2002 LAND ROVER DISCOVERY fuel

ENGINE MANAGEMENT SYSTEM - TD5
18-1-60 REPAIRS
11.Remove fuel temperature sensor and discard
sealing washer.
12.Remove fuel hose and fuel pipe and discard 'O'
rings.
Refit
1.Clean fuel pressure regulator and mating face.
2.Clean fuel pipe unions.
3.Using new 'O' rings, fit fuel pipe and fuel hose
to pressure regulator and tighten unions to 25
Nm (18 lbf.ft).
4.Using new sealing washer, fit fuel temperature
sensor and tighten to 14 Nm (10 lbf.ft).
5.Fit new fuel filter and 'O' ring.
6.Using a new gasket, position pressure
regulator and tighten bolts to 25 Nm (18 lbf.ft).
7.Connect multiplug to fuel temperature sensor.
8.Connect fuel hoses to pressure regulator and
fuel cooler.
9.Fit engine lifting eye and tighten bolts to 25 Nm
(18 lbf.ft).
10.Fit engine acoustic cover and tighten bolts to 10
Nm (6 lbf.ft).
11.Connect battery earth lead.
12.Fit battery cover and secure fixings.
Glow plugs
$% 19.60.31
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Release turnbuckles and remove battery cover.
3.Disconnect battery earth lead.
4.Disconnect 4 glow plug leads.
5.Loosen and remove 4 glow plugs.
Refit
1.Thoroughly clean glow plugs and seating area
in cylinder head.
2.Apply a suitable anti-sieze compound to
threads of glow plugs.
3.Fit glow plugs and tighten to 16 Nm (12 lbf. ft).
4.Connect glow plug leads.
5.Fit engine acoustic cover and secure fixings.
6.Connect battery earth lead.
7.Fit battery cover and secure fixings.

ENGINE MANAGEMENT SYSTEM - TD5
REPAIRS 18-1-61
Injectors
$% 19.60.12
Remove
1.Remove cooling fan.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
2.Remove rocker shaft.

+ ENGINE - Td5, REPAIRS, Rocker
shaft assembly.
3.Position container to catch fuel spillage.
4.Disconnect quick release fuel hose connectors
from fuel connector block on cylinder head and
fuel cooler to drain fuel from cylinder head. 5.Disconnect 5 multiplugs from injectors.
6.Remove 5 Torx bolts securing injectors to
cylinder head.
7.Using LRT-12-154/1, remove injectors from
cylinder head. Collect retainers.
8.Using LRT-12-154/4, remove sealing washers
from injectors. Discard sealing washers.
9.Remove and discard 'O' rings from injectors.
10.Rotate engine manually until each cylinder
being worked on is at TDC, and remove excess
fuel from piston bowl using a syringe.

ENGINE MANAGEMENT SYSTEM - TD5
18-1-62 REPAIRS
Refit
1.Clean injector units and mating faces in
cylinder head.
2.Using LRT-12-154/2, fit a new 'O' ring to each
injector.
3.Using LRT-12-154/3, fit a new sealing washer
to each injector.
4.Fit retainer to injector. Carefully fit injector,
ensuring retainer is located on its dowel, and
tighten Torx bolt to 32 Nm (24 lbf.ft)
5.Connect multiplug to injector.
6.Repeat above operations for remaining
injectors.
7.Connect fuel hoses to connector block and fuel
cooler.
8.Programme new injectors using TestBook.
9.Fit rocker shaft.

+ ENGINE - Td5, REPAIRS, Rocker
shaft assembly.
10.Fit cooling fan.

+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
Switch - cruise control (on/off)
$% 19.75.30
Remove
1.Carefully remove switch from instrument cowl.
2.Disconnect multiplug and remove switch.
Refit
1.Position new switch and connect multiplug.
2.Carefully push switch into instrument cowl.

ENGINE MANAGEMENT SYSTEM - V8
DESCRIPTION AND OPERATION 18-2-3
Engine management component
location - Engine compartment
1Mass air flow/ inlet air temperature sensor
2Fuel injectors
3High tension leads/spark plugs
4Fuel pump relay
5ATC compressor clutch relay/ cooling fan relay
6Throttle position sensor
7Heated oxygen sensor
8Idle air control valve
9Ignition coils
10Engine coolant temperature sensor
11Crankshaft speed and position sensor
12Knock sensor
13Camshaft position sensor

ENGINE MANAGEMENT SYSTEM - V8
DESCRIPTION AND OPERATION 18-2-5
1Engine control module
2Crankshaft speed and position sensor
3Camshaft position sensor
4Engine coolant temperature sensor
5Mass air flow/ inlet air temperature sensor
6Throttle position sensor
7Heated oxygen sensors
8Fuel injectors
9Idle air control valve
10Fuel pump relay
11EVAP canister
12EVAP canister vent valve
13EVAP canister purge valve
14Fuel tank pressure sensor
15Ignition coils
16Knock sensor
17Spark plugs
18High/ Low ratio switch
19Malfunction indication lamp
20Diagnostic connector
21Air temperature control clutch relay
22Air temperature control cooling fan relay
23ATC ECU
24CAN link to EAT
25SLABS ECU
26BCU
27Instrument cluster
28Thermostat monitoring sensor (where fitted)

ENGINE MANAGEMENT SYSTEM - V8
18-2-6 DESCRIPTION AND OPERATION
Description - engine management
General
The V8 engine is equipped with the Bosch Motronic M5.2.1 engine management system. This system is a sequential
multiport fuel injection system controlled by an Engine Control Module (ECM).
A single ECM is used for the control of the existing 4.0 litre engine and the new 4.6 litre engine introduced with 03
model year vehicles for the NAS market only. The ECM contains the tunes for both engines variants. When the ECM
is replaced, TestBook/T4 must be used to select the correct tune to match the engine fitment.
The ECM has On Board Diagnostic (OBD) strategies as required by various market legislative bodies. To meet these
requirements the system monitors and reports on any faults that cause excessive exhaust emissions.
In markets that mandate OBD, the ECM monitors performance of the engine for misfires, catalyst efficiency, exhaust
leaks and evaporative control loss. If a fault occurs, the ECM stores the relevant fault code and warns the driver of
component failure by illuminating the Malfunction Indicator Light in the instrument pack.
In markets where OBD is not mandatory, the ECM will still monitor performance of the engine and store the fault code,
but will not illuminate the Malfunction Indicator Light.
The ECM uses input and output information from its sensors and actuators to control the following engine conditions:
lFuel quantity.
lClosed loop fuelling.
lOpen loop fuelling.
lIgnition timing.
lKnock control.
lIdle speed control.
lEmission control.
lOn-Board Diagnostic (OBD) where applicable.
lVehicle immobilisation.
lMisfire detection (where applicable).
lVehicle speed signal.
lRough road signal (where applicable).
lLow fuel level signal (where applicable).
lCoolant temperature gauge signal.
The ECM processes sensor information from the following input sources:
lIgnition switch (position II).
lCrankshaft speed and position sensor.
lCamshaft position sensor.
lEngine coolant temperature sensor.
lMass air flow sensor.
lIntake air temperature sensor.
lKnock sensor.
lThrottle position sensor.
lHeated oxygen sensors.
lHigh/ Low ratio switch.
lFuel tank pressure sensor (where fitted)
lThermostat monitoring sensor (where fitted)

ENGINE MANAGEMENT SYSTEM - V8
DESCRIPTION AND OPERATION 18-2-7
The ECM controls the following outputs:
lFuel injectors (1 per cylinder).
lIgnition coils/ high tension leads/ spark plugs.
lFuel pump relay.
lIdle air control valve.
lHeated oxygen sensors.
lEVAP canister purge valve.
lEVAP canister vent solenoid (CVS) valve (where fitted).
lMalfunction Indicator Lamp (MIL)/ service engine soon lamp (where fitted).
lHill descent control (via SLABS interface).
lEVAP system fuel leak detection pump (where fitted)
lSecondary air injection pump (where fitted)
The ECM also interfaces with the following:
lDiagnostics via diagnostic connector with TestBook.
lController Area Network (CAN) link to EAT ECU.
lAir conditioning system.
lSelf Levelling & Anti-lock Braking System (SLABS) ECU.
lImmobilisation system via the body control unit (BCU).
lInstrument cluster.
lCruise control ECU
lActive Cornering Enhancement (ACE) ECU
Engine Control Module (ECM)
The engine control module (ECM) is located on the RH side A post below the face panel inside the vehicle. It has a
cast aluminium case and is mounted on a bracket. The ECM has 5 independent connectors totalling 134 pins.
The ECM is available in 4 variants:
lNAS.
lNAS low emission vehicles.
lUK/ Europe/ Japan/ Australia.
lROW/ Gulf.
The ECM uses a 'flash' electronic erasable programmable read only memory (EEPROM). This enables the ECM to
be externally configured, to ensure that the ECM can be updated with any new information, this also allows the ECM
to be configured with market specific data. TestBook must be used to configure replacement ECM's. The ECM can
be reconfigured up to 16 times to meet changing specifications and legislation.
The ECM memorises the positions of the crankshaft and the camshaft when the engine has stopped via the CKP and
CMP sensors. This allows immediate sequential fuel injection and ignition timing during cranking. This information is
lost if battery voltage is too low (i.e. flat battery). So the facility will be disabled for the first engine start.

ENGINE MANAGEMENT SYSTEM - V8
18-2-8 DESCRIPTION AND OPERATION
Input/Output
The ECM has various sensors fitted to the engine to allow it to monitor engine condition. The ECM processes these
signals and decides what actions to carry out to maintain optimum engine operation by comparing the information
from these signals to mapped data within its memory.
Connector 1 (C0634): This connector contains 9 pins and is used primarily for ECM power input and earth. The ECM
requires a permanent battery supply, if this permanent feed is lost i.e. the battery discharges or is disconnected the
ECM will lose its adapted values and its Diagnostic Trouble Codes (DTC). These adapted values are a vital part of
the engine management's rolling adaptive strategy. Without an adaptive strategy, driveability, performance, emission
control, and fuel consumption are adversely affected. The ECM can be damaged by high voltage inputs, so care must
be taken when removing and replacing the ECM.
Pin out details connector C0634
Connector 2 (C0635): This connector contains 24 pins and is primarily used for Heated Oxygen Sensors (HO
2S)
control and earth. The HO
2S sensors require a heater circuit to assist in heating the tip of the sensors to enable closed
loop fuelling to be implemented quickly after cold starting.
Pin out details connector C0635
Pin No. Function Signal type Reading
1 Ignition position II Input 12 V
2 Not used - -
3 Not used - -
4 Chassis earth Earth 0V
5 Fuel injectors earth Earth 0V
6 Power stage earth Earth 0V
7 Permanent battery supply Input battery supply 12V
8 Switched relay positive Input switched 0-12V
9 Not used - -
Pin No. Function Signal type Reading
1HO
2S heater RH bank - downstream Output PWM 12-0V
2 Not used - -
3 Not used - -
4 Not used - -
5 Thermostat monitoring sensor Earth 0V
6 Not used - -
7HO
2S heater LH bank - downstream Output PWM 12-0V
8HO
2S sensor RH bank - downstream Earth/ Signal 0V
9HO
2S sensor LH bank - upstream Earth/ Signal 0V
10 HO
2S sensor RH bank - upstream Earth/ Signal 0V
11 HO
2S sensor LH bank - downstream Earth/ Signal 0V
12 Not used - -
13 HO
2S heater RH bank - upstream Output PWM 12-0V
14 HO
2S sensor RH bank - downstream Input/ Signal Analogue 0-5V
15 HO
2S sensor LH bank - upstream Input/ Signal Analogue 0-5V
16 HO
2S sensor RH bank - upstream Input/ Signal Analogue 0-5V
17 HO
2S sensor LH bank - downstream Input/ Signal Analogue 0-5V
18 Fuel pump relay Output Switch to earth
19 HO
2S heater LH bank - upstream Output PWM 12-0V
20 Not used - -
21 Thermostat monitoring sensor Signal Analogue 0-5V
22 Not used - -
23 Main relay Output Switch to earth
24 EVAP system leak detection pump motor (NAS
vehicles with positive pressure type, EVAP system
leak detection capability only)Output Switch to earth