2002 LAND ROVER DISCOVERY sensor

CONTENTS
CONTENTS 3
Alarm handset battery ..................................................................................................................... 10-6
Road wheels ................................................................................................................................... 10-7
Tyres .............................................................................................................................................. 10-7
Brake pads, discs and calipers ....................................................................................................... 10-7
Road wheel speed sensors ............................................................................................................. 10-7
Brake fluid ....................................................................................................................................... 10-8
Fuel filter - diesel engine ................................................................................................................. 10-8
Fuel filter sedimenter ...................................................................................................................... 10-8
Road wheels ................................................................................................................................... 10-8
Radiator/Intercooler ........................................................................................................................ 10-8
Ambient air Temperature and pressure sensor .............................................................................. 10-8
Doors, bonnet and fuel filler flap ..................................................................................................... 10-9
Air suspension intake filter .............................................................................................................. 10-9
Anti-freeze....................................................................................................................................... 10-9
Cooling system ............................................................................................................................... 10-9
Spark plugs - V8 engine.................................................................................................................. 10-10
Air cleaner - V8 engine ................................................................................................................... 10-11
Air cleaner and dump valve - diesel engine .................................................................................... 10-11
Auxiliary drive belt ........................................................................................................................... 10-11
Auxiliary drive belt - V8 engine ....................................................................................................... 10-12
Auxiliary drive belt - diesel engine .................................................................................................. 10-12
Fluid reservoirs ............................................................................................................................... 10-12
Steering box .................................................................................................................................... 10-13
Battery ............................................................................................................................................. 10-13
Intercooler - diesel engine............................................................................................................... 10-14
Engine oil - V8 engine ..................................................................................................................... 10-14
Engine oil - diesel engine ................................................................................................................ 10-14
Centrifuge rotor – diesel engine ...................................................................................................... 10-15
Engine oil filter - diesel engine ........................................................................................................ 10-15
Engine oil filter – V8 engine ............................................................................................................ 10-15
Manual gearbox .............................................................................................................................. 10-16
Automatic gearbox ......................................................................................................................... 10-17
Transfer box .................................................................................................................................... 10-18
Front and rear axle .......................................................................................................................... 10-19
Propeller shafts ............................................................................................................................... 10-19
Anti-roll bar links ............................................................................................................................. 10-20
ACE actuators ................................................................................................................................. 10-21
ACE filter ......................................................................................................................................... 10-21
Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ 10-22
Engine, gearbox, transfer box and axles ........................................................................................ 10-23
Exhaust system............................................................................................................................... 10-23
Steering box and front suspension ................................................................................................. 10-23
Steering rod ball joints ................................................................................................................... 10-25
Dampers and SLS height sensors .................................................................................................. 10-25
Front and rear axle suspension links .............................................................................................. 10-26
Towing bracket................................................................................................................................ 10-27
Engine mountings - V8 engine ........................................................................................................ 10-27
Road/roller test................................................................................................................................ 10-28
ENGINE - Td5 ........................................................................................... 12-1-1
DESCRIPTION AND OPERATION
Td5 Engine...................................................................................................................................... 12-1-1
Cylinder block components ............................................................................................................. 12-1-2

CONTENTS
6CONTENTS
EGR systems .................................................................................................................................. 17-1-10
REPAIRS
Modulator - EGR ........................................................................................................................... 17-1-13
Inlet Throttle (ILT) Modulator .......................................................................................................... 17-1-13
Valve - EGR - Pre EU3 models ...................................................................................................... 17-1-14
Valve - EGR - EU3 models ............................................................................................................. 17-1-15
EMISSION CONTROL - V8 ....................................................................... 17-2-1
DESCRIPTION AND OPERATION
Crankcase emission control system ............................................................................................... 17-2-1
Exhaust emission control ................................................................................................................ 17-2-2
Evaporative emission system component layout ............................................................................ 17-2-3
Evaporative emission system (with positive pressure leak detection) component layout (NAS only) 17-2-4
Evaporative emission system control diagram ............................................................................... 17-2-5
Secondary air injection system component layout.......................................................................... 17-2-6
Secondary air injection system control diagram ............................................................................. 17-2-8
Emission Control Systems .............................................................................................................. 17-2-9
Crankcase emission control system ............................................................................................... 17-2-9
Exhaust emission control system ................................................................................................... 17-2-10
Evaporative emission control system ............................................................................................. 17-2-15
Secondary air injection system ....................................................................................................... 17-2-26
Crankcase emission control operation............................................................................................ 17-2-33
Exhaust emission control operation ................................................................................................ 17-2-34
Evaporative emission control operation .......................................................................................... 17-2-38
Secondary air injection system ....................................................................................................... 17-2-42
REPAIRS
Canister - EVAP ............................................................................................................................ 17-2-43
Canister - EVAP - Models with Fuel Leak Detection Pump - up to 03MY ...................................... 17-2-43
Canister - EVAP - Models with Fuel Leak Detection Pump - from 03MY ....................................... 17-2-44
Valve - purge control ..................................................................................................................... 17-2-46
Solenoid - evap canister vent solenoid (CVS) valve ..................................................................... 17-2-46
Sensor - heated oxygen (HO2S) - pre-catalytic converter .............................................................. 17-2-47
Sensor - heated oxygen (HO2S) - post-catalytic converter ............................................................ 17-2-48
Control Valve - Secondary Air Injection (SAI) ............................................................................... 17-2-49
Reservoir - Vacuum - Secondary Air Injection (SAI) - up to 03MY ................................................. 17-2-49
Reservoir - vacuum - Secondary Air Injection (SAI) - from 03MY .................................................. 17-2-50
Pump - Air - Secondary Air Injection (SAI) ..................................................................................... 17-2-50
Air Manifold - LH - Secondary Air Injection (SAI) ........................................................................... 17-2-51
Air Manifold - RH - Secondary Air Injection (SAI) .......................................................................... 17-2-51
Solenoid - Vacuum - Secondary Air Injection (SAI) ...................................................................... 17-2-52
Pipe - Secondary Air Injection (SAI) .............................................................................................. 17-2-52
Pump - Fuel Leak Detection - up to 03MY...................................................................................... 17-2-54
Pump - fuel leak detection - from 03MY ......................................................................................... 17-2-54
Filter - fuel leak detection pump - up to 03MY ................................................................................ 17-2-55
Filter - fuel leak detection pump - from 03MY ................................................................................. 17-2-55
ENGINE MANAGEMENT SYSTEM - Td5 ................................................ 18-1-1
DESCRIPTION AND OPERATION
Engine management component location - passenger compartment ............................................ 18-1-2
Engine management component location - engine compartment .................................................. 18-1-3
Engine management block diagram ............................................................................................... 18-1-4
Description ...................................................................................................................................... 18-1-6

CONTENTS
CONTENTS 7
Operation ........................................................................................................................................ 18-1-38
ADJUSTMENTS
Glow plug ....................................................................................................................................... 18-1-45
REPAIRS
Engine control module (ECM) ........................................................................................................ 18-1-47
Sensor - engine coolant temperature (ECT) ................................................................................. 18-1-47
Sensor - crankshaft (CKP) .............................................................................................................. 18-1-48
Air filter assembly ........................................................................................................................... 18-1-48
Element - air filter ............................................................................................................................ 18-1-49
Sensor - fuel temperature .............................................................................................................. 18-1-50
Sensor - mass air flow (MAF) ....................................................................................................... 18-1-51
Sensor - combined MAP and IAT ................................................................................................. 18-1-51
Sensor - ambient air pressure (AAP) ............................................................................................ 18-1-52
Element - fuel filter ........................................................................................................................ 18-1-53
Cooler - fuel .................................................................................................................................. 18-1-53
Sensor - Throttle position (TP) ........................................................................................................ 18-1-54
Turbocharger ................................................................................................................................ 18-1-55
Intercooler ..................................................................................................................................... 18-1-56
Valve - solenoid boost control ........................................................................................................ 18-1-58
Regulator - fuel pressure .............................................................................................................. 18-1-59
Glow plugs ...................................................................................................................................... 18-1-60
Injectors .......................................................................................................................................... 18-1-61
Switch - cruise control (on/off) ........................................................................................................ 18-1-62
Switch - cruise control (set/resume) ................................................................................................ 18-1-63
Switch - clutch ................................................................................................................................. 18-1-63
ENGINE MANAGEMENT SYSTEM - V8 .................................................. 18-2-1
DESCRIPTION AND OPERATION
Engine management component location - Passenger compartment ............................................ 18-2-2
Engine management component location - Engine compartment .................................................. 18-2-3
Engine management block diagram ............................................................................................... 18-2-4
Description - engine management .................................................................................................. 18-2-6
Operation - engine management .................................................................................................... 18-2-43
DESCRIPTION AND OPERATION
Cruise control component layout .................................................................................................... 18-2-55
Cruise control block diagram .......................................................................................................... 18-2-56
Description - cruise control ............................................................................................................. 18-2-57
Operation - cruise control................................................................................................................ 18-2-66
ADJUSTMENTS
Cable - throttle ............................................................................................................................. 18-2-69
Cable - cruise control .................................................................................................................... 18-2-69
REPAIRS
Spark plugs .................................................................................................................................. 18-2-71
Coil - ignition ................................................................................................................................. 18-2-71
Engine control module (ECM) ......................................................................................................... 18-2-72
Sensor - engine coolant temperature (ECT) ................................................................................ 18-2-73
Sensor - crankshaft position (CKP) ............................................................................................... 18-2-74
Sensor - radiator temperature ....................................................................................................... 18-2-75
Sensor - camshaft position (CMP) ................................................................................................. 18-2-76

CONTENTS
8CONTENTS
Knock sensor (KS) .......................................................................................................................... 18-2-76
Air cleaner assembly .................................................................................................................... 18-2-77
Element - air filter .......................................................................................................................... 18-2-78
Cable - throttle ................................................................................................................................ 18-2-78
Sensor - Mass Air Flow (MAF) ...................................................................................................... 18-2-79
Throttle Body .................................................................................................................................. 18-2-80
Plenum chamber............................................................................................................................. 18-2-81
Sensor - throttle position (TP) ....................................................................................................... 18-2-82
Valve - idle air control (IACV) ....................................................................................................... 18-2-82
Injectors ......................................................................................................................................... 18-2-83
Actuator - cruise control ................................................................................................................ 18-2-84
Vacuum control unit - up to 03MY .................................................................................................. 18-2-85
Vacuum control unit - from 03MY ................................................................................................... 18-2-85
Cable - cruise control ..................................................................................................................... 18-2-86
Switch - cruise control (on/off) ........................................................................................................ 18-2-87
Switch - cruise control (set/resume) .............................................................................................. 18-2-87
Switch - clutch pedal - cruise control ............................................................................................ 18-2-88
ECU - Cruise control ..................................................................................................................... 18-2-88
FUEL DELIVERY SYSTEM - Td5 ............................................................. 19-1-1
DESCRIPTION AND OPERATION
Fuel delivery system component location ....................................................................................... 19-1-1
Fuel tank and breather components ............................................................................................... 19-1-2
Description ...................................................................................................................................... 19-1-3
Operation ........................................................................................................................................ 19-1-11
ADJUSTMENTS
Fuel system purging ....................................................................................................................... 19-1-13
Fuel tank - drain .............................................................................................................................. 19-1-13
REPAIRS
Switch - inertia - fuel cut-off ............................................................................................................ 19-1-15
Pump - fuel .................................................................................................................................... 19-1-15
Tank - fuel ..................................................................................................................................... 19-1-17
Solenoid - fuel filler flap release .................................................................................................... 19-1-18
Switch - fuel filler flap release - up to 03MY ................................................................................... 19-1-18
Switch - fuel filler flap release - from 03MY .................................................................................... 19-1-19
FUEL DELIVERY SYSTEM - V8 ............................................................... 19-2-1
DESCRIPTION AND OPERATION
Fuel delivery system ....................................................................................................................... 19-2-1
Fuel tank and breather components (all except NAS) .................................................................... 19-2-2
Fuel tank and breather components (NAS) .................................................................................... 19-2-3
Description ...................................................................................................................................... 19-2-4
Operation ........................................................................................................................................ 19-2-10
ADJUSTMENTS
Fuel tank - drain .............................................................................................................................. 19-2-11
REPAIRS
Switch - inertia - fuel cut-off ............................................................................................................ 19-2-13
Pump - fuel .................................................................................................................................... 19-2-13
Tank - fuel ...................................................................................................................................... 19-2-15
Filler tube - fuel ............................................................................................................................. 19-2-16

CONTENTS
12 CONTENTS
Operation ........................................................................................................................................ 41-19
ADJUSTMENTS
Cable - high/low selector ................................................................................................................ 41-21
REPAIRS
Bottom cover - transfer box ......................................................................................................... 41-23
Transfer box - Diesel ...................................................................................................................... 41-24
Transfer box - V8 ............................................................................................................................ 41-27
Gasket - rear cover plate ................................................................................................................ 41-30
Switch - differential lock - Up to 03 MY ........................................................................................... 41-30
Cable - high/low selector ................................................................................................................ 41-31
Oil seal - input shaft ...................................................................................................................... 41-32
Seal - front output shaft .................................................................................................................. 41-33
Seal - rear output shaft ................................................................................................................... 41-34
Gasket - rear output shaft housing ................................................................................................. 41-35
Solenoid - interlock - Up to 03 MY .................................................................................................. 41-36
Sensor - neutral ........................................................................................................................... 41-36
Sensor - oil temperature ................................................................................................................ 41-37
Switch - high low - warning ........................................................................................................... 41-37
OVERHAUL
Intermediate gear assembly ......................................................................................................... 41-39
Differential assembly ................................................................................................................... 41-42
Dog clutch - differential lock .......................................................................................................... 41-57
Input gear/bearing .......................................................................................................................... 41-60
Low gear - differential ................................................................................................................... 41-62
AUTOMATIC GEARBOX - ZF4HP22 - 24 ................................................ 44-1
DESCRIPTION AND OPERATION
Automatic gearbox component layout ............................................................................................ 44-1
Control schematic ........................................................................................................................... 44-2
Description ...................................................................................................................................... 44-4
Operation ........................................................................................................................................ 44-17
ADJUSTMENTS
Cable - selector ............................................................................................................................. 44-21
Stall test .......................................................................................................................................... 44-21
REPAIRS
Cable and lever assembly - selector .............................................................................................. 44-23
Selector indicator .......................................................................................................................... 44-24
Switch - starter inhibitor ................................................................................................................. 44-24
Seal - selector shaft ........................................................................................................................ 44-25
Gearbox - convertor and transfer gearbox - Diesel ....................................................................... 44-26
Gearbox - convertor and transfer gearbox - V8 ............................................................................ 44-30
Torque converter and oil seal ......................................................................................................... 44-34
Housing - torque converter ............................................................................................................ 44-35
Gasket - intermediate plate ............................................................................................................ 44-37
Intermediate plate .......................................................................................................................... 44-38
Pump - fluid .................................................................................................................................... 44-40
Seal - rear extension housing ......................................................................................................... 44-41
Gasket - rear extension housing. .................................................................................................. 44-42
Parking pawl assembly. ................................................................................................................ 44-43
Gasket - oil sump ........................................................................................................................... 44-44
Filter - oil ........................................................................................................................................ 44-45
Cooler - fluid - Td5 .......................................................................................................................... 44-45

CONTENTS
CONTENTS 15
Bushes - radius arm ...................................................................................................................... 60-39
ECU - ACE ..................................................................................................................................... 60-40
Accelerometer - ACE - upper ........................................................................................................ 60-41
Accelerometer - ACE - lower ........................................................................................................ 60-42
Pump - ACE - V8 ............................................................................................................................ 60-42
Pump - ACE - diesel ....................................................................................................................... 60-44
Valve block - ACE ......................................................................................................................... 60-46
Filter - high pressure - ACE .......................................................................................................... 60-48
Pressure transducer - ACE ........................................................................................................... 60-49
Solenoid - pressure control valve - ACE ....................................................................................... 60-50
Solenoid - directional control valve - ACE ..................................................................................... 60-51
Pipe assembly - valve block to front actuator - ACE ...................................................................... 60-51
Pipe assembly - pump or reservoir to valve block - ACE - V8 ....................................................... 60-54
Pipe assembly - pump or reservoir to valve block - ACE - diesel .................................................. 60-57
Pipe assembly - valve block to rear actuator - ACE ........................................................................ 60-61
Actuator - front - ACE .................................................................................................................... 60-63
Bushes - front long arm - ACE ........................................................................................................ 60-65
REAR SUSPENSION ................................................................................ 64-1
DESCRIPTION AND OPERATION
Rear suspension component layout (vehicles with SLS) ............................................................... 64-2
Rear suspension component layout (vehicles without SLS) .......................................................... 64-3
Rear suspension components ........................................................................................................ 64-4
Description ...................................................................................................................................... 64-6
DESCRIPTION AND OPERATION
SLS component layout .................................................................................................................... 64-9
SLS system control diagram ........................................................................................................... 64-10
Description - SLS ............................................................................................................................ 64-12
Operation ........................................................................................................................................ 64-20
ADJUSTMENTS
SLS calibration blocks..................................................................................................................... 64-23
REPAIRS
Wheel hub ....................................................................................................................................... 64-25
Road spring - rear ........................................................................................................................... 64-27
Air spring - SLS ............................................................................................................................... 64-28
Damper - rear ................................................................................................................................ 64-29
Bushes - radius arm ...................................................................................................................... 64-29
Bushes - Watts linkage ................................................................................................................. 64-31
Sensor - height - SLS...................................................................................................................... 64-32
Compressor unit - air - SLS ............................................................................................................ 64-32
Filter - intake - SLS ......................................................................................................................... 64-34
Switch - ride height ......................................................................................................................... 64-34
Air valve - SLS ................................................................................................................................ 64-35
Actuator - rear - ACE ...................................................................................................................... 64-36
Bushes - rear long arm - ACE ......................................................................................................... 64-38
BRAKES ................................................................................................... 70-1
DESCRIPTION AND OPERATION

CONTENTS
16 CONTENTS
Brake system control component layout ......................................................................................... 70-1
Brake system control diagram ........................................................................................................ 70-2
Brake system hydraulic component layout ..................................................................................... 70-4
Description ...................................................................................................................................... 70-5
Operation ........................................................................................................................................ 70-20
DESCRIPTION AND OPERATION
Handbrake component layout ......................................................................................................... 70-25
Description ...................................................................................................................................... 70-26
ADJUSTMENTS
Handbrake .................................................................................................................................... 70-29
Brake system bleeding .................................................................................................................. 70-30
REPAIRS
Brake disc - front .......................................................................................................................... 70-33
Brake disc - rear ........................................................................................................................... 70-34
Master cylinder - brake ................................................................................................................. 70-35
Cable - handbrake ........................................................................................................................ 70-36
Switch - brake light ....................................................................................................................... 70-37
Brake pads - front ......................................................................................................................... 70-37
Brake pads - rear .......................................................................................................................... 70-38
Brake shoes - handbrake................................................................................................................ 70-39
Servo - brake .................................................................................................................................. 70-41
Vacuum pump - servo..................................................................................................................... 70-42
Housing - caliper - front ................................................................................................................ 70-43
Housing - caliper - rear ................................................................................................................. 70-44
ECU - Self levelling and anti locking brakes (SLABS) ................................................................. 70-45
Sensor – ABS – front ..................................................................................................................... 70-46
Sensor – ABS – rear ....................................................................................................................... 70-47
Modulator unit - ABS ...................................................................................................................... 70-47
Switch - Hill descent control............................................................................................................ 70-48
Switch - handbrake ....................................................................................................................... 70-49
RESTRAINT SYSTEMS ............................................................................ 75-1
DESCRIPTION AND OPERATION
SRS component layout ................................................................................................................... 75-1
SRS block diagram ......................................................................................................................... 75-2
Description - SRS ........................................................................................................................... 75-3
Operation - SRS ............................................................................................................................. 75-9
DESCRIPTION AND OPERATION
Description - seat belts ................................................................................................................... 75-11
REPAIRS
Seat belt - front .............................................................................................................................. 75-13
Seat belt - rear - centre ................................................................................................................. 75-13
Seat belt - rear - side .................................................................................................................... 75-15
Mounting - seat belt - 'B' post ...................................................................................................... 75-16
Seat belts - third row ....................................................................................................................... 75-17
Pre-tensioner - front seat belt ....................................................................................................... 75-18
Airbag module - drivers .................................................................................................................. 75-18
Airbag module - passenger ........................................................................................................... 75-19
DCU ................................................................................................................................................ 75-20
Rotary coupler ................................................................................................................................ 75-21
Airbag deployment tool - self test ................................................................................................... 75-22
Airbag module - drivers - deployment ............................................................................................. 75-23

CONTENTS
22 CONTENTS
Condenser .................................................................................................................................... 82-33
Receiver drier and dual pressure switch......................................................................................... 82-36
ECU - air temperature control ......................................................................................................... 82-37
Sensor - ambient air temperature ................................................................................................ 82-38
Sensor - solar light ........................................................................................................................ 82-38
Sensor - air temperature ............................................................................................................. 82-39
Evaporator, evaporator thermistor and thermal expansion valve (TXV) ........................................ 82-40
Expansion valve - (TXV) - rear ....................................................................................................... 82-42
Evaporator - rear............................................................................................................................. 82-43
Evaporator and motor assembly - rear ........................................................................................... 82-44
Blower motor assembly - rear ......................................................................................................... 82-46
Resistor - blower motor ................................................................................................................. 82-46
Duct - centre - rear.......................................................................................................................... 82-47
WIPERS AND WASHERS ........................................................................ 84-1
DESCRIPTION AND OPERATION
Wipers and washers component layout .......................................................................................... 84-1
Front wiper components ................................................................................................................. 84-2
Rear wiper components .................................................................................................................. 84-3
Washer components ....................................................................................................................... 84-4
Wipers and washers block diagram ................................................................................................ 84-6
Description ...................................................................................................................................... 84-8
Operation ........................................................................................................................................ 84-16
REPAIRS
Reservoir - washer - up to 03MY .................................................................................................... 84-19
Reservoir - washer - from 03MY ..................................................................................................... 84-20
Jet - washer - windscreen ............................................................................................................... 84-21
Pump - washer - screen and headlamp ....................................................................................... 84-21
Motor and linkage - wiper - windscreen .......................................................................................... 84-22
Switch - wiper and washer - windscreen ........................................................................................ 84-23
Jet - washer - headlamp ................................................................................................................ 84-24
Jet - washer - rear screen ............................................................................................................ 84-25
Switch - rear wash .......................................................................................................................... 84-25
Motor - wiper - rear screen ............................................................................................................ 84-26
Switch - wiper - rear - up to 03MY .................................................................................................. 84-27
Switch - wiper - rear - from 03MY ................................................................................................... 84-27
CHARGING AND STARTING ................................................................... 86-1-1
REPAIRS
Alternator - diesel .......................................................................................................................... 86-1-1
Alternator - V8................................................................................................................................. 86-1-2
Belt - auxiliary drive ........................................................................................................................ 86-1-3
Battery ........................................................................................................................................... 86-1-4
Battery carrier ................................................................................................................................ 86-1-4
Starter motor - diesel ...................................................................................................................... 86-1-5
Starter motor - V8 ........................................................................................................................... 86-1-6
LIGHTING.................................................................................................. 86-2-1
ADJUSTMENTS
Headlamps beam alignment - up to 03MY ..................................................................................... 86-2-1