connect engine harness multiplugs to fuse
box.
19.Position glow plug lead to fuse box and tighten
bolt to 3.5 Nm (2.6 lbf.ft).
20.Position battery and alternator leads to fuse
box and tighten bolts to 6 Nm (4.4 lbf.ft).
21.Fit engine compartment fuse box cover.
22.Fit battery carrier.
23.Fit engine acoustic cover.

HARNESSES
86-7-24 REPAIRS
70.Release fusebox and disconnect 8 multiplugs.
71.Remove fusebox.
72.Disconnect 7 multiplugs from ignition passive
coil and steering column switch assembly.

HARNESSES
86-7-28 REPAIRS
18.Secure multiplugs to steering column support
bracket and connect brake and clutch pedal
multiplugs.
19.Connect multiplugs to column switch and
passive coil.
20.Position passenger compartment fusebox,
connect multiplugs, fit fusebox to fascia and
secure with nut.
21.Connect ignition switch multiplug to fuse box.
22.With assistance feed LH side of harness into
engine bay.
23.Connect multiplugs to front door harness and
body harness.
24.Position earth headers to LH lower 'A' post and
secure with nuts.
25.Connect multiplugs to ECU pack.
26.Position harness in engine bay.
27.Connect and secure heated front screen
multiplugs.
28.Fit plenum molding.

+ HEATING AND VENTILATION,
REPAIRS, Plenum Air Intake.
29.Connect multiplugs to ABS sensor and fuel
cut-off switch.
30.Using draw string feed harness through inner
wing, remove draw string, connect repeater
lamp multiplug and fit lamp.
31.Connect multiplugs to ABS modulator.
32.Feed harness through to front panel.
33.Position body earth leads and secure with
bolts.
34.Connect washer reservoir multiplugs and
pipes, secure pipes with clips.
35.Secure fog lamp multiplug.
36.Secure earth header behind headlamp.
37.Connect multiplugs to headlamp level motor,
headlamp and side lamp.
38.Fit indicator lamp

+ LIGHTING, REPAIRS, Lamp - front
repeater.
39.Connect multiplug to LH horn.
40.Feed harness to ACE accelerometer, connect
multiplug and secure with cable ties.
41.Connect cruise control, ABS sensor and brake
fluid level switch multiplugs.
42.Connect engine harness multiplug and feed
harness along RH wing to fuse box.
43.Using draw string pull harness through inner
wing, remove draw string, connect repeater
lamp multiplug and fit lamp. 44.Connect chassis harness multiplugs.
45.Position engine bay fuse box and connect
multiplugs, fit fuse box and secure with screws.
46.Connect multiplugs to front of fuse box.
47.Position battery and starter cables and secure
with screws.
48.Fit fuse box cover.
49.Position earth lead and secure with nut.
50.Feed harness through to front panel.
51.Secure fog lamp multiplug.
52.Connect headlamp level motor, headlamp and
side lamp multiplugs.
53.Fit indicator lamp.

+ LIGHTING, REPAIRS, Lamp - front
repeater.
54.Secure harness to RH front panel.
55.Connect cooling fan and horn multiplug.
56.Secure harness to lower support rail.
57.Connect receiver drier and air temperature
sensor multiplugs.
58.Fit front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
59.Fit battery tray.
60.Fit air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
61.Position both lower 'A' post trims and secure
with studs.
62.Fit heater assembly.

+ HEATING AND VENTILATION,
REPAIRS, Heater assembly - models with
air conditioning.

+ HEATING AND VENTILATION,
REPAIRS, Heater assembly - models
without air conditioning.

DRIVING AIDS
DESCRIPTION AND OPERATION 86-8-7
Sensors
Four sensors are positioned in the rear bumper. Each sensor comprises an outer housing with an angled rubber trim
which differs between the inner and outer sensors and the sensor body. The outer housing has a slot which engages
with a pin on the sensor body and is locked by rotating the sensor. A coil spring around the sensor is compressed
when the sensor is installed in the bumper and maintains the sensor housing engaged on the pin. The sensor housing
has a raised lip at the top which locates in a corresponding groove in the bumper mounting hole and sets the correct
orientation for the sensor body.
Each sensor has a three pin connector which connects into a common harness linking all four sensors. This harness
is connected to the main vehicle body harness. The three pins are for sensor negative and positive feeds and a signal
line.
Each sensor comprises a plastic housing which contains a piezoelectric disc. The disc resonates at a frequency of
38.4kHz, producing an ultrasonic signal output. The disc also receives the reflected echo signal.
The PDC ECU controls the operating mode of each sensor by output of a digital signal on the signal line. Each sensor
has two modes of operation; combined transmitter and receiver mode or receiver mode only.

INSTRUMENTS
DESCRIPTION AND OPERATION 88-1
INS TRUMENTS DESCRIPTION AND OPERAT ION
Instrument pack
1Hill descent control information warning lamp
2Overspeed warning lamp
3Brake system warning lamp
4Malfunction Indicator Lamp (MIL)
5Tachometer
6Direction indicator warning lamp
7Main beam warning lamp
8Direction indicator warning lamp
9Speedometer
10SRS warning lamp
11Off road mode warning lamp
12Glow plug warning lamp
13Trailer warning lamp
14Water in fuel filter warning lamp
15Transmission high temperature warning lamp
16Seat belt warning lamp17Fuel tank level gauge
18Low fuel level warning lamp
19LCD odometer/trip meter
20Anti-theft status warning lamp
21ABS warning lamp
22Gearbox manual/sport mode warning lamp
23Alternator charge warning lamp
24ACE warning lamp
25Oil pressure warning lamp
26SLS warning lamp
27Hill descent control warning lamp
28Engine coolant temperature gauge
29High coolant temperature warning lamp
30Traction control warning lamp
31Differential lock warning lamp
32Transfer box neutral warning lamp

INSTRUMENTS
88-2 DESCRIPTION AND OPERATION
Instrument component location - Engine
compartment / underneath vehicle
1ECM (diesel models)
2Alternator
3Glow plugs
4Transmission temperature sensor
5Water in fuel filter sensor
6Fuel tank sender unit
7Differential lock switch – vehicles up to 03
model year8Differential lock switches – vehicles from 03
model year (where fitted)
9Parking brake switch
10Brake fluid level switch
11Oil pressure switch

INSTRUMENTS
88-4 DESCRIPTION AND OPERATION
Instrument block diagram
1Instrument pack
2ECM
3Brake fluid level switch
4Parking brake switch
5Oil pressure switch
6Alternator
7Fuel tank sender unit
8Water in fuel filter sensor
9Transmission temperature sensor
10Differential lock switch - vehicles up to 03
model year or Differential lock switches -
vehicles from 03 model year11Audible warning speaker
12SRS DCU
13SLABS ECU
14BCU
15ACE ECU
16EAT ECU
17Diagnostic connector
18Serial communications link