2002 LAND ROVER DISCOVERY AUX

FRONT SUSPENSION
60-44 REPAIRS
Pump - ACE - diesel
$% 60.60.10
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Disconnect multiplugs from mass air flow
sensor and ambient air pressure sensor.
3.Release clips and disconnect mass air flow
sensor from air cleaner.
4.Loosen hose clip, disconnect inlet air hose
from turbo charger and move hose aside. 5.Release ACE/PAS reservoir from bracket and
move aside.
6.Loosen clip and disconnect inlet hose from
intercooler.
7.Position container to catch spillage.

FRONT SUSPENSION
REPAIRS 60-45
8.Release clip and disconnect suction hose from
ACE pump.
9.Remove banjo bolt and disconnect pressure
pipe from ACE pump. Discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
10.Remove 3 bolts securing ACE pump to
mounting and remove ACE pump.
11.Restrain pulley, remove 3 securing bolts and
remove pulley from ACE pump.Refit
1.Clean mating faces of pulley and ACE pump.
2.Position pulley to ACE pump and fit bolts.
Restrain pulley and tighten bolts to 25 Nm (18
lbf.ft).
3.Clean mating faces of ACE pump and
mounting.
4.Connect suction hose to ACE pump and secure
with clip.
5.Ensure there is sufficient fluid in ACE/PAS
reservoir to prime ACE pump.
6.Position ACE pump below level of ACE/PAS
reservoir, with suction hose uppermost, and
allow fluid from ACE/PAS reservoir to
completely fill ACE pump.
7.Position ACE pump to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
8.Rotate ACE pump clockwise (viewed from
pulley end) until a steady flow of fluid runs from
outlet port.
9.Connect pressure pipe to ACE pump with banjo
bolt and new sealing washers. Tighten banjo
bolt to 28 Nm (21 lbf.ft).
10.Connect hose to intercooler and secure with
clip.
11.Fit ACE/PAS reservoir into mounting bracket.
12.Connect air hose to turbo charger and secure
with clip.
13.Fit mass air flow sensor to air filter and secure
with clips.
14.Connect multiplugs to mass air flow sensor and
ambient air pressure sensor.
15.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
16.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.

BRAKES
70-10 DESCRIPTION AND OPERATION
Vacuum pump (diesel models only)
1Alternator
2Vacuum pump
3Brake servo assembly vacuum connection
4Oil feed pipe
5Oil drain pipe
As the diesel engine air inlet system does not produce sufficient depression to operate the brake servo assembly, an
engine driven vacuum pump is installed.
The vacuum pump is integrated with the engine alternator and driven by the auxiliary drive belt. The pump is a rotary
vane type, lubricated and cooled by engine oil supplied through a pipe connected to the engine block and returned
through a pipe connected to the engine oil sump. Air extracted from the brake servo assembly is vented into the oil
sump with returning lubricating oil.

BRAKES
70-42 REPAIRS
Vacuum pump - servo
$% 70.50.19
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Release cover and remove nut securing lead
to alternator.
3.Disconnect alternator multiplug.
4.Remove bolt (LH thread) and remove auxiliary
drive belt tensioner. 5.Remove bolt securing support stay to
alternator.
6.Release clip and disconnect oil drain hose from
vacuum pump.
7.Disconnect vacuum pump oil supply pipe from
cylinder head and discard 'O' ring.
8.Remove bolt securing alternator and release
from mounting bracket.
9.Disconnect vacuum hose from vacuum pump.
10.Remove alternator. Take care not to damage
radiator cooling fins.
11.Remove 4 bolts, and remove vacuum pump
from alternator.
CAUTION: Always fit plugs to open
connections to prevent contamination.

BRAKES
REPAIRS 70-43
Refit
1.Clean mating faces of alternator and vacuum
pump.
2.Fit vacuum pump to alternator and tighten
bolts to 8 Nm (6 lbf.ft).
3.Position alternator to engine and connect
multiplug.
4.Connect vacuum hose and oil drain hose to
vacuum pump and secure clips.
5.With assistance align alternator to mounting
bracket and fit but do not tighten bolt.
6.Fit bolt securing support stay to alternator and
tighten to 25 Nm (18 lbf.ft) .
7.Tighten bolt securing alternator to mounting
bracket to 45 Nm (33 lbf.ft).
8.Using new 'O' ring, connect oil supply pipe to
cylinder head and tighten to 10 Nm (7 lbf.ft).
9.Connect lead to alternator and tighten nut to 6
Nm (4.4 lbf.ft).
10.Fit auxiliary drive belt tensioner and tighten bolt
to 50 Nm (37 lbf.ft).
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
Housing - caliper - front
$% 70.55.24
Remove
1.Raise front of vehicle, one side.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel(s).
3.Clamp brake hose to prevent fluid loss.
4.Remove brake hose banjo bolt and discard
sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove 2 guide pin bolts and remove caliper
housing from carrier.
6.Remove 2 brake pads from caliper carrier.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-13
Panel - auxiliary switch
$% 76.46.38
Remove
1.Carefully remove electric exterior mirror switch
from auxiliary switch panel and disconnect
multiplug.
2. Models with headlamp levelling: Release
knob and remove nut securing headlamp
levelling switch to auxiliary switch panel.
3.Release 2 fasteners and open fascia access
panel.
4. Models with headlamp levelling: Remove
headlamp levelling switch from auxiliary switch
panel and disconnect multiplug.
5. Models with A/C: Remove 2 screws securing
in-car temperature sensor to auxiliary switch
panel.
6. Models with A/C: Disconnect multiplug from
in-car temperature sensor and remove from
auxiliary switch panel.
7.Release 2 clips securing auxiliary switch panel
to fascia and remove panel.
Refit
1.Position auxiliary switch panel to fascia and clip
into position.
2. Models with A/C: Connect multiplug to in-car
temperature sensor.
3. Models with A/C: Position in-car temperature
sensor to auxiliary switch panel and secure with
screws.
4. Models with headlamp levelling: Position
headlamp levelling switch to auxiliary switch
panel and secure with nut.5. Models with headlamp levelling: Replace
cap and connect multiplug to headlamp
levelling switch.
6.Connect multiplug to exterior mirror switch and
fit switch to auxiliary switch panel.

HEATING AND VENTILATION
80-8DESCRIPTION AND OPERATION
Control panel
The controls for heating and ventilation are installed on a control panel in the centre of the fascia, below the radio.
Three rotary knobs control the LH and RH outlet temperatures and distribution. A slider switch controls blower speed.
A latching pushswitch controls the selection of fresh/recirculated air; an amber LED in the switch illuminates when
recirculated air is selected.
Graphics on the panel and the controls indicate the function and operating positions of the controls.
Outlet vent
The outlet vent promotes the free flow of heating and ventilation air through the cabin. The outlet vent is installed in
the RH rear quarter body panel and vents cabin air into the sheltered area between the rear quarter body panel and
the outer body side panel. The vent consists of a grille covered by soft rubber flaps and is effectively a non-return
valve. The flap opens and closes automatically depending on the differential between cabin and outside air pressures.
FBH system (diesel models only)
The FBH system is an auxiliary heating system that compensates for the relatively low coolant temperatures inherent
in the diesel engine. At low ambient temperatures, the FBH system heats the coolant supply to the heater assembly,
and maintains it within the temperature range required for good in-car heating performance. Operation is fully
automatic, with no intervention required by the driver.
The system consists of an air temperature sensor, a FBH fuel pump and a FBH unit. Fuel for the FBH system is taken
from the fuel tank, through a line attached to the fuel tank's fuel pump, and supplied via the FBH fuel pump to the FBH
unit. The connection on the fuel tank's fuel pump incorporates a tube which extends down into the tank. At the FBH
unit connection, the fuel line incorporates a self-sealing, quick disconnect coupling. In the FBH unit, the fuel delivered
by the FBH fuel pump is burned and the resultant heat output is used to heat the coolant. An ECU integrated into the
FBH unit controls the operation of the system at one of two heat output levels, 2.5 kW at part load and 5 kW at full load
Ambient temperature sensor
The ambient temperature sensor controls a power supply from the alternator to the FBH unit. The sensor is installed
on the RH support strut of the bonnet closing panel and contains a temperature sensitive switch that is closed at
temperatures below 5
°C (41 °F) and open at temperatures of 5 °C (41 °F) and above.

AIR CONDITIONING
DESCRIPTION AND OPERATION 82-5
To accomplish the transfer of heat, the refrigerant is circulated around the system, where it passes through two
pressure/temperature regimes. In each of the pressure/temperature regimes, the refrigerant changes state, during
which process maximum heat absorption or release occurs. The low pressure/temperature regime is from the
thermostatic expansion valve, through the evaporator to the compressor; the refrigerant decreases in pressure and
temperature at the thermostatic expansion valve, then changes state from liquid to vapour in the evaporator, to absorb
heat. The high pressure/temperature regime is from the compressor, through the condenser and receiver drier to the
thermostatic expansion valve; the refrigerant increases in pressure and temperature as it passes through the
compressor, then releases heat and changes state from vapour to liquid in the condenser.
Compressor
1Pulley
2Inlet connection
3Outlet connection
4Pressure relief valve
5Clutch connector
The compressor circulates the refrigerant around the system by compressing low pressure, low temperature vapour
from the evaporator and discharging the resultant high pressure, high temperature vapour to the condenser.
The compressor is attached to a mounting bracket on the engine, and is a ten cylinder swash plate unit with a fixed
displacement of 177 ml/rev (0.19 US qt/rev). The auxiliary drive belt drives the compressor via a pulley and an
electrically actuated clutch. Operation of the clutch is controlled by the Engine Control Module (ECM).
To protect the refrigerant system from unacceptably high pressure, a pressure relief valve is installed in the outlet side
of the compressor. The pressure relief valve is set to operate at 34.3 to 41.4 bars (497 to 600 lbf.in
2) and vents excess
pressure into the engine compartment.