horn LAND ROVER DISCOVERY 2002 Workshop Manual

CONTENTS
2CONTENTS
IDENTIFICATION NUMBERS .................................................................. 05-1
Vehicle Identification Number ......................................................................................................... 05-1
Identification Number Locations ..................................................................................................... 05-3
TORQUE WRENCH SETTINGS .............................................................. 06-1
Maintenance ................................................................................................................................... 06-1
Engine Td5 ..................................................................................................................................... 06-2
Engine V8 ....................................................................................................................................... 06-4
Emission control - Td5 .................................................................................................................... 06-5
Emission control - V8 ...................................................................................................................... 06-5
Engine management system - Td5 ................................................................................................. 06-5
Engine management system - V8................................................................................................... 06-6
Cooling system ............................................................................................................................... 06-6
Manifolds and exhaust systems - Td5 ............................................................................................ 06-6
Manifolds and exhaust systems - V8 .............................................................................................. 06-7
Clutch.............................................................................................................................................. 06-7
Manual gearbox - R380 .................................................................................................................. 06-8
Transfer box - LT230SE ................................................................................................................. 06-8
Automatic gearbox - ZF4HP22/24 .................................................................................................. 06-9
Propeller shafts ............................................................................................................................... 06-9
Axles ............................................................................................................................................... 06-9
Steering .......................................................................................................................................... 06-10
Front suspension ............................................................................................................................ 06-11
Rear suspension ............................................................................................................................. 06-12
Brakes............................................................................................................................................. 06-12
Restraint systems ........................................................................................................................... 06-13
Body................................................................................................................................................ 06-14
Heating and air conditioning ........................................................................................................... 06-15
Wipers and washers ....................................................................................................................... 06-15
Electrical ......................................................................................................................................... 06-15
LIFTING AND TOWING ........................................................................... 08-1
LIFTING .......................................................................................................................................... 08-1
TOWING ......................................................................................................................................... 08-2
TRANSPORTING ........................................................................................................................... 08-3
CAPACITIES, FLUIDS AND LUBRICANTS ............................................ 09-1
Capacities ....................................................................................................................................... 09-1
Fluids .............................................................................................................................................. 09-2
Anti-Freeze Concentration .............................................................................................................. 09-3
Lubrication ...................................................................................................................................... 09-3
MAINTENANCE ........................................................................................ 10-1
PROCEDURES
V8 engine underbonnet view .......................................................................................................... 10-1
Diesel underbonnet view ................................................................................................................ 10-2
Seats and seat belts ...................................................................................................................... 10-3
Lamps, horns and warning indicators ........................................................................................... 10-5
Wipers and washers ...................................................................................................................... 10-5
Handbrake .................................................................................................................................. 10-6

CONTENTS
CONTENTS 23
Headlamps beam alignment - from 03MY ...................................................................................... 86-2-2
REPAIRS
Lamp - front repeater .................................................................................................................... 86-2-3
Headlamp - up to 03MY .................................................................................................................. 86-2-4
Headlamp - from 03MY .................................................................................................................. 86-2-5
Lamp - tail ..................................................................................................................................... 86-2-6
Lamp - front fog up to 03MY ........................................................................................................... 86-2-6
Lamp - front fog from 03MY ............................................................................................................ 86-2-7
Housing - number plate lamp ......................................................................................................... 86-2-8
Motor - headlamp levelling ............................................................................................................ 86-2-9
Lamp - stop - centre high mounted (CHMSL) .............................................................................. 86-2-10
Lamp - tail/flasher - bumper ............................................................................................................ 86-2-10
Lamp - interior - front .................................................................................................................... 86-2-11
Lamp - interior - rear ..................................................................................................................... 86-2-11
Rheostat - panel lights dimmer ...................................................................................................... 86-2-12
Switch - hazard warning ................................................................................................................. 86-2-13
Switch - indicator and exterior lighting - combined.......................................................................... 86-2-13
Socket - accessory ......................................................................................................................... 86-2-14
Switch - front/rear fog lamps ......................................................................................................... 86-2-14
BODY CONTROL UNIT ............................................................................ 86-3-1
DESCRIPTION AND OPERATION
Description ...................................................................................................................................... 86-3-1
Operation ........................................................................................................................................ 86-3-19
REPAIRS
Body control unit (BCU) .................................................................................................................. 86-3-39
ALARM SYSTEM AND HORN ................................................................. 86-4-1
DESCRIPTION AND OPERATION
Alarm system component layout ..................................................................................................... 86-4-2
Alarm system block diagram ........................................................................................................... 86-4-4
Description ...................................................................................................................................... 86-4-5
Operation ........................................................................................................................................ 86-4-16
REPAIR
Switch - central door locking ......................................................................................................... 86-4-25
Switches - horn ............................................................................................................................. 86-4-25
Vehicle horn .................................................................................................................................. 86-4-26
Sounder - alarm ............................................................................................................................ 86-4-26
Sounder - battery backed-up (BBUS) ............................................................................................. 86-4-27
Switch - bonnet ............................................................................................................................. 86-4-27
Receiver - alarm system - models with sunroof ............................................................................. 86-4-28
Receiver - alarm system - models without sunroof ......................................................................... 86-4-28
Coil - passive immobilisation ......................................................................................................... 86-4-29
WINDOWS ................................................................................................ 86-5-1
DESCRIPTION AND OPERATION

TORQUE WRENCH SETTINGS
06-15
Heating and air conditioning
Wipers and washers
Electrical
TORQUE DESCRIPTION METRIC IMPERIAL
Heater assembly16 Nm (12 lbf.ft)
Compressor bolts 22 Nm (16 lbf.ft)
Blower motor19 Nm (14 lbf.ft)
Compressor to mounting bracket bolts 25 Nm (18 lbf.ft)
A/C pipes to compressor bolts 10 Nm (7 lbf.ft)
Condenser pipe bolt 5 Nm (3.7 lbf.ft)
Receiver drier to bracket bolts 5 Nm (3.7 lbf.ft)
Adaptor block to receiver drier bolt 5 Nm (3.7 lbf.ft)
Evaporator pipe bolts 5 Nm (3.7 lbf.ft)
Dual pressure switch to receiver drier 10 Nm (7 lbf.ft)
Air conditioning pipes to receiver drier bolts 5 Nm (3.7 lbf.ft)
TX valve pressure pipe union 22 Nm (16 lbf.ft)
Evaporator pipe to TXV valve 32 Nm (24 lbf.ft)
Evaporator assembly to body bolts 16 Nm (12 lbf.ft)
High and low pressure pipe, bolts 10 Nm (7 lbf.ft)
Fuel burning heater Torx bolts 25 Nm (18 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Link to motor spindle 7 Nm (5.2 lbf.ft)
Front motor assembly 2.5 Nm (1.8 lbf.ft)
Spindle nut 3 Nm (2.2 lbf.ft)
Wiper arm nut13 Nm (10 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Alternator support stay 25 Nm (18 lbf.ft)
Alternator lead - Td5 6 Nm (4.4 lbf.ft)
Auxiliary drive belt tensioner bolt 50 Nm (37 lbf.ft)
Alternator pulley80 Nm (59 lbf.ft)
Alternator B+ nut - V8 18 Nm (13 lbf.ft)
Alternator B+ nut - V8 5 Nm (3.7 lbf.ft)
Starter motor - Td5 27 Nm (20 lbf.ft)
Starter motor solenoid 10 Nm (7 lbf.ft)
Starter motor - V8 44 Nm (32 lbf.ft)
Alternator45 Nm (33 lbf.ft)
Starter motor heat shield - V8 10 Nm (7 lbf.ft)
Horn13 Nm (10 lbf.ft)
Battery carrier bolts 28 Nm (21 lbf.ft)

MAINTENANCE
PROCEDURES 10-5
Lamps, horns and warning indicators
Check
1.Switch on side, head and tail lamps and check
operation.
2.Check headlamp levelling operation.
3.Check turn signals and hazard warning lamps
for correct operation.
4.Press brake pedal and check operation of
brake lamps.
5.Check all exterior lamp lenses for clarity and
condition. Pay particular attention to headlamp
lenses for signs of stone chips or damage.
6.Check horn for loud, clear sound.
7.Switch on headlamps (with ignition switch at 'O'
position) and check light reminder warning
operates when door is opened.
8.Check operation of interior courtesy lights.
9.Check operation of all instrument pack warning
and indicator lights.
Wipers and washers
Check
1. Operate screen washer and switch on wipers.
Ensure washer jets are correctly aimed and
check for smooth, smear free operation of
wiper blades across screen at all speeds
including intermittent.
2.Repeat operation for rear screen washers/
wipers.

ENGINE - V8
REPAIRS 12-2-39
Cooler - engine oil
$% 12.60.68
Remove
1.Release fixings and remove battery cover.
2.Release fixings and remove cooling fan cowl.
3.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
4.Remove 6 scrivets and remove LH and RH air
deflectors from front panel.
5.Remove nut and move LH horn aside. 6.Remove 2 bolts securing radiator LH and RH
upper mounting brackets to body panel and
remove brackets.
7.Remove 4 screws securing air conditioning
condenser LH and RH upper mounting
brackets to condenser.
8.Remove condenser upper mounting brackets
with rubber mounts from radiator extension
brackets.
9.Remove 2 bolts securing LH and RH extension
brackets to radiator and remove brackets.
10.Position absorbent cloth under each oil cooler
hose connection to collect oil spillage.

ENGINE - V8
12-2-40 REPAIRS
11.Push against coupling release rings and
disconnect both hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
12.Remove screw securing oil cooler to radiator.
13.Release cooler from its location on radiator.
14.Release radiator lower mountings from
location in chassis and carefully move radiator
towards engine sufficiently only to release
engine oil cooler from radiator.
15.Remove engine oil cooler.
Refit
1.Fit engine oil cooler to radiator, engage in
location and secure with screw.
2.Fit radiator to location in chassis.
3.Ensure connections are clean, then secure
hoses to oil cooler.
4.Fit extension brackets to radiator and secure
with bolts.
5.Fit brackets with rubber mounts to extension
brackets and secure to air conditioning
condenser with screws.
6.Fit radiator upper mounting brackets and
secure to body with bolts.
7.Fit LH horn and secure with nut.
8.Fit LH and RH air deflectors to front panel and
secure with scrivets.
9.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY..
10.Fit cooling fan cowl and secure with fixings.
11.Fit battery cover and secure with fixings.
12.Top up engine oil.
Gasket - timing gear cover
$% 12.65.04
Remove
1.Remove oil pick-up strainer.

+ ENGINE - V8, REPAIRS, Strainer -
oil pick-up.
2.Remove timing gear cover oil seal.

+ ENGINE - V8, REPAIRS, Seal - cover
- timing gears.
3.Remove engine oil filter.

+ ENGINE - V8, REPAIRS, Filter - oil.
4.Remove and discard 3 bolts securing coolant
pump pulley and remove pulley.
5.Remove 3 bolts securing PAS pump pulley and
remove pulley.
6.Drain cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.

ENGINE MANAGEMENT SYSTEM - TD5
REPAIRS 18-1-57
9.Loosen clip and disconnect inlet hose from
intercooler.
10.Loosen clip and disconnect outlet hose from
intercooler.
11.Remove nut securing horn and move horn
aside. 12.Remove 2 bolts securing radiator LH and RH
upper mounting brackets to body panel and
remove brackets.
13.Remove 4 screws securing LH and RH upper
mounting brackets to condenser.
14.Remove brackets with rubber mounts from
intercooler.
15.Remove 2 bolts securing intercooler to radiator.
16.Release radiator lower mountings from location
in chassis and carefully move radiator towards
engine sufficiently only to release intercooler
from radiator.
17.Remove intercooler.
Refit
1.Fit intercooler to radiator, and fit and tighten
bolts.
2.Engage radiator lower mountings in chassis.

ENGINE MANAGEMENT SYSTEM - TD5
18-1-58 REPAIRS
3.Fit brackets with rubber mountings to
intercooler and fit and tighten screws securing
brackets to condenser.
4.Fit radiator upper mounting brackets and
tighten bolts.
5.Fit LH horn and secure with nut.
6.Connect inlet and outlet hoses to intercooler
and tighten clips.
7.Fit lower half of fan cowl and secure with
screws.
8.Fit LH and RH air deflectors to front panel and
secure with scrivets.
9.Fit front grille.
10.Fit battery carrier and secure with bolts.
11.Fit ECM and secure with screw.
12.Fit jack to battery carrier.
13.Fit battery.
14.Fit cooling fan and coupling.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
Valve - solenoid boost control
$% 19.42.30
Remove
1.Loosen clip and release air intake hose from
MAF sensor.
2.Release clips and disconnect vacuum hoses
from solenoid valve.
3.Disconnect multiplug from solenoid valve.
4.Remove 2 bolts and remove solenoid valve.
Refit
1.Position solenoid valve and tighten bolts.
2.Connect multiplug to solenoid valve.
3.Connect vacuum hoses and secure with clips.
4.Position air intake hose to MAF sensor and
secure clip.

COOLING SYSTEM - V8
26-2-16 REPAIRS
8.Remove 6 scrivets and remove LH and RH air
deflectors from front panel. Disconnect
multiplug of gearbox oil temperature sensor
(arrowed).
9.Remove nut and move horn aside. 10.Remove 2 bolts securing radiator LH and RH
upper mounting brackets to body panel and
remove brackets.
11.Remove 4 screws securing air conditioning
condenser LH and RH upper mounting
brackets to condenser.
12.Remove brackets with rubber mounts from
radiator extension brackets.
13.Position absorbent cloth under each cooler
hose to collect oil spillage.
14.Push against coupling release rings and
disconnect hoses from gearbox oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
15. If fitted: Push against coupling release rings
and disconnect hoses from engine oil cooler.

COOLING SYSTEM - V8
REPAIRS 26-2-17
16.Remove radiator assembly.
17.Release clip and remove bottom hose from
radiator.
18.Remove 2 bolts and remove extension
brackets from radiator.
19.Remove 2 captive nuts from radiator.
20.Remove 2 screws and remove gearbox oil
cooler from radiator.
21. If fitted: Remove 2 screws and remove engine
oil cooler from radiator.
22.Remove 2 rubber mountings from radiator.
23.Remove sealing strip from bottom of radiator.
24.Remove 2 cowl retaining clips from radiator. Refit
1.Fit cowl retaining clips to radiator.
2.Fit sealing strip to radiator.
3.Fit rubber mountings to radiator.
4.Fit gearbox oil cooler to radiator and secure
with screws.
5. If fitted: Fit engine oil cooler to radiator and
secure with screws.
6.Fit captive nuts to radiator.
7.Fit extension brackets to radiator and secure
with bolts.
8.Fit bottom hose to radiator and secure with clip.
9.Fit radiator and engage lower mountings in
chassis.
10.Ensure connections are clean, then secure
hoses to oil coolers.
11.Fit air conditioning condenser brackets and
secure with screws.
12.Fit radiator upper mounting brackets and
secure with bolts.
13.Fit LH horn and secure with nut.
14.Fit air deflectors and secure with scrivets.
15.Connect multiplug of gearbox oil temperature
sensor.
16.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
17.Connect bottom hose to thermostat housing
and secure with clip.
18.Connect top hose to radiator and secure with
clip.
19.Connect bleed hose to radiator and fit clip.
20.Fit lower fan cowl and secure with screws.
21.Fit viscous fan.

+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.
22.Top up gearbox oil.
23.Top up engine oil.
24.Refill cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.