2002 LAND ROVER DISCOVERY service

BODY SEALING MATERIALS
MATERIALS AND APPLICATIONS 77-3-5
Cooper Pegler Falcon Junior Pneumatic Gun (Airless)
Intended primarily for applying transit wax, this pneumatic sprayer has a 5-litre container with integral hand pump and
provides an effective means of wax spraying without the need for compressed air or additional services.
A selection of nozzles, lances, hose lengths and a trigger valve assembly with integral filter allows flexibility in use.
Additional applications include general maintenance, wax injection and paint application. Heavy-bodied materials
may also be applied. All parts are fully replaceable and a wide range of nozzle configurations is available.
SATA Schutz Gun Model UBE
The SATA Schutz Gun is approved for the retreatment of vehicle underbody areas with protective coatings as
supplied in 1 litre, purpose-designed 'one-way' containers. The screw thread fitting (female on the gun) is standard
to most Schutz-type packs.
SATA HKD1 Wax Injection Injection Equipment
This equipment is approved for carrying out cavity wax re-treatment. The SATA HKD1 set comprises a high quality
forged gun with 1-litre pressure feed container, a flexible nylon lance, a straight 1100 mm (43.307 in) steel lance and
hooked- wand lance. A quick-change coupling is provided as a standard fitting to allow lances to be easily
interchanged. Each lance has an integral, machined nozzle with specialised spray characteristics to suit the type of
box section to be treated.
NOTE: Always clean gun after use with appropriate solvent to maintain efficiency.
Specifications of Model UBE:
Air consumption 7 ft
3/min (200 litres/min) @ 45 lbf.in2
Weight: 23.3oz (220 grams)

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.

CORROSION PREVENTION AND SEALING
CORROSION PREVENTION 77-4-7
The checks described above are intended to be visual only. It is not intended that the operator should remove trim
panels, finishers, rubbing strips or sound-deadening materials when checking the vehicle for corrosion and paint
damage.
With the vehicle on a lift, and using an inspection or spot lamp, visually check for the following:
lCorrosion damage and damaged paintwork, condition of underbody sealer on front and rear lower panels, sills
and wheel arches;
lDamage to underbody sealer. Corrosion in areas adjacent to suspension mountings and fuel tank fixings.
NOTE: The presence of small blisters in the underbody sealer is acceptable, providing they do not expose bare metal.
Pay special attention to signs of damage caused to panels or corrosion protection material by incorrect jack
positioning.
WARNING: It is essential to follow the correct jacking and lifting procedures.
With the vehicle lowered, visually check for evidence of damage and corrosion on all visible painted areas, in
particular the following:
lFront edge of bonnet;
lVisible flanges in engine compartment;
lLower body and door panels.
Rectify any bodywork damage or evidence of corrosion found during inspection as soon as is practicable, both to
minimise the extent of the damage and to ensure the long term effectiveness of the factory-applied corrosion
prevention treatment. Where the cost of rectification work is the owner's responsibility, the Dealer must advise the
owner and endorse the relevant documentation accordingly.
Where corrosion has become evident and is emanating from beneath a removable component (e.g. trim panel,
window glass, seat etc.), remove the component as required to permit effective rectification.
Underbody protection repairs
Whenever body repairs are carried out, ensure that full sealing and corrosion protection treatments are reinstated.
This applies both to the damaged areas and also to areas where protection has been indirectly impaired, as a result
either of accident damage or repair operations.
Remove corrosion protection from the damaged area before straightening or panel beating. This applies in particular
to panels coated with wax, PVC underbody sealer, sound deadening pads etc.
WARNING: DO NOT use oxy-acetylene gas equipment to remove corrosion prevention materials. Large
volumes of fumes and gases are liberated by these materials when they burn.
NOTE: Equipment for the removal of tough anti-corrosion sealers offers varying degrees of speed and effectiveness.
The compressed air-operated scraper (NOT an air chisel) offers a relatively quiet mechanical method using an
extremely rapid reciprocating action. Move the operating end of the tool along the work surface to remove the material.
The most common method of removal is by means of a hot air blower with integral scraper.
Another tool, and one of the most efficient methods, is the rapid-cutting 'hot knife'. This tool uses a wide blade and is
quick and versatile, able to be used easily in profiled sections where access is otherwise difficult.
Use the following procedure when repairing underbody coatings:
1Remove existing underbody coatings
2After panel repair, clean the affected area with a solvent wipe, and treat bare metal with an etch phosphate
material
3Re-prime the affected area
CAUTION: DO NOT, under any circumstances, apply underbody sealer directly to bare metal surfaces.
4Replace all heat-fusible plugs which have been disturbed. Where such plugs are not available use rubber
grommets of equivalent size, ensuring that they are embedded in sealer
5Mask off all mounting faces from which mechanical components, hoses and pipe clips, have been removed.
Underbody sealer must be applied before such components are refitted
6Brush sealer into all exposed seams
7Spray the affected area with an approved service underbody sealer
8Remove masking from component mounting faces, and touch-in where necessary. Allow adequate drying time
before applying underbody wax

CORROSION PREVENTION AND SEALING
77-4-14 SEALING
Seam sealer - doors. Seams symmetrically opposite to those shown are also treated. Ensure drain holes in doors are
not blocked by sealant.
A heat cured, PVC based sealant is applied to specific joint seams during factory assembly. This material is not
suitable for service use and, during repair, should be substituted by an approved Seam Sealer.

+ BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.
Seams to which seam sealer is applied during factory assembly are detailed in the previous illustrations.
Apply seam sealers after the application of primer and before the application of surfacer and top coat. The seam
sealer must form a continuous bead, with the profile of the bead dependant on the type of seam. If seam sealer is
applied with a brush, take particular care to maintain the required coverage of the seam. Where shaping of the seam
sealer is required, use a cloth soaked with solvent such as white spirit or Shell SBP3 to achieve the required finish.
Ensure that ALL accessible repair seams are sealed following a repair. Damage to a vehicle often flexes areas of the
body remote from the impact. As a result, the seam sealer in these areas may be disturbed by subsequent
straightening and repair operations. Check all seams in the vicinity of the area undergoing repair for evidence of
cracked seam sealer, then clean out as required and apply fresh seam sealer using the following procedure:
lClean the affected seam and re-treat any exposed metal areas with a suitable etch phosphate primer;
lApply appropriate seam sealer as necessary;
lTreat affected area with an acid-etch prime (and underbody sealer as applicable);
lApply appropriate colour coat.
Where seams are inaccessible following the reassembly or fitting of components, ensure that a paste-type seam
sealer is applied to such seams. Certain seams also become inaccessible after the completion of panel repairs. In
such instances apply seam sealer and paint before final assembly.
Provided access is adequate, apply seam sealer to both sides of a repair joint. Where access is limited to one side
only (e.g. box sections), treat the affected box member with cavity wax.
M77 1666A

CORROSION PREVENTION AND SEALING
77-4-18 SEALING
Structural adhesive
Adhesive on rear wheel arch outer assembly.
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads to all joints shown.
Metal-to-metal adhesive is applied to critical joint areas during factory assembly. The material used is a high-
temperature, heat cured, nitrile phenolic which serves to bond two metal surfaces and also to seal the joint against
ingress of dust, moisture and fumes. This material is not suitable for service use and, during repair, should be
substituted by an approved Structural Adhesive.

+ BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.
Those joints which require the application of structural adhesive are detailed in the following figures. Only joints
applicable to service panels are included. Apply structural adhesive where indicated or to the mating panel surface.
CAUTION: When separating a joint treated with metal-to-metal adhesive, it is important to avoid distortion.
Heat the joint gradually until the bond weakens sufficiently to permit panel separation.
NOTE: When spot welding through metal-to-metal adhesive, take particular care to adjust the transformer setting to
ensure a reliable weld.
M77 1684A

CORROSION PREVENTION AND SEALING
SEALING 77-4-21
Those joints which require the application of interweld sealers are detailed in the previous illustrations. Only joints
applicable to service panels are included.

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.

NAVIGATION SYSTEM
DESCRIPTION AND OPERATION 87-3
Navigation Computer
The navigation computer is installed in the DIN radio slot in the fascia. A spring loaded catch on each side of the
navigation computer secures it in position. Slide tools, installed in slots at the bottom front corners of the navigation
computer, are required to unlock the catches during removal.
The navigation computer contains all the hardware and software required for control of the navigation, radio and CD
systems, including the GPS receiver and a solid state piezo gyro for the navigation system. The piezo gyro measures
the motion of the vehicle around its vertical axis.
The controls for the navigation computer are all located on the front panel of the unit. The centre section of the front
panel hinges to allow access to the CD player and, for security purposes, can be removed from the unit. The controls
perform the following functions:
lOn/Off (ON) button, for switching the unit on and off.
lTone button, for activating the tone menu to adjust bass, treble, balance, fade and loudness functions.
lTraffic Programme (TP) button, for activating the traffic information programme menu (Europe only).
lCompact Disc (CD) mode button, for selecting CD operation.
lRadio (Rad) mode button, for selecting radio operation and tuning menus.
lNavigation (Nav) mode button, for entry and exit of the navigation menu and service mode.
lCD eject button, opens the removable panel and ejects the CD.
lRH rotary control, scrolls through menus when turned and enters a selection when pressed. Also mutes audio
navigation instructions when pressed in navigation mode.
lMultifunction buttons, for entering the security code and menu selections.
lLiquid Crystal Display (LCD), green screen that displays navigation, radio and CD information.
lLH rotary control, adjusts volume when turned. When pressed, restores, repeats or interrupts audio navigation
instructions or provides destination details.
1On/Off button
2Tone button
3Traffic programme button (Europe only)
4CD mode button
5Radio mode button
6Navigation mode button7CD eject button
8RH rotary control
9Release tool slot
10Multifunction buttons
11LCD
12LH rotary control