2002 LAND ROVER DISCOVERY heater

HEATING AND VENTILATION
80-18REPAIRS
Refit
1.Position servo and connect operating lever.
2.Fit and tighten screws securing servo.
3.Connect multiplug to servo.
4.Position ECU assembly, fit and tighten nuts.
5.Position BCM, fit and tighten bolt.
6.Position toe board and secure with studs.
7.Position glove box, fit and tighten screws.
Switch - recirculation control
$% 80.10.21
Remove
1.Remove louvre panel assembly.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Louvre panel assembly - centre
fascia.
2.Disconnect multiplug from recirculation switch.
3.Remove recirculation switch from heater
control panel.
Refit
1.Fit recirculation switch to heater control panel
and connect multiplug.
2.Fit louvre panel assembly.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Louvre panel assembly - centre
fascia.

HEATING AND VENTILATION
REPAIRS 80-19
Servo - air distribution control
$% 80.10.30
Remove
1.Disconnect battery earth lead.
2. RHD models: Remove heater assembly.

+ HEATING AND VENTILATION,
REPAIRS, Heater assembly - models with
air conditioning.
3. LHD models: Remove heater motor assembly.

+ HEATING AND VENTILATION,
REPAIRS, Blower assembly.
4.Release clip securing operating lever and
release the lever from linkage.
5.Remove 3 screws securing servo support
bracket to casing and release servo.
6.Disconnect multiplug from servo and remove
servo. 7.Release clip securing operating lever to servo
and remove lever.
8.Remove 2 screws securing support bracket
and remove support bracket.
Refit
1.Position support bracket to servo and secure
with screws.
2.Position servo lever to servo and secure clip.
3.Connect multiplug to servo.
4.Position servo to casing and secure with
screws.
5.Connect operating lever to servo and secure
with clip.
6. RHD models: Fit heater assembly.

+ HEATING AND VENTILATION,
REPAIRS, Heater assembly - models with
air conditioning.
7. LHD models: Fit heater motor assembly.

+ HEATING AND VENTILATION,
REPAIRS, Blower assembly.
8.Connect battery earth lead.

HEATING AND VENTILATION
80-20REPAIRS
Servo - air temperature control
$% 80.10.42
Remove
1.Disconnect battery earth lead.
2. Driver side: Remove heater assembly.

+ HEATING AND VENTILATION,
REPAIRS, Heater assembly - models with
air conditioning.
3. Passenger side: Remove blower assembly.

+ HEATING AND VENTILATION,
REPAIRS, Blower assembly.
4.Disconnect multiplug from servo.
5.Remove 3 screws securing servo to casing and
release servo.
6.Release clip securing operating lever, release
the lever and remove servo. lever.
Refit
1.Connect operating lever to servo and secure
with clip.
2.Position servo to casing, engage locating pegs
and secure with screws.
3.Connect multiplug to servo.
4. Driver side: Fit heater assembly.

+ HEATING AND VENTILATION,
REPAIRS, Heater assembly - models with
air conditioning.
5. Passenger side: Fit blower assembly.

+ HEATING AND VENTILATION,
REPAIRS, Blower assembly.
6.Connect battery earth lead.
Plenum Air Intake
$% 80.15.62
Remove
1.Remove both windscreen side finishers.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
2.Remove caps from windscreen wiper arms.
3.Remove nuts securing wiper arms to wiper
linkage.
4.Remove both wiper arms.
5.Remove lock nuts from wiper linkage and
collect washer and rubber spacers.
6.Remove 2 trim clips and centre bolt securing
plenum air intake to body.
7.Remove plenum air intake.

HEATING AND VENTILATION
REPAIRS 80-21
Refit
1.Fit plenum air intake.
2.Fit trim clips and centre bolt securing plenum
air intake to body.
3.Fit rubber spacers and washers to wiper
linkage.
4.Fit locknuts to wiper linkage and tighten to 7
Nm (5.2 lbf.ft).
5.Fit wiper arms to wiper linkage.
6.Fit nuts securing wiper arms to wiper linkage
and tighten to 15 Nm (11 lbf.ft).
7.Fit caps to wiper arms.
8.Fit both windscreen side finishers.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
Heater assembly - models without air
conditioning
$% 80.20.01.99
Remove
1.Drain cooling system.
l

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
l

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
2. Diesel models: Remove 3 bolts and remove
engine cover.
3.Release clips and disconnect coolant hoses
from heater pipes.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove facia assembly.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.

HEATING AND VENTILATION
80-22REPAIRS
5.Disconnect harness multiplug from heater
blower motor.
6.Remove bolt and 2 nuts securing heater
blower housing assembly to body and remove
blower.
7.Disconnect 2 drain tubes from base of heater. 8.Remove 2 screws securing console bracket to
tunnel and remove bracket.
9.Release radio coaxial cable from behind heater
pipes.
10.Protect the carpet from coolant spillage.
11.Remove 4 nuts and 1 bolt securing heater to
body.
12.Remove heater from vehicle.
13.Remove 2 screws securing heater RH and LH
footwell outlet duct to heater casing and
remove ducts.

HEATING AND VENTILATION
REPAIRS 80-23
14.Remove 2 screws securing matrix pipe bracket
to heater casing.
15.Remove screw securing pipe clamp to heater
casing and remove clamp.
16.Carefully remove matrix from heater.
Refit
1.Fit matrix into heater casing.
2.Fit screws securing pipe bracket to heater
casing.
3.Fit pipe clamp and secure with screw.
4.Fit heater ducts and secure with screws.
5.Position heater assembly to vehicle, ensure
heater coolant pipe grommet is correctly
located in bulkhead and secure with nuts and
bolt.
6.Fit radio coaxial cable behind heater pipes.
7.Fit console bracket and secure with screws.
8.Connect drain tubes to base of heater.
9.Fit blower unit to heater and secure to body
with nuts and bolt.
10.Connect harness multiplug to blower motor.
11.Fit facia assembly

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
12.Connect heater hoses and secure with clips.
13. Diesel models: Fit engine cover and secure
with bolts.
14.Refill cooling system
l

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
l

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
Heater assembly - models with air
conditioning
$% 80.20.01.98
Remove
1.Drain cooling system.
l

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
l

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
2.Evacuate air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3.Release 2 clips securing heater hoses to
heater and release hoses.
4.Remove 2 bolts securing air conditioning pipes
to evaporator, release pipes and discard 'O'
rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.

HEATING AND VENTILATION
80-24REPAIRS
6.Remove screws securing rear heater ducting
and remove ducting.
7.Disconnect multiplug from heater motor.
8.Remove 2 nuts and bolt securing heater motor
assembly and remove motor assembly from
heater casing. 9.Remove 2 screws securing centre console
support bracket and remove bracket.
10.Remove 2 nuts securing RH fascia support
bracket and remove bracket.

HEATING AND VENTILATION
REPAIRS 80-25
11.Disconnect both evaporator drain hoses.
12.Remove front heater ducting.
13.Remove 4 nuts and bolt securing heater
assembly, release heater assembly from
bulkhead grommet and remove from vehicle.
Refit
1.Position heater assembly to bulkhead, locate
heater in bulkhead grommet.
2.Fit nuts and bolt securing heater and tighten to
16 Nm (12 lbf.ft).
3.Position RH fascia support bracket, fit and
tighten nuts.
4.Fit front heater ducting.
5.Position centre console support bracket, fit and
tighten screws.
6.Connect evaporator drain hoses.
7.Position heater motor to heater casing, fit nuts
and bolt and tighten to 19 Nm (14 lbf.ft).
8.Connect multiplug heater motor.
9.Position rear heater ducting and secure with
screws.
10.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
11.Using new 'O' rings, position air conditioning
pipes to evaporator fit bolts and tighten to 5 Nm
(3.7 lbf.ft).
12.Position heater hoses and secure hose clips.
13.Recharge air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
14.Refill cooling system.
l

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
l

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
Blower assembly
$% 80.20.12
Remove
1.Remove 4 studs securing toe board and
remove toe board.
2.Remove 4 screws securing glove box, release
catch and remove glove box.
3.Disconnect battery earth lead.