2002 LAND ROVER DISCOVERY oil

SEATS
76-5-4 DESCRIPTION AND OPERATION
Description - electric seats
General
All markets use the same electric seat system. Electically operated lumbar support is optional. The system consists
of an electrical sub-system and a mechanical sub-system.
The electrical sub-system consists of the following components:
lBCU.
lSeat power relays.
lSeat switch packs.
lSeat fore/ aft motors.
lSeat cushion front up/ down motors.
lSeat cushion rear up/ down motors.
lSeat squab motor.
lLumbar pump.
lLumbar deflate solenoid.
The mechanical sub-system consist of the following components:
lGear wheels.
lRack and pinion assemblies.
Seat power relay
Located beneath the seat, the seat power relay supplies battery voltage to the satellite fuse box. Operation of the
relays is controlled by the BCU.
Voltage to the seat power relays is from fuse 5 in the engine compartment fuse box. The BCU controls the earth for
the relay coils. Operating the seat power relays provides voltage to the satellite fuse box under each seat.
Satellite fuse box
Located beneath the seat, the satellite fuse box provides circuit protection for the wiring to the seat switches and
motors. It also protects the lumbar inflate and deflate circuits.
The seat power relay provides voltage directly to the 40A fuse in the satellite fuse box. Voltage from this fuse feeds
the seat switch pack. The 3A fuses in the satellite fuse box protect the wiring to the lumbar pump and lumbar deflate
solenoid. Voltage to the 3A fuses comes from the seat switch pack.

SEATS
DESCRIPTION AND OPERATION 76-5-7
Operation - electric seats
Seat power relay enable line
The BCU provides the seat power relays with an earth supply to the relay coil that enables the relay operation. When
this seat power relay enable line is active, the seat power relay energises allowing seat operation.
In order for the seat power relay to be active the BCU must detect either of the following condition options:
lIgnition switch in position II.
lIgnition switch in position II or driver's door within 45 seconds of opening.
Seat fore/ aft movement
When the cushion switch is operated and the seat power relay enable line is operating, power and earth are supplied
to the motor in the seat, allowing the seat to move forward or backward depending on switch position. The motor
drives a gear wheel along a gear rack connected to the seat base. Sliding the cushion switch forward causes the motor
to drive the seat forward. Sliding the cushion switch rearward reverses polarity of the voltage at the seat motor, driving
the seat rearward.
Seat cushion front up/ down movement
When the cushion switch is operated and the seat power relay enable line is operating, power and earth are supplied
to the motor in the seat, allowing the front of the seat cushion to move upward or downward depending on switch
position. The motor drives a gear wheel along a gear rack connected to the seat base. Sliding the front of the cushion
switch upward causes the motor to drive the seat upward. Sliding the front of the cushion switch downward reverses
polarity of the voltage at the seat motor driving the seat downward.
Seat cushion rear up/ down movement
When the cushion switch is operated and the seat power relay enable line is operating, power and earth are supplied
to the motor in the seat, allowing the seat to move upwards or downwards depending on switch position. The motor
drives a gear wheel along a gear rack connected to the seat base. Sliding the rear of the cushion switch upward
causes the motor to drive the seat upward. Sliding the rear of the cushion switch downward reverses polarity of the
voltage at the seat motor driving the seat downward.
Squab fore/ aft movement
When the squab switch is operated and the seat power relay enable line is operating, power and earth is supplied to
the motor in the squab, allowing the squab to move forward or backward depending on switch position. The motor
drives a gear wheel along a rotary gear rack connected to the squab. Sliding the squab switch forward causes the
motor to drive the squab forward. Sliding the squab switch rearward reverses polarity of the voltage at the seat motor
driving the squab rearward.
Lumbar inflate/ deflate
Sliding the squab switch upwards when the seat power relay enable line is operating applies voltage to the lumbar
pump. The lumbar pump inflates the lumbar bladder, increasing lumbar support. The lumbar pump and the normally
closed lumbar deflate solenoid hold the air in the bladder. Sliding the squab switch downwards applies voltage to the
deflate solenoid, venting the air in the lumbar bladder to atmosphere, decreasing lumbar support.
Diagnostics
TestBook can only verify that the seat power relay line is enabled. It cannot determine the status of the system or any
of the components.

HEATING AND VENTILATION
DESCRIPTION AND OPERATION 80-9
FBH fuel pump
The FBH fuel pump regulates the fuel supply to the FBH unit. The FBH fuel pump is installed in a rubber mounting on
the chassis crossmember immediately in front of the fuel tank. The pump is a self priming, solenoid operated plunger
pump, with a fixed displacement of 0.063 ml/Hz. The ECU in the FBH unit outputs a pulse width modulated signal to
control the operation of the pump. When the pump is de-energised, it provides a positive shut-off of the fuel supply to
the FBH unit.
FBH fuel pump nominal operating speeds/outputs
Sectioned view of FBH fuel pump
1Solenoid coil
2Plunger
3Filter insert
4Fuel line connector
5'O' ring seal6Spring
7Piston
8Bush
9Fuel line connector
10Non return valve
The solenoid coil of the FBH fuel pump is installed around a housing which contains a plunger and piston. The piston
locates in a bush, and a spring is installed on the piston between the bush and the plunger. A filter insert and a fuel
line connector are installed in the inlet end of the housing. A non return valve and a fuel line connector are installed
in the fuel outlet end of the housing.
While the solenoid coil is de-energised, the spring holds the piston and plunger in the 'closed' position at the inlet end
of the housing. An 'O' ring seal on the plunger provides a fuel tight seal between the plunger and the filter insert,
preventing any flow through the pump. When the solenoid coil is energised, the piston and plunger move towards the
outlet end of the housing, until the plunger contacts the bush, and draw fuel in through the inlet connection and filter.
The initial movement of the piston also closes transverse drillings in the bush and isolates the pumping chamber at
the outlet end of the housing. Subsequent movement of the piston then forces fuel from the pumping chamber through
the non return valve and into the line to the FBH unit. When the solenoid coil de-energises, the spring moves the piston
and plunger back towards the closed position. As the piston and plunger move towards the closed position, fuel flows
passed the plunger and through the annular gaps and transverse holes in the bush to replenish the pumping chamber.
Operating phase Speed, Hz Output, l/h (US galls/h)
Start sequence 0.70 0.159 (0.042)
Part load 1.35 0.306 (0.081)
Full load 2.70 0.612 (0.163)

HEATING AND VENTILATION
REPAIRS 80-29
Pipe - Heater - Feed
$% 80.25.07
Remove
1.Remove heater return pipe.

+ HEATING AND VENTILATION,
REPAIRS, Pipe - Heater - Return.
2.Release clip securing heater feed hose to
heater feed pipe and disconnect hose from
pipe.
3.Remove nut securing heater feed pipe to
plenum chamber.
4.Press quick release connector and release
heater feed pipe from plenum chamber.
5.Remove and discard 'O' ring from pipe.
Refit
1.Fit new 'O' ring to heater feed pipe and lubricate
with castor oil.
2.Secure heater feed pipe to plenum chamber.
3.Fit and tighten nut securing heater feed pipe to
plenum chamber.
4.Connect heater feed hose to heater feed pipe
and secure with clip.
5.Fit heater return pipe.

+ HEATING AND VENTILATION,
REPAIRS, Pipe - Heater - Return.
Pipe - Heater - Return
$% 80.25.12
Remove
1.Drain engine coolant.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
2.Release clip securing heater return hose to
heater return pipe and disconnect hose from
pipe.
3.Remove bolt securing heater return pipe to
heater feed pipe.
4.Release clips securing engine harness and
vacuum pipe to heater return pipe.
5.Remove bolt securing heater return pipe to
cylinder head.
6.Release clip securing engine coolant hose to
heater return pipe.
7.Release engine coolant hose from heater
return pipe and collect pipe.
M80 0435
23
4
M80 0437
M80 0438
4
46
7
5

AIR CONDITIONING
82-4DESCRIPTION AND OPERATION
Refrigerant system
Schematic of air conditioning system
1Evaporator
2Thermostatic expansion valve
3Low pressure servicing connection
4Outlet to rear A/C system (where fitted)
5Dual pressure switch
6Receiver drier
7Cooling fan
8Condenser
9Compressor10Inlet from rear A/C system (where fitted)
11High pressure servicing connection
12Air flows
aAmbient air
bCooled air
cAmbient air through condenser
13Refrigerant
aLiquid
bVapour
The refrigerant system transfers heat from the vehicle interior to the outside atmosphere to provide the heater
assembly with dehumidified cool air. The system comprises a compressor, condenser, receiver drier, thermostatic
expansion valve and evaporator, joined together by refrigerant lines. The system is a sealed, closed loop, filled with
a charge weight of R134a refrigerant as the heat transfer medium. Oil is added to the refrigerant to lubricate the
internal components of the compressor.

AIR CONDITIONING
82-6DESCRIPTION AND OPERATION
Condenser
1Condenser matrix
2Outlet connection
3Inlet connection
The condenser transfers heat from the refrigerant to the surrounding air.
The condenser is installed immediately in front of the oil coolers. Rubber mounting bushes are used to mount the
condenser to the chassis sidemembers and brackets on the headlamp panels.
Ambient air, passing through the condenser matrix due to ram effect and/or the cooling fan, absorbs heat from the
refrigerant, which changes state from a vapour to a liquid.

AIR CONDITIONING
DESCRIPTION AND OPERATION 82-17
RH temperature. Illuminates to show the RH temperature selection, external air temperature or diagnostic fault code.
Blower speed. Illuminates when the blower speed is manually selected. Also illuminates in the automatic modes when
one of the temperatures is set to LO or HI.
External air temperature. EXT illuminates to show that external air temperature is selected on.
All temperature indications on the display are in either
°C or °F. For 1 second after the system is first switched on, the
display shows only
°C or °F, in the LH temperature window, to indicate which temperature scale is in use. After 1
second, the
°C or °F indication goes off and the display shows all relevant outputs.
Temperature conversion: While the system is on, the temperature indications on the display can be switched between
the two scales by pressing and holding the fresh/recirculated air switch, then pressing and holding the A/C on/off
switch until the audible warning sounds (approximately 3 seconds).
Dual pressure switch
The dual pressure switch protects the refrigerant system from extremes of pressure. The normally closed switch is
installed in the top of the receiver drier. If minimum or maximum pressure limits are exceeded the switch contacts
open, causing the compressor clutch to be disengaged. The minimum pressure limit protects the compressor, by
preventing operation of the system unless there is a minimum refrigerant pressure (and thus refrigerant and
lubricating oil) in the system. The maximum pressure limit keeps the refrigerant system within a safe operating
pressure.
Dual pressure switch nominal operating pressures
Evaporator temperature sensor
The evaporator temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input of the
evaporator air outlet temperature. The evaporator temperature sensor is installed in a clip which locates in the
evaporator matrix in the heater assembly. The ATC ECU uses the input to prevent the formation of ice on the
evaporator.
In-car temperature sensor
The in-car temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input of cabin air
temperature. The sensor is integrated into the inlet of an electric fan, which is installed behind a grille in the fascia
outboard of the steering column. The fan runs continuously, while the ignition is on, to draw air through the grille and
across the sensor.
Sunlight sensor
The sunlight sensor consists of two diodes that provide the ATC ECU with inputs of light intensity, one as sensed
coming from the left of the vehicle and one as sensed coming from the right. The inputs are used as a measure of the
solar heating effect on vehicle occupants. The sensor is installed in the centre of the fascia upper surface.
Heater coolant temperature sensor
The heater coolant temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input related
to heater matrix coolant temperature. The sensor is installed in the casing of the heater assembly and presses against
the end tank of the heater matrix.
Ambient temperature sensor
The ambient temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input of external
air temperature. The sensor is attached to the cooling fan mounting bracket in front of the condenser.
Limit Opening pressure, bar (lbf.in2) Closing pressure, bar (lbf.in2)
Minimum 2.0 (29.0), pressure decreasing 2.3 (33.4), pressure increasing
Maximum 32 (464), pressure increasing 26 (377), pressure decreasing

AIR CONDITIONING
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 82-29
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Refrigerant recovery, recycling and
recharging
$% 82.30.02
Recovery
1.Remove dust caps from high and low pressure
connectors.
2.Connect high and low pressure hoses to
appropriate connections.
3.Open valves on connectors.
4.Turn valves on refrigerant station to correct
positions.
Operate the refrigerant station in accordance
with the manufacturers instructions.
5.Turn Process switch to correct position.
6.Turn Main switch to 'ON'.
7.Allow station to recover refrigerant from
system.
WARNING: Refrigerant must always be
recycled before re-use to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system.
Recycling should always be carried out with
equipment which is design certified by
Underwriter Laboratory Inc. for compliance
with SAE J1991. Other equipment may not
recycle refrigerant to the required level of
purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with
any other type of refrigerant.
Refrigerant R134a from domestic and
commercial sources must not be used in
motor vehicle air conditioning systems.
8.Close valves on refrigerant station.
9.Turn Main switch to 'OFF'.
10.Close valves on connectors.
11.Disconnect connectors high and low pressure
hoses from connectors.
12.Fit dust caps to connectors. 13.Open tap at rear of station to drain refrigerant
oil.
14.Measure and record quantity of refrigerant oil
recovered from system.
15.Close tap at rear of station.
Evacuation
WARNING: Servicing must only be carried
out by personnel familiar with both the
vehicle system and the charging and testing
equipment. All operations must be carried
out in a well ventilated area away from open
flame and heat sources.
1.Remove dust caps from high and low pressure
connectors.
2.Connect high and low pressure hoses to
appropriate connections.
3.Open valves on connectors.
4.Turn valves on refrigerant station to correct
positions.
5.Turn Process switch to correct position.
6.Turn Main switch to 'ON'.
7.Allow station to evacuate system.
Recharging
NOTE: When recharging, always make
allowance for refrigerant in the line between the
charging station and the vehicle. This is
calculated at 30 grammes/metre of charging
line. System charge weights are 700
± 25
grammes for front A/C system only and 900
±
25 grammes for combined front and rear A/C
system.
1.Close valves on refrigerant station.
2.Close valve on oil charger.
3.Disconnect yellow hose from refrigerant
station.
4.Remove lid from oil charger.
5.Pour same quantity of refrigerant oil into oil
charger as collected during recovery. If the
following components have been renewed, add
the following additional quantity of lubricating
oil:
lCondenser = 40 cm
3
lEvaporator = 40 cm3
lPipe or hose = 5 cm3/metre
lReceiver/dryer = 15 cm3.
6.Fit lid to oil charger.
7.Connect yellow hose to refrigerant station.
8.Open valve on oil charger.
9.Move pointer on refrigerant gauge to mark
position of refrigerant charge quantity.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Capacities.