maintenance LAND ROVER DISCOVERY 2002 Manual Online

CORROSION PREVENTION AND SEALING
77-4-6 CORROSION PREVENTION
Corrosion prevention
Factory treatments
During production, vehicle bodies are treated with the following anti-corrosion materials:
lA PVC-based underbody sealer which is sprayed onto the underside of the main floor, rear floor, front and rear
wheelarches and the front valance assembly;
lAn application of cavity wax which is sprayed into the sill panels, 'A' post, 'B-C' post, fuel filler aperture, body rear
panel and the lower areas of the door panels;
lA coating of underbody wax which is applied to the entire underbody inboard of the sill vertical flanges, and
covers all moving and flexible components EXCEPT for wheels, tyres, brakes and exhaust;
lA coat of protective wax applied to the engine bay area.
Whenever body repairs are carried out, ensure the anti-corrosion materials in the affected area are repaired or
renewed as necessary using the approved materials.

+ BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.
Precautions during body repairs and handling
Take care when handling the vehicle in the workshop. Underbody sealers, seam sealers, underbody wax and body
panels may be damaged if the vehicle is carelessly lifted.

+ LIFTING AND TOWING, LIFTING.
Proprietary anti-corrosion treatments
The application of proprietary anti-corrosion treatments, in addition to the factory-applied treatment, could invalidate
the Corrosion Warranty and should be discouraged. This does not apply to Rover approved, compatible, preservative
waxes which may be applied on top of existing coatings.
Fitting approved accessories
When fitting accessories ensure that the vehicle's corrosion protection is not affected, either by breaking the protective
coating or by introducing a moisture trap.
Do not screw self-tapping screws directly into body panels. Fit suitable plastic inserts to the panel beforehand. Always
ensure that the edges of holes drilled into panels, chassis members and other body parts are protected with a suitable
zinc rich or acid etch primer, and follow with a protective wax coating brushed onto the surrounding area.
Do not attach painted metal surfaces of any accessory directly to the vehicle's bodywork unless suitably protected.
Where metal faces are bolted together always interpose a suitable interface material such as weldable zinc rich
primer, extruded strip, or zinc tape.
Steam cleaning and dewaxing
Due to the high temperatures generated by steam cleaning equipment, there is a risk that certain trim components
could be damaged and some adhesives and corrosion prevention materials softened or liquified.
Adjust the equipment so that the nozzle temperature does not exceed 90
° C (194° F). Take care not to allow the steam
jet to dwell on one area, and keep the nozzle at least 300 mm (11.811 in) from panel surfaces.
DO NOT remove wax or lacquer from underbody or underbonnet areas during repairs. Should it be necessary to
steam clean these areas, apply a new coating of wax or underbody protection as soon as possible.
Inspections during maintenance servicing
It is a requirement of the Corrosion Warranty that the vehicle body is checked for corrosion by an authorised Land
Rover Dealer at least once a year, to ensure that the factory-applied protection remains effective.
Service Job Sheets include the following operations to check bodywork for corrosion:
lWith the vehicle on a lift, carry out visual check of underbody sealer for damage;
lWith the vehicle lowered, inspect exterior paintwork for damage and body panels for corrosion.
It will be necessary for the vehicle to be washed by the Dealer prior to inspection of bodywork if the customer has
offered the vehicle in a dirty condition.

HEATING AND VENTILATION
REPAIRS 80-31
7.Position container to collect spillage and
disconnect quick release fuel pipe from FBH.
CAUTION: Before disconnecting any part of
the fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign
matter into fuel system.
8.Remove Torx bolt securing FBH to bulkhead
mounting bracket.
9.Release and remove FBH.
10.Collect locating bushes from pegs.Refit
1.Fit bushes to pegs.
2.Align FBH to pegs, fit Torx bolt and tighten to 25
Nm (18 lbf.ft).
3.Clean quick release connection and fit fuel pipe
to FBH.
4.Connect multiplugs to FBH.
5.Connect coolant hoses to FBH and secure with
clips.
6.Release clamps from hoses.
7.Connect battery earth lead.
8.Fit and secure battery cover.
9.Top-up cooling system.

+ MAINTENANCE, PROCEDURES,
Cooling system.

WIPERS AND WASHERS
REPAIRS 84-19
REPAIRS
Reservoir - washer - up to 03MY
$% 84.10.03
Remove
1.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
2.Remove front bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
3.Disconnect multiplug from headlamp washer
pump.
4.Identify multiplugs for refit and disconnect from
rear screen and windscreen washer pumps.
5.Identify hoses for refit and disconnect hoses
from rear screen and windscreen washer
pumps.
6.Release clip securing washer hose to
headlamp washer pump. 7.Remove 2 nuts and 1 bolt securing reservoir,
release reservoir from filler neck and remove
reservoir assembly.
8.Remove filler neck grommet.
NOTE: Do not carry out further dismantling if
component is removed for access only.
9.Remove fluid level indicator.
10.Remove washer pumps from reservoir,
remove and discard pump seals.
Refit
1.Use new seals and fit washer pumps to new
reservoir.
2.Fit filler neck grommet to reservoir.
3.Fit level indicator into filler neck.
4.Fit reservoir assembly and secure with nuts
and bolt.
5.Connect hoses to rear screen pump,
windscreen washer pump and headlamp
washer pump. Secure hoses with clips.
6.Identify and connect multiplugs to washer
pumps.
7.Fit front bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
8.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
9.Refill reservoir

+ MAINTENANCE, PROCEDURES,
Wipers and washers.