2002 LAND ROVER DISCOVERY airbag

GENERAL INFORMATION
03-23
Airbag and pretensioner deployment
Deployment procedures and precautions as detailed
in this manual should be strictly adhered to. Only
personnel who have undergone the appropriate
training should undertake deployment of airbag and
pretensioner modules. The following precautions
must be complied with:
lOnly use deployment equipment approved for
the intended purpose.
lBefore beginning deployment procedure,
ensure deployment tool functions properly by
performing the self test procedure detailed in
SRS section of this manual.
lDeployment of airbag/ pretensioner modules
should be performed in a well ventilated area
which has been designated for the purpose.
lEnsure airbag/pretensioner modules are not
damaged or ruptured before attempting to
deploy.
lNotify the relevant authorities of intention to
deploy airbag and pretensioner units.
lWhen deploying airbag pretensioner units,
ensure that all personnel are at least 15 metres
(45 feet) away from the deployment zone.
lEnsure deployment tool is connected correctly,
in compliance with the instructions detailed in
the SRS section of this manual. In particular,
ensure deployment tool is NOT connected to
battery supply before connecting to airbag
module connector.
lWhen deploying seat belt pretensioners, ensure
pretensioner unit is secured correctly to the
seat.
lWhen removing deployed airbag modules and
pretensioner units, wear protective clothing.
Use gloves and seal deployed units in a plastic
bag.
lFollowing deployment of any component of the
SRS system within the vehicle, all SRS
components must be replaced. DO NOT re-use
or salvage any parts of the SRS system.
lDo not lean over airbag module when
connecting deployment equipment.
If a vehicle is to be scrapped, undeployed airbag
modules and pretensioner units must be manually
deployed. In this case airbags can be deployed in the
vehicle; before deployment, ensure the airbag
module is secure within its correct mounting position.
Deployment of the driver's airbag in the vehicle may
damage the steering wheel; if the vehicle is not being
scrapped, deploy the module outside of the vehicle.
WARNING: During deployment parts of the
airbag module become hot enough to burn you.
Wait 30 minutes after deployment before
touching the airbag module.
SRS Component Replacement Policy
The following information details the policy for
replacement of SRS components; either as a result
of a vehicle accident or as a result of vehicle age.
Impacts which do not deploy the airbags or pre-
tensioners
Check for structural damage in the area of the
impact, paying particular attention to bumper
armatures, longitudinals, crash cans and bracketry.
Impacts which deploy the airbags or pre-
tensioners
The replacement and inspection policy is dependent
on the type and severity of of the crash condition.
The following guidelines are the minimum that
should be exercised as a result of the deployment of
specific SRS components.
If the front airbags or seat belt pre-tensioners are
deployed, the following parts must be replaced:
lSRS DCU.
lDriver airbag module
lPassenger airbag module
lFront seat belt buckle pre-tensioners
lRotary coupler
lDriver's seat belt retractor
lFlyleads (where applicable) connecting airbags
and seat belt pre-tensioners to SRS harness
In addition, the following should be inspected for
damage and replaced as necessary:
lFront passenger's seat belt retractor (webbing,
tongue latching, 'D' loop, body anchorage point)
lRear seat belt buckles (webbing, buckle covers,
body anchorage and tongue latching function)
lFascia moulding adjacent to passenger airbag
module
lSteering wheel (if damage is evident)
lFront seat frames and head restraints (if there is
evidence of damage to the seat frame or
cushion pan)
lSteering column (if adjustment is lost or there
are signs of collapse)
lThird row seats, seat belts and head restraints
(where fitted). Check third row seat latching
mechanism operates correctly.
Periodic replacement of SRS components
The performance of the propellants within airbags
and pre-tensioners will deteriorate over a period of
time. As a result, it is essential that the airbags are
replaced after 10 years and seat belt pre-tensioners
are replaced after 15 years in order to maintain
occupant safety.

ENGINE MANAGEMENT SYSTEM - TD5
REPAIRS 18-1-63
Switch - cruise control (set/resume)
$% 19.75.33
Remove
1.Remove the key from the starter switch.
Disconnect both battery leads, negative lead
first. Wait ten minutes before starting work.
2.Remove driver's airbag module.

+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.
3.Release remote control switches multiplug and
leads from steering wheel base.
4.Disconnect remote control switches multiplug
from harness.
5.Remove 2 screws securing remote control
switches to steering wheel base.
6.Release and remove remote control switches
from steering wheel.
Refit
1.Fit remote control switches to steering wheel
and secure with screws.
2.Connect remote control switches multiplug to
harness.
3.Secure leads and multiplug to base of steering
wheel.
4.Fit driver's airbag module.

+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.
Switch - clutch
$% 19.75.34
Remove
1.Disconnect the multiplug from the clutch switch.
2.Position a container below the clutch switch to
collect the fluid.
3.Unscrew and remove the clutch switch.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Fit the clutch switch and tighten to 10 Nm (7
lbf.ft).
2.Connect the multiplug.
3.Bleed the clutch hydraulic system.

+ CLUTCH - Td5, ADJUSTMENTS,
Clutch hydraulic system - bleed.

ENGINE MANAGEMENT SYSTEM - V8
REPAIRS 18-2-87
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.
Switch - cruise control (set/resume)
$% 19.75.33
Remove
1.Remove the key from the starter switch.
Disconnect both battery leads, negative lead
first. Wait ten minutes before starting work.
2.Remove driver's airbag module.

+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.
3.Release remote control switches multiplug and
leads from steering wheel base.
4.Disconnect remote control switches multiplug
from harness.
5.Remove 2 screws securing remote control
switches to steering wheel base.
6.Release and remove remote control switches
from steering wheel.
Refit
1.Fit remote control switches to steering wheel
and secure with screws.
2.Connect remote control switches multiplug to
harness.
3.Secure leads and multiplug to base of steering
wheel.
4.Fit driver's airbag module.

+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.

STEERING
DESCRIPTION AND OPERATION 57-5
Description
General
The major steering components comprise an impact absorbing telescopic steering column, a Power Assisted Steering
(PAS) box, a PAS pump, and fluid reservoir. Hydraulic fluid from the fluid reservoir is filtered and then supplied
through the suction line to the inlet on the PAS pump. The PAS pump supplies fluid to the steering box through a
pressure line routed above the front cross member. Fluid returns to the reservoir along the same route through a
return line. On LH drive vehicles the pipe route above the front cross member is still used, the length of pipe acting
as an oil cooler.
To minimise driver's injury in the event of an accident the steering system has a number of safety features including
a collapsible steering column. An additional safety feature is an air bag located in the steering wheel.

+ RESTRAINT SYSTEMS, DESCRIPTION AND OPERATION, Description - SRS.
Steering column assembly and intermediate shaft
The steering column central shaft comprises of two shafts, the upper shaft is splined to accept the steering wheel and
located in bearings in the column tube. A universal joint is located on the bottom of the upper shaft, the joint allows
for angular movement between the upper and lower shafts. The lower shaft is made in two parts, the top section of
the lower shaft is located outside of the lower section. The two sections of the lower shaft are connected by two nylon
injection moulded shear pins. The lower shaft goes through a lower bearing attached to the bulkhead, the lower shaft
is connected by a universal joint to the intermediate shaft in the engine compartment.
Steering column
An upper column tube provides for the location of the steering lock and ignition switch and also the steering switch
gear and a rotary coupler. The rotary coupler provides the electrical connection for the steering wheel mounted airbag,
switches and horn. The upper mounting bracket has two slots, a slotted metal bracket is held in each slot by four resin
shear pins.
The column is mounted on four captive studs which are located on a column mounting bracket. The captive studs
pass through the metal brackets, locknuts secure the steering column to the bulkhead. The two lower mountings are
fixed and cannot move when loads are applied to them. The upper mounting is designed to disengage or deform when
a load is applied, allowing the column to collapse in the event of an accident. The steering column must be replaced
as a complete assembly if necessary.
When an axial load is applied to the upper column tube, energy absorption is achieved by the following mechanism:
lthe mounting bracket deforms,
lthe resin shear pins holding the slotted metal brackets shear,
lthe top mounting bracket slides out of the slotted metal brackets.
The slotted metal brackets remain on the captive studs on the bulkhead. If the column mounting moves, injection
moulded shear pins retaining the two sections of the lower column shaft will shear. This allows the two sections of the
lower shaft to 'telescope' together.
In the event of a collision where the steering box itself moves, two universal joints in the column allow the intermediate
shaft to articulate, minimising movement of the column towards the driver. If movement continues energy absorption
is achieved by the following mechanism:
lthe decouple joint in the intermediate shaft will disengage,
lthe lower section of the steering column shaft will move through the lower bearing,
lthe injection moulded shear pins retaining the two sections of the lower column shaft will shear.
This allows the two sections of the lower shaft to 'telescope' together reducing further column intrusion. Protection to
the drivers face and upper torso is provided by an SRS airbag module located in the centre of the steering wheel.

+ RESTRAINT SYSTEMS, DESCRIPTION AND OPERATION, Description - SRS.

STEERING
57-6 DESCRIPTION AND OPERATION
Tilt adjustment
The column tilt adjuster lever mechanism is located on the LH side of the steering column and allows the upper column
tube, nacelle and steering wheel assemblies to be tilted up or down a maximum of 7.5
° or 47 mm (NAS vehicles have
a smaller range of movement than the ROW vehicles).
The pawl of the mechanism is attached to the lower column and is allowed to pivot, a toothed quadrant is fixed to the
upper column tube.
When the lever on the LH side of the steering column is raised the mechanism releases the pawl from the toothed
quadrant, this allows the column to be moved. When the lever is released two return springs pull the pawl into
engagement with the toothed quadrant.
Steering column lock (All except NAS)
The steering column lock houses the ignition switch, ignition illumination light ring, key lock barrel and the alarm
passive coil. The steering lock is attached to the upper column with two shear bolts. The bolts are tightened to a
torque which shears off the heads of the bolts preventing easy removal of the steering lock.
The steering lock operates by a bolt, which emerges when the ignition key is turned to position 'O' and the ignition key
removed. The bolt engages in a lock collar located on the upper shaft in the upper column tube. The lock collar is
attached to the upper shaft by a 'wave form' interference ring. If a high torque is applied via the steering wheel with
the lock engaged, the lock collar will slip on the upper shaft. This prevents damage to the steering lock, yet still
prevents the vehicle from being driven.
Steering column lock (NAS only)
The steering column lock houses the ignition switch, ignition illumination light ring, key lock barrel and the alarm
passive coil. The steering lock is attached to the upper column with two shear bolts. The bolts are tightened to a
torque which shears off the heads of the bolts preventing easy removal of the steering lock.
The steering column lock operates by a bolt, which emerges when the ignition key is turned to position 'O' and the
ignition key removed. The bolt engages in a groove machined into the upper shaft in the column tube.
Steering wheel
The steering wheel comprises a cast centre and wire frame onto which the soft polyurethane foam is moulded. The
steering wheel is located on the upper column shaft by a spline and is secured with a nut. A remote radio control switch
(if fitted) is located on the LH side of the steering wheel, a cruise control switch may be located on the RH side. Horn
switches are located on each side of the centre of the steering wheel and protrude through the airbag module cover.
Both switches are connected by wires to the rotary coupler connector.
Intermediate shaft
One end of the intermediate shaft is attached to the steering column lower shaft by a splined universal joint and a bolt,
the universal joint is part of a rubber coupling assembly. The rubber coupling assembly is covered by a heat shield
and connects to the lower section of the intermediate shaft via a decouple joint. The rubber coupling reduces the
shocks felt by the driver through the steering wheel. A second universal joint on the other end of the intermediate shaft
is held in by a bolt. The universal joint is splined and engages with the splined rotor (input) shaft of the steering box.
The decouple joint consists of a metal plate that has open ended slots, the plate is bolted through the slots into the
other half of the decouple joint. The top half of the decouple joint has a slot that accepts the lower section of the
intermediate shaft. The slotted metal plate clamps the lower section of the intermediate shaft to the top section. An
indicator clip is installed between the slotted metal plate and the top half of the decouple joint.
If the intermediate shaft is compressed in an accident, the slotted metal plate in the decouple joint will disengage if
sufficient force is applied to the front end of the shaft. If the forces involved do not disengage the shaft, the red
indicator clip located in the decouple joint will break off if the shaft moves. The intermediate shaft cannot be repaired
and must be replaced as an assembly if accident damage occurs.

STEERING
REPAIRS 57-51
Damper - steering
$% 57.55.21
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove 2 nuts and bolts securing steering
damper to drag link and chassis.
3.Compress damper and remove from vehicle.
Refit
1.Position damper to chassis and drag link. Fit
nuts and bolts and tighten to 125 Nm (92 lbf.ft).
2.Remove stand(s) and lower vehicle.
Steering wheel
$% 57.60.01.30
Remove
1.Remove drivers airbag.

+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.
2.Disconnect horn multiplug.
3.Centralise steering wheel with road wheels in
straight ahead position.
4.Restrain steering wheel and loosen self locking
nut securing steering wheel to column.
5.Release steering wheel from column.
6.Remove and discard self locking nut.
7.Remove steering wheel.
8.Attach tape across edge of rotary coupler to
retain correct setting.

STEERING
57-52 REPAIRS
9.Release 2 clips securing each horn button to
steering wheel.
10.Remove screw securing horn earth lead to
steering wheel.
11.Disconnect radio and cruise control multiplugs.
12.Remove 2 screws securing radio switches to
steering wheel.
13.Remove radio switches from steering wheel.
14.Remove 2 screws securing cruise control
switches to steering wheel.
15.Remove cruise control switches from steering
wheel.
16.Remove horns from steering wheel. Refit
1.Fit horn switches to steering wheel and secure
with clips.
2.Fit and tighten screw securing horn earth lead
to steering wheel.
3.Fit cruise control switches to steering wheel
and secure with screws.
4.Fit radio switches to steering wheel and secure
with screws.
5.Connect radio and cruise control multiplugs.
6.Remove tape from rotary coupler.
7.Ensure road wheels are in straight ahead
position and indicator cancelling cam are
aligned horizontally.
8.Fit steering wheel to column.
9.Connect horn multiplug.
10.Fit and tighten new self locking nut securing
steering wheel to column to 43 Nm (32 lbf.ft).
11.Fit drivers airbag.
+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.

RESTRAINT SYSTEMS
DESCRIPTION AND OPERATION 75-1
RESTRAINT SYSTEMS DESCRIPTION AND OPERAT ION
SRS component layout
RHD shown, LHD similar
1DCU
2SRS warning lamp
3Driver airbag module
4Driver seat belt pretensioner
5Passenger airbag module
6Passenger seat belt pretensioner