steering wheel LAND ROVER DISCOVERY 2002 Repair 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 1143 of 1672
EXTERIOR FITTINGS
76-2-6 REPAIRS
4.Drill out 2 rivets securing mud flap to wheel
arch liner.
5.Remove mud flap.
6.Drill out rivet securing wheel arch liner to
support bracket.
7.Drill out 3 rivets securing wheel arch liner to
body.
8.Remove wheel arch liner.
Refit
1.Position wheel arch liner to vehicle and secure
to body with rivets.
2.Fit rivet securing wheel arch liner to support
bracket.
3.Fit mud flap to wheel arch liner and secure with
rivets.
4.Fit rear bumper side section to body and
secure with screws.
5.Fit trim clips securing mud flaps to side section.
Panel - underbelly
$% 76.10.50
Remove
1.Raise front of vehicle, support underbody and
lower front axle
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove nut securing drag link to drop arm.
3.Using tool LRT-57-036 break taper joint and
release drag link from drop arm.
4.Remove nut and bolt securing steering damper
to chassis and remove damper.
5.Remove 7 screws securing underbelly panel.
6.Remove underbelly panel.
7.Remove 7 studs securing sound deadening to
underbelly panel.
8.Remove sound deadening.
Refit
1.Position sound deadening to underbelly panel
and secure with studs.
2.Fit underbelly panel and secure with screws.
3.Position steering damper, fit nut and bolt and
tighten to 125 Nm (92 lbf.ft)
4.Fit drag link to drop arm and tighten nut to 80
Nm (59 lbf.ft).
5.Lower front of vehicle.
Page 1162 of 1672
INTERIOR TRIM COMPONENTS
REPAIRS 76-3-9
16.Remove console.
NOTE: Do not carry out further dismantling if
component is removed for access only.
17.Remove 4 screws securing storage bin lid to
console and remove lid.
18.Release cigar lighter body from console and
remove.
Refit
1.Fit and secure cigar lighter body to console.
2.Fit lid to console and secure with screws.
3.Fit console.
4.Connect multiplug and bulb to cigar lighter.
5.Fit centre console to fascia.
6.Fit 2 bolts securing rear of console to
transmission tunnel.
7.Connect multiplugs to seat switches.
8.Fit switches to console.
9.Move handbrake to lowered position.
10.Fit cable to handbrake and secure with clevis
pin and clip.
11.Fit handbrake gaiter to console.
12.Fit bolts securing forward edge of console to
transmission tunnel.
13. Models with veneer trim: Position veneered
console cover and connect multiplugs to switch
pack. Fit cigar lighter element and secure
veneered console cover to console.
14. Models with base trim: Connect multiplugs to
switch pack, fit switch pack to console and
secure with screws.
15. Models with base trim: Fit cover plate to
switch pack, and rubber mat to console.
16.Fit transfer gearbox gaiter and knob to lever.
17.Secure gaiter to console.
18.Fit knob and gaiter to gear lever and secure
gear lever gaiter to console with clips.
19. Models from 03MY:Fit both centre console
cup holders.
Fascia
$% 76.46.23/99
Remove
1.Remove the key from the starter switch.
Disconnect both battery leads, negative lead
first. Wait ten minutes before starting work.
2.Remove radio cassette player.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio cassette player.
3.Remove steering wheel.
+ STEERING, REPAIRS, Steering
wheel.
4.Remove steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
steering column.
5.Remove centre console.
lFor models with automatic gearbox:
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
lFor models with manual gearbox:
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
6.Remove 'A' post trim panels.
Page 1165 of 1672
INTERIOR TRIM COMPONENTS
76-3-12 REPAIRS
25.Remove 4 bolts securing lower edge of fascia
to mounting brackets on transmission tunnel.
26.Remove 4 bolts securing lower edge of fascia
to brackets on 'A' post.
27.With assistance carefully remove fascia from
vehicle.
28.If renewing fascia, transfer components to new
fascia as necessary.
Refit
1.With assistance carefully fit fascia and tighten
bolts securing lower edge of fascia to 26 Nm
(19 lbf.ft).
2.Tighten bolts securing fascia to body to 26 Nm
(19 lbf.ft).
3.Fit nuts securingfascia to steering column
bracket to 11 Nm (8 lbf.ft).
4.Secure coaxial cables to fascia and secure blue
multiplug to main ICE multiplug.
5. Models with A/C: Connect heater control
multiplug.
6. Models without A/C: Connect temperature
and air distribution inner cables to heater
control levers. Set temperature control knobs to
fully hot, distribution knob to demist position
and, with flap levers fully closed, secure outer
cables to clips on heater casing.
7.Connect multiplugs to blower motor and
passenger air bag (where fitted).
8.Fit glove box and secure with bolts.
9.Connect fascia harness multiplugs to main
harness and fuse box.
10.Position instrument pack and connect
multiplugs.11.Fit instrument pack to fascia and secure with
screws.
12.Position instrument cowl and connect
multiplugs to switches.
13.Fit cowl to clips on fascia and secure with
screws.
14.Fit fascia access panel.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Panel - fascia access - driver's
side.
15.Fit fascia lower closing panels and secure with
clips.
16.Fit fascia mats.
17.Fit 'A' post trim panels.
18.Fit centre console
lFor models with automatic gearbox:
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
lFor models with manual gearbox:
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
19.Fit steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
steering column.
20.Fit steering wheel.
+ STEERING, REPAIRS, Steering
wheel.
21.Fit radio cassette player.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio cassette player.
22.Connect battery.
Page 1283 of 1672
PANEL REPAIRS
77-2-34 REPAIRS
Refit
1.Fit windscreen side finisher.
+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
2.Fit insulation pad to engine bulkhead.
3.Fit front mud flap.
4.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
5.Fit wiring harness to valance assembly.
6. Models with A/C: Fit A/C pipes to valance
assembly.
7.Fit PAS/ACE reservoir.
8.Fit brake pipes to valance assembly.
9. LHD models: Fit brake servo.
+ BRAKES, REPAIRS, Servo - brake.
10.Fit ABS modulator unit.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
11.Fit front bulkhead assembly.
+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
12.Connect leads/multiplug to alternator.
13.Connect battery leads, negative lead last.
'A' post assembly
In this procedure, the front wing and the valance
outer reinforcement (rear section) are replaced in
conjunction with the 'A' post assembly. The dash side
assembly can also be replaced in this procedure if
required.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove bonnet.
4.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
5.Remove RH or LH front door.
+ DOORS, REPAIRS, Door - front.
6.Remove RH or LH sill finisher.
7.Remove windscreen.
+ SCREENS, REPAIRS, Windscreen.
8. Diesel models: Remove ECM.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Engine control module
(ECM).
9.Remove RH or LH 'A' post inner finishers and
disconnect speaker multiplug (if fitted).
10.Release sunroof drain tube and position aside.
11.Remove RH or LH front seat.
+ SEATS, REPAIRS, Seat - front.
12. RH side: Remove CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
13.Remove fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
14. Driver's side: Remove steering column
support bracket.
15.Remove relevant wiring from 'A' post.
16.Remove tread plate from front door aperture.
17.Release front carpet and position aside.
18.Remove front door aperture seal.
19.Remove engine bulkhead insulation.
Page 1429 of 1672
WIPERS AND WASHERS
84-8 DESCRIPTION AND OPERATION
Description
General
All markets have a common wiper system with headlamp powerwash as an option.
The wipers system comprises two front wipers and one rear wiper which are powered by electric motors. A washer
reservoir is located in the front left hand wheel arch and is fitted with two electric pumps. Each pump supplies washer
fluid to either the front or rear screens. On certain models, a third pump can be fitted to operate a headlamp power
wash function. Operation of the front and rear wipers and washers is controlled by the driver using switches located
on a steering column stalk and push button switches on the fascia.
Control of the wipers and washers is achieved by the following components:
lBCU.
lIDM.
lFront wiper relay.
lFront wash/ wipe switch.
lVariable delay switch.
lFront wiper motor assembly.
lFront washer pump motor.
lRear wiper relay.
lRear wiper switch.
lRear washer switch.
lRear wiper motor.
lRear washer pump motor.
Both the Body Control Unit (BCU) and the Intelligent Driver Module (IDM) control the wiper system. The BCU controls
the time delay function of the wiper system and is located below and behind the passenger glovebox. During engine
cranking the BCU prevents wiper functions. Two relays are located in the passenger compartment fusebox. The
relays control the delay operation of the front and rear wipers. The relays are an integral part of the fusebox and
cannot be renewed separately.
Power for the wiper system is supplied by the IDM, which is integral with the passenger fusebox and cannot be
renewed as a component. A serial communication link allows communication between the IDM and the BCU.
The system has diagnostic capabilities through TestBook.
Front wipers
The two front windscreen wipers are operated by a linkage assembly and an electric motor located under the plenum
grill below the windscreen. The linkage and motor assembly is handed for left and right hand drive vehicles. The motor
is an integral part of the linkage and cannot be replaced separately.
The linkage comprises a pressed steel mounting plate which provides for the attachment of a wheel box at each end.
The mounting plate is secured to the bulkhead with flanged nuts which attach to a stud plate located behind the
bulkhead. A link arm is attached to each wheel box by a short link and secured with circlips. The link arm has an
attachment hole centrally located along its length for the electric motor drive link.
The electric motor is mounted in a recess in the bulkhead below a sealed cover plate. The drive spindle of the motor
protrudes through the cover plate and is fitted with a link. The link is attached to a tapered spline on the motor spindle
and is secured with a lock washer and nut. The opposite end of the link is attached to the central attachment point on
the link arm and secured with a circlip.
Each wheel box has a taper splined shaft which allows for the attachment of the wiper arm which is secured with a
washer and nut. The shaft of each wheel box is passed through a rubber sealed aperture in the plenum. The wiper
arm attachment to the splined shaft has a pivot to which the remainder of the arm is attached. The two parts of the
arm are connected by a spring which controls the pressure of the blade on the screen to a predetermined amount.
Page 1433 of 1672
WIPERS AND WASHERS
84-12 DESCRIPTION AND OPERATION
Rear wiper motor
The DC motor contains two permanent magnets and a park switch. An earth braid attached between the motor casing
and the brush pack is utilised to minimise radio interference during wiper functions.
The rear wiper switch provides an earth signal to the BCU, which determines the delay interval, if appropriate. The
BCU then signals the IDM to activate the rear wiper motor relay, which provides power to the rear wiper motor.
To allow the rear wiper to park when the rear wiper is switched off, power flows through the park switch until a cam
in the wiper motor assembly breaks the contact of the park switch. Triggering the park switch grounds the positive
side of the wiper motor causing it to stop abruptly
Washers
The washer system comprises a reservoir, washer pumps, hoses and washer jets. The front washers are controlled
from a stalk switch on the steering column and the rear washers are operated by a non-latching pushbutton switch on
the fascia adjacent to the instrument pack.
Reservoir
The reservoir is located behind the front bumper in the inner wheel arch and has a capacity of 6.0 litres (12.5 US pints).
A filler neck tube is connected to the reservoir with a seal and extends into the engine compartment on the front left
hand side. The filler neck tube contains a removable filter to prevent particle contamination and a yellow float to show
reservoir contents. The washer filler neck tube is sealed with a cap which is coloured blue for identification.
Two electric washer pumps are located on the rear face of the reservoir and supply washer fluid to the front
windscreen and the tail door window. Each pump is sealed to the reservoir with a rubber sealing grommet.
On vehicles with headlamp powerwash fitted, a third pump is fitted with a sealing grommet to the front face of the
reservoir.
The reservoir and filler neck tube are manufactured from moulded opaque nylon. The reservoir has moulded lugs for
attachment to the vehicle body. A bracket is attached to the top of the filler neck tube and locates in a hole in the body
to secure the top of the tube.
Page 1484 of 1672
BODY CONTROL UNIT
DESCRIPTION AND OPERATION 86-3-15
The BCU controls the wiper motor frequency of operation via the IDM when intermittent wipe or wash is selected. The
front intermittent wipe option features five different intermittent delay periods. The shortest delay period is 3 seconds
and this is increased by 2 second increments up to a maximum delay of 11 seconds. The desired delay period for the
front wipers is set by the position of the rotary switch located on the wiper column stalk.
The rear wiper switch is located on the instrument pack cowl and is latched when pressed. The rear wiper electric
motor is located in the tail door. The rear wiper operation is controlled according to a programmed strategy via the
BCU and the IDM. The BCU also checks for a signal from either the reverse lamp switch located in the vehicle gearbox
(manual gearbox models) or the gear position switch (automatic gearbox models) for operating the rear wipers when
the vehicle is in reverse. The rear wiper and washer only operate when the ignition switch is in position II.
The front and rear washer pumps and the headlamp powerwash (where fitted) are also controlled through the BCU.
The washers are operated from electric pumps attached to the washer reservoir located in the left hand wheel arch.
The front wash switch is located on the wiper column stalk and is pulled towards the steering wheel to select the
washer function. When the front washers are operated, the wipers are also activated for three full cycles. The rear
wash switch is located on the instrument pack cowl. The BCU programme can be configured in one of two modes of
operation:
lNo wiper operation when the wash switch is pressed.
lWiper action after an initial delay of 400 ms.
Headlamp wash is activated by the BCU via the IDM and operates when the headlamps are on and the front washers
function is selected.
Electric seats
The BCU controls the logical operation of the electrically operated front seats. Two modes of operation are available:
+ SEATS, DESCRIPTION AND OPERATION, Description - electric seats.
lElectric seat adjustment is enabled if the ignition is on or the driver's door is opened for a short time period.
lElectric seat adjustment is enabled if the ignition is on and the driver's door is closed.
The seats are operated by four electric motors which control the seat cushion rear up/ down, the seat cushion front
up/ down, seat cushion forward/ rearward and seat squab recline. The electrically powered lumbar adjustment in each
seat is operated by a single motorised air pump and a solenoid located on the seat squab frame. The air pump inflates
a cushion in the seat squab and the solenoid operates a valve to deflate the cushion. The seat squab and cushion
may also contain heater elements to provide heated seat operation.
The switches for electrically operated seats are located either side of the centre console.
Direction indicators and hazard warning lamps
The direction indicator lamps are operated from a three position direction indicator switch on the left hand, steering
column stalk. The BCU only allows the lamps to work as direction indicators when the ignition switch is in position II.
The BCU also controls the lamps to operate as hazard warning lamps and as a visual warning for the anti-theft system,
in which cases all lamps flash simultaneously irrespective of the ignition switch position.
System control of the direction indicators and hazard warning lamps is provided by the BCU operating with the IDM
and two electronic relays located in the passenger compartment fuse box. The IDM and relays are integral parts of
the passenger compartment fuse box and cannot be serviced individually. The serial data bus is used for
communication of status and operation requests between the BCU, IDM and instrument pack.
The hazard warning lamps are operated from a latching pushbutton switch located on the fascia.
All direction indicator/ hazard warning lamp bulbs are rated at 5 Watts.
Page 1534 of 1672
ALARM SYSTEM AND HORN
REPAIR 86-4-25
REPAIR
Switch - central door locking
$% 86.26.30
Remove
1.Carefully remove clock assembly from louvre
panel.
2.Disconnect multiplug from door lock switch.
3.Remove door lock switch from clock.
Refit
1.Fit door lock switch to clock assembly.
2.Connect multiplug to door lock switch.
3.Position clock assembly and push to secure in
position.
Switches - horn
$% 86.30.01
Remove
WARNING: It is imperative that before any
work is undertaken on the SRS system the
appropriate information is read thoroughly.
1.Disconnect both battery leads, negative lead
first, and wait 10 minutes.
2.Remove driver's airbag module.
+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.
3.Release horn switch multiplugs and leads from
steering wheel base.
4.Disconnect horn switch multiplugs from
harness.
5.Disconnect horn switch multiplug from rotary
coupler harness.
6.Remove screw securing earth leads to steering
wheel.
7.Using a broad round edged tool, carefully prise
horn switches from steering wheel.
Refit
1.Fit to steering wheel and connect multiplugs.
2.Fit earth leads and secure with screw.
3.Secure leads and multiplugs to base of steering
wheel.
4.Fit driver's airbag module.
+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.
Page 1557 of 1672
IN CAR ENTERTAINMENT
86-6-4 DESCRIPTION AND OPERATION
Description
General
The in car entertainment (ICE) system allows the driver and passengers to listen to audio output from the speakers
or optional headphones inside the vehicle. Buttons or knobs on the radio cassette allow changes of levels or
selections during the various modes of operation. The system can be controlled from the fascia mounted radio
cassette, or optional remote control switches on the left hand side of the steering wheel. High line systems may also
have rear headphone amplifiers that have some control of the system via the radio cassette player.
One or two amplified aerials located in the rear side windows send radio signals to the radio cassette player. On high
line systems a power amplifier and a CD-autochanger may be located under the front seats. Speakers are located in
the lower door panels, additional speakers may be located in upper door trim, the A-post and the tail door. A display
screen shows the user the current system status.
The ICE supplied varies with trim level and market. Vehicles may not have all of the speakers, amplified aerials, CD-
autochanger, rear headphone amplifiers or power amplifier.
Base system radio cassette
The base radio cassette has buttons for LD (loudness) AM, FM, EJECT (tape), Reverse, Base/Balance, treble, MAN
forward and reverse. The base radio cassette is located in the center of the fascia and contains the radio and tape
player, four clips (accessible through holes in the front of the unit) secure the unit in the fascia. To remove the unit
the four clips must be released with a special tool. The base system can be controlled from the fascia mounted radio
cassette. A logic control circuit in the radio cassette player controls the operation in the various control modes.
The radio cassette has a display screen, the information shown can be the current radio frequency, tape operating,
bass or loudness settings. Power for the illumination on the radio cassette is supplied from the passenger
compartment fuse box. A main fuse is also located in the connector socket area on the back of the radio cassette.
Security code function
A combination of buttons on the radio cassette are used to input and change security codes. Security codes make the
unit unusable if the unit is disconnected from the vehicle without deactivating the security code. The radio cassette
has an internal memory chip that stores the code information, if the power is removed from the unit the chip will
activate the security code feature. For this reason the security code feature must be deactivated before the unit is
removed or the vehicles battery is disconnected.
Audio functions
The radio cassette has buttons for the following audio functions: LD (loudness), bass/balance, fader, treble and
volume.
Cassette functions
The radio cassette has buttons for the following cassette functions: eject, forward, reverse and tape reversal.
Multi function buttons
The function of presets 1-6 and the MAN button depends on current mode of operation and allows selection of radio
band, radio on, tape track and search/seek functions. The MAN button is mode dependent, when pressed the button
allows manual operation or alternate mode selections such as manual tuning.
Internal memory
An internal memory chip stores the station presets and security code, power is supplied internally to the chip via a
permanent power feed, supplied from the passenger compartment fuse box.
Page 1558 of 1672
IN CAR ENTERTAINMENT
DESCRIPTION AND OPERATION 86-6-5
Radio cassette player connector pin details.
Connector/Pin No. Description Input/Output
C0092
1 Rear RH speaker line Output +
2 Rear RH speaker line Output -
3 Front RH speaker line Output +
4 Front RH speaker line Output -
5 Front LH speaker line Output +
6 Front LH speaker line Output -
7 Rear LH speaker line Output +
8 Rear LH speaker line Output -
C0098
1 Telephone mute Input
2 Steering wheel remote radio controls Input
3 Steering wheel remote radio controls Output
4 Permanent battery feed Input
5 System enable Output
6 Illumination Input
7 Auxilary feed Input
8EarthInput
C0921 (high line systems)
1 Radio headphone left channel Output +
2 Radio headphone right channel Output +
3 Telephone audio Input +
4 Radio headphone left channel Output -
5 Radio headphone right channel Output -
6 Telephone audio Input -
C0922 (high line systems)
7 Radio headphone active Input