2002 LAND ROVER DISCOVERY brake

ENGINE MANAGEMENT SYSTEM - V8
DESCRIPTION AND OPERATION 18-2-67
Function
The cruise control ECU activates the vacuum pump assembly to move the pneumatic actuator. This moves the
throttle to the set speed by adjusting the position of the throttle disc.
Accelerating while cruise control is active
There are three ways of increasing vehicle speed when cruise control is active:
lTemporarily increase vehicle speed (e.g. when overtaking another vehicle).
lIncrease vehicle set speed in 1 mph (1.5 km/h) increments.
lIncrease vehicle set speed.
To temporarily increase vehicle speed press the accelerator pedal until the desired speed is reached. When the
accelerator pedal is released, the vehicle coasts back to the set speed. When it reaches the set speed, cruise control
operation continues.
To increase the vehicle set speed in 1 mph (1.5 km/h) increments, tap the SET+ switch. Each tap on the switch
increases vehicle speed.
To increase the vehicle set speed, press and hold the SET+ switch until the desired set speed is reached.
The vehicle set speed will increase if the following conditions are met:
lThe vehicle is under cruise control operation.
lVehicle speed is between 28 - 125 mph (45 - 200 km/h).
lThe brake pedal is not pressed.
lThe clutch pedal is not pressed (manual gearbox only).
lThe gearbox is not in park, reverse or neutral (automatic gearbox only).
Function
The vehicle responds as follows:
lIf the driver accelerates using the accelerator pedal, vehicle speed increases overriding pneumatic actuator
position. When the driver releases the accelerator pedal, the vehicle returns to the set speed.
lIf the SET+ switch is tapped, the driver increases the stored speed and vehicle speed by 1 mph (1.5 km/h) per
tap on the switch.
lIf the driver presses and holds the SET+ switch, the vehicle speed increases until the SET+ switch is released.
This becomes the new set speed for the cruise control ECU.
Switching off cruise control
Switching off cruise control allows the driver to regain control of vehicle speed. It erases the set road speed from the
cruise control ECU memory.
To switch off cruise control, press the cruise control master switch to the off position.
Function
When the cruise control master switch is turned off, the cruise control ECU switches off power to the vacuum pump
assembly. The vacuum dump valve opens releasing the vacuum in the pneumatic actuator, returning the throttle disc
to driver control via the accelerator pedal.

MANIFOLDS AND EXHAUST SYSTEMS - V8
DESCRIPTION AND OPERATION 30-2-3
1Upper manifold
2Bolt 5 off
3Bolt 1 off
4Gasket
5IAC Valve
6IAC valve hose 2 off
7Bolt 4 off
8Bolt 4 off
9Schraeder valve
10Injector 8 off
11Retaining clip 8 off
12Bolt 12 off
13Bolt 2 off
14Clamp 2 off
15Seal 2 off
16Lower manifold/engine gasket
17Coolant pipe18Bolt 3 off
19Bolt
20Heater return pipe
21Pipe connection
22Lower manifold
23Gasket
24Hose clip 2 off
25Throttle housing coolant hose
26Fuel rail
27Throttle housing
28Gasket
29Bolt 4 off
30Plenum
31Rocker cover breather hose connection
32Brake servo vacuum pipe connection
33Hose clip 4 off

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-6 DESCRIPTION AND OPERATION
Inlet plenum
The plenum is mounted transversely on the front of the upper manifold. The plenum divides into two galleries which
connect with the galleries on the upper manifold. The plenum is secured to the upper manifold with four bolts and
sealed with a coated metal gasket.
The plenum provides attachment for the throttle housing, which is secured with four bolts and sealed with a coated
metal gasket. The plenum also has vacuum connections for brake servo, rocker cover breather and fuel vapour from
the charcoal canister. A port on the top of the plenum connects via a hose to the IAC valve.
Exhaust manifolds
Two handed, cast iron exhaust manifolds are used on the V8 engine. Each manifold has four ports which merge into
one flanged outlet positioned centrally on the manifold.
Each manifold is attached to its cylinder head with eight Torx bolts. Each bolt is fitted with a 'cotton reel' shaped spacer
which allows for a longer bolt resulting in increased torque loading on each bolt. Two laminated metal gaskets seal
each manifold to its cylinder head. The flanged outlet on each manifold provides the attachment for the front pipe of
the exhaust system.
Exhaust system
The exhaust system comprises a front pipe assembly with two front pipes each incorporating a catalytic converter, an
intermediate pipe incorporating a silencer and a tail pipe assembly which also has a silencer. The exhaust system is
constructed mainly of 63 mm (2.48 in) diameter extruded pipe with a 1.5 mm (0.06 in) wall thickness. All pipes are
aluminized to resist corrosion and the silencers are fabricated from stainless steel sheet.
Front pipe assembly
The front pipe assembly is of welded and fabricated construction. A front pipe from each exhaust manifold merges
into one flanged connection. Two captive studs on the flange provide attachment to the intermediate pipe with
locknuts. Each front pipe has a welded flange which is attached to each manifold and secured with three studs and
flanged nuts and sealed with a metal laminated gasket. The gasket comprises a heat resistant fibre between two thin
metallic layers to enhance the sealing properties of the gasket.
A catalytic converter is located in each front pipe. The catalytic converters are different shapes to allow clearance
between the body and transmission. Both catalytic converters are of similar internal construction.

+ EMISSION CONTROL - V8, DESCRIPTION AND OPERATION, Emission Control Systems.
CAUTION: Ensure the exhaust system is free from leaks. Exhaust gas leaks upstream of the catalytic
converter could cause internal damage to the catalytic converter.
From the catalytic converters, the front pipes merge into one pipe which terminates at a flanged joint. The flange
connects with the intermediate pipe, sealed with an olive and secured with studs and locknuts.
Intermediate pipe and silencer
The intermediate pipe is of welded and fabricated tubular construction. It connects at its forward end with a flange on
the front pipe assembly and is secured with locknuts to captive studs in the front pipe assembly flange. The rear
section of the intermediate pipe connects to the tail pipe assembly via a flanged joint, sealed with a metal gasket and
secured with locknuts and studs.
The forward and rear sections are joined by a silencer. The silencer is fabricated from stainless steel sheet to form
the body of the silencer. An end plate closes each end of the silencer and is attached to the body with seam joints.
Perforated baffle tubes inside the silencer are connected to the inlet and outlet pipes on each end plate. Internal baffle
plates support the baffle tubes and together with a stainless steel fibre absorb combustion noise as the exhaust gases
pass through the silencer.
The intermediate pipe is attached by two brackets, positioned at each end of the silencer, and mounting rubbers to
the chassis. The mounting rubbers allow ease of alignment and vibration absorption. The two mounting rubbers are
fitted with removable heat deflectors to prevent heat from the silencer damaging the material.

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-11
Tail pipe
$% 30.10.22
Remove
1.Raise vehicle on ramp.
2.Remove 3 nuts securing intermediate pipe/
silencer to tail pipe.
3.Release and remove tail pipe from mounting.
4.Collect intermediate pipe/silencer to tail pipe
gasket.
Refit
1.Clean silencer and tail pipe mating faces.
2.Position tail pipe and secure on mounting.
3.Using a new gasket, align tail pipe to
intermediate pipe/silencer.
4.Fit nuts to intermediate pipe/silencer and
tighten to 25 Nm (18 lbf.ft).
Heat shield - brake servo - Without
Secondary Air Injection
$% 30.10.48
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove nut securing heat shield bracket to
valance.
4.Remove 2 bolts securing heat shield and
remove heat shield.
Refit
1.Fit heat shield, tightening bolts to 25 Nm (18
lbf.ft) and nut to 10 Nm (7 lbf.ft).
2.Connect battery earth lead.
3.Fit battery cover and secure with fixings.

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-12 REPAIRS
Heat shield - brake servo - With
Secondary Air Injection
$% 30.10.48
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove nut securing heat shield bracket to
valance.
4.Remove 2 bolts securing heat shield and
remove heat shield.
Refit
1.Fit heat shield, tightening bolts to 25 Nm (18
lbf.ft) and nut to 10 Nm (7 lbf.ft).
2.Connect battery earth lead.
3.Fit battery cover and secure with fixings.
Gasket - inlet manifold - lower
$% 30.15.08
Remove
1.Remove both rocker covers.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - LH.
l

+ ENGINE - V8, REPAIRS, Gasket
- rocker cover - RH.
2.Release and disconnect LH injector harness
and multiplugs.
3.Release 3 clips securing top hose and remove
top hose.
4.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

MANIFOLDS AND EXHAUST SYSTEMS - V8
REPAIRS 30-2-17
Gasket - inlet manifold - upper - Without
Secondary Air Injection
$% 30.15.24
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
4.Release MAF sensor harness from clip.
5.Loosen clips securing air intake hose. Release
and remove air intake hose.
Note: Pre 03 MY air intake hose illustrated.
6.Disconnect throttle and cruise control cables.
Release cables from abutment bracket and
position aside. 7.Disconnect EVAP pipe from inlet plenum.
8.Disconnect multiplug from throttle body.
9.Remove clip securing breather hose to throttle
body and release breather hose.
10.Position a drain tray beneath the engine to
collect coolant.
11.Release clips securing coolant hoses to
throttle body and disconnect hoses.
12.Disconnect brake servo vacuum pipe from inlet
plenum.

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-18 REPAIRS
13.Disconnect breather hose from inlet plenum.
14.Remove bolt securing coolant rails.
15.Release engine harness from bulkhead clips
and position aside.
16.Remove 4 bolts securing ignition coils and
position ignition coils aside.
17.Release plug leads from upper manifold clips.
18.Disconnect multiplug from IACV.
19.Release and disconnect IACV hose.
20.Remove 6 bolts securing upper inlet manifold
and remove upper inlet manifold. 21.Collect upper inlet manifold gasket.
Refit
1.Clean upper and lower inlet manifold mating
faces, dowels and dowel holes.
2.Using a new gasket, position upper inlet
manifold. Fit bolts and, working in a diagonal
sequence, tighten to 22 Nm (16 lbf.ft).
3.Connect hose and multiplug to TP sensor.
4.Connect hose and multiplug to IACV. Secure
hose with clip.
5.Secure ht leads to upper inlet manifold.
6.Position ignition coils, fit bolts and tighten to 8
Nm (6 lbf.ft).
7.Ensure clip under ignition coils is located on
fuel pipe.
8.Secure engine harness in bulkhead clips.
9.Fit coolant rail bolt and tighten to 22 Nm (16
lbf.ft).
10.Connect breather hose to inlet plenum.
11.Connect brake servo vacuum pipe to inlet
plenum.
12.Connect EVAP pipe to inlet plenum.
13.Position coolant hoses to throttle body and
secure hose clips.
14.Fit breather hose to throttle body and secure
clip.
15.Connect multiplug to throttle body.
16.Connect throttle and cruise control cables and
secure in throttle body cams.
17.Adjust throttle and cruise control cables.
l

+ ENGINE MANAGEMENT SYSTEM
- V8, ADJUSTMENTS, Cable - cruise
control.
l

+ ENGINE MANAGEMENT SYSTEM
- V8, ADJUSTMENTS, Cable - throttle.
18.Connect air intake hose and tighten clips.
Secure harness to air intake hose.
19.Top-up cooling system

+ MAINTENANCE, PROCEDURES,
Cooling system..
20.Fit bonnet.

+ EXTERIOR FITTINGS, REPAIRS,
Bonnet.
21.Connect battery earth lead.
22.Fit battery cover and secure with fixings.

MANIFOLDS AND EXHAUST SYSTEMS - V8
30-2-20 REPAIRS
20.Position container to collect spillage.
21.Release clips and disconnect 2 coolant hoses
from throttle housing.
22.Loosen outer cable locknuts and release
throttle and cruise control cables from
abutment.
23.Release throttle and cruise control cables from
clips and throttle cams and position aside.
24.Depress plastic collar and disconnect brake
servo hose from inlet manifold.
25.Release clip and disconnect breather hose
from manifold.
26.Disconnect vacuum hose from manifold.
27.Release engine harness from bulkhead clips
and position aside.
28.Release and remove bonnet seal from rear of
engine bay.
29.Remove 2 bolts securing air pipe and coil
bracket to manifold.
30.Loosen 2 lower bolts securing coil bracket
sufficiently to allow bracket to clear manifold.31.Release plug leads from upper manifold clips.
32.Loosen clip and disconnect air hose from air
valve.
33.Remove 2 nuts securing RH air manifold
support bracket to upper inlet manifold.