2002 LAND ROVER DISCOVERY warning light

CONTENTS
CONTENTS 23
Headlamps beam alignment - from 03MY ...................................................................................... 86-2-2
REPAIRS
Lamp - front repeater .................................................................................................................... 86-2-3
Headlamp - up to 03MY .................................................................................................................. 86-2-4
Headlamp - from 03MY .................................................................................................................. 86-2-5
Lamp - tail ..................................................................................................................................... 86-2-6
Lamp - front fog up to 03MY ........................................................................................................... 86-2-6
Lamp - front fog from 03MY ............................................................................................................ 86-2-7
Housing - number plate lamp ......................................................................................................... 86-2-8
Motor - headlamp levelling ............................................................................................................ 86-2-9
Lamp - stop - centre high mounted (CHMSL) .............................................................................. 86-2-10
Lamp - tail/flasher - bumper ............................................................................................................ 86-2-10
Lamp - interior - front .................................................................................................................... 86-2-11
Lamp - interior - rear ..................................................................................................................... 86-2-11
Rheostat - panel lights dimmer ...................................................................................................... 86-2-12
Switch - hazard warning ................................................................................................................. 86-2-13
Switch - indicator and exterior lighting - combined.......................................................................... 86-2-13
Socket - accessory ......................................................................................................................... 86-2-14
Switch - front/rear fog lamps ......................................................................................................... 86-2-14
BODY CONTROL UNIT ............................................................................ 86-3-1
DESCRIPTION AND OPERATION
Description ...................................................................................................................................... 86-3-1
Operation ........................................................................................................................................ 86-3-19
REPAIRS
Body control unit (BCU) .................................................................................................................. 86-3-39
ALARM SYSTEM AND HORN ................................................................. 86-4-1
DESCRIPTION AND OPERATION
Alarm system component layout ..................................................................................................... 86-4-2
Alarm system block diagram ........................................................................................................... 86-4-4
Description ...................................................................................................................................... 86-4-5
Operation ........................................................................................................................................ 86-4-16
REPAIR
Switch - central door locking ......................................................................................................... 86-4-25
Switches - horn ............................................................................................................................. 86-4-25
Vehicle horn .................................................................................................................................. 86-4-26
Sounder - alarm ............................................................................................................................ 86-4-26
Sounder - battery backed-up (BBUS) ............................................................................................. 86-4-27
Switch - bonnet ............................................................................................................................. 86-4-27
Receiver - alarm system - models with sunroof ............................................................................. 86-4-28
Receiver - alarm system - models without sunroof ......................................................................... 86-4-28
Coil - passive immobilisation ......................................................................................................... 86-4-29
WINDOWS ................................................................................................ 86-5-1
DESCRIPTION AND OPERATION

GENERAL INFORMATION
03-15
Hose clips
Markings (4) are usually provided on the hose to
indicate the correct clip position. If no markings are
provided, position the clip directly behind the
retaining lip at the end of the stub as shown. Worm
drive clips should be oriented with the crimped side
of the drive housing (5) facing towards the end of the
hose, or the hose may become pinched between the
clip and the stub pipe retaining lip. Worm drive clips
should be tightened to 3 Nm (2 lbf.ft) unless
otherwise stated. Ensure that hose clips do not foul
adjacent components.
Heat protection
Always ensure that heatshields and protective
sheathing are in good condition. Replace if damage
is evident. Particular care must be taken when
routing hoses close to hot engine components, such
as the exhaust manifold and the Exhaust Gas
Recirculation (EGR) pipe. Hoses will relax and
deflect slightly when hot; ensure this movement is
taken into account when routing and securing hoses.
Rolling Road Testing
General
IMPORTANT: Use a four wheel rolling road for
brake testing if possible.
WARNING: Do not attempt to test ABS function
on a rolling road.
Four wheel rolling road
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Before testing a vehicle with anti-lock brakes on a
four wheel rolling road, disconnect the ABS
modulator. The ABS function will not work, the ABS
warning light will illuminate. Normal braking will be
available.
Two wheel rolling road
Up to 03MY
ABS will not function on a two wheel rolling road. The
ABS light will illuminate during testing. Normal
braking will be available.
If brake testing on a two wheel rolling road is
necessary, the following precautions should be
taken:
lPropeller shaft to the rear axle is removed.
lNeutral selected in gearbox.
When checking brakes, run engine at idle speed to
maintain servo vacuum.
From 03MY
The differential lock must be engaged for two wheel
rolling road testing. It will also be necessary to
disconnect the propeller shaft from the transfer box
output shaft driving the axle whose wheels are NOT
on the rolling road. Additionally, the ETC system
must be deactivated by either removing the 10 amp
fuse (Number 28, labelled ABS in the main fuse box)
or disconnecting the ABS modulator pump. This
must be done with the ignition OFF ; a fault in the
ABS system may still be recorded.
WARNING; VEHICLES NOT FITTED WITH A
DIFFERENTIAL LOCK MUST NOT BE TESTED
ON A ROLLING ROAD WHERE THE ROLLERS
ARE DRIVEN BY THE VEHICLE.

TORQUE WRENCH SETTINGS
06-8
Manual gearbox - R380
Transfer box - LT230SE
Note: † New Patchlok nut must be fitted.
TORQUE DESCRIPTION METRIC IMPERIAL
Bias plate bolts25 Nm (18 lbf.ft)
Gearbox to engine bolts 45 Nm (33 lbf.ft)
Coolant pipe housing bolts 25 Nm (18 lbf.ft)
Breather pipe banjo bolt 15 Nm (11 lbf.ft)
Gear lever extension clamp bolt 25 Nm (18 lbf.ft)
Gearbox mounting bolts 85 Nm (63 lbf.ft)
Gearbox mounting nuts 48 Nm (37 lbf.ft)
Seal housing bolts 18 Nm (13 lbf.ft)
Bearing sleeve bolts 25 Nm (18 lbf.ft)
Fork bolt7 Nm (5.2 lbf.ft)
Reverse light switch 24 Nm (18 lbf.ft)
Extension housing bolts 25 Nm (18 lbf.ft)
Gear selector housing bolts 25 Nm (18 lbf.ft)
Oil pump to housing Torx screws 6 Nm (4.4 lbf.ft)
Gear change lever yoke Allen screw 25 Nm (18 lbf.ft)
5th gear stake nut 350 Nm (258 lbf.ft)
Spool retainer bolts 8 Nm (6 lbf.ft)
Centre plate detent spring and ball Torx screw 25 Nm (18 lbf.ft)
Selector lever to housing bolts 25 Nm (18 lbf.ft)
Clutch Bell housing bolts 73 Nm (54 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
High/low selector cable 30 Nm (22 lbf.ft)
Bottom plate bolts 25 Nm (18 lbf.ft)
Transfer box to gearbox 45 Nm (33 lbf.ft)
Rear cover plate25 Nm (18 lbf.ft)
Differential lock warning lamp switch locknut - Up to 03 MY
11 Nm(8 lbf.ft)
Differential lock warning lamp switches - 03 MY onwards
25 Nm (18 lbf.ft)
Drive flange nut148 Nm (109 lbf.ft)
Output shaft housing 45 Nm (33 lbf.ft)
Oil temperature sensor 42 Nm (31 lbf.ft)
Inhibitor switch to transfer box 26 Nm (19 lbf.ft)
Intermediate shaft nut †88 Nm (65 lbf.ft)
Side cover bolts25 Nm (18 lbf.ft)
Bearing retaining nut 72 Nm (53 lbf.ft)
Output flange nut 162 Nm (119 lbf.ft)
Selector housing bolts 25 Nm (18 lbf.ft)
Bearing housing/cover bolts 25 Nm (18 lbf.ft)

MAINTENANCE
PROCEDURES 10-5
Lamps, horns and warning indicators
Check
1.Switch on side, head and tail lamps and check
operation.
2.Check headlamp levelling operation.
3.Check turn signals and hazard warning lamps
for correct operation.
4.Press brake pedal and check operation of
brake lamps.
5.Check all exterior lamp lenses for clarity and
condition. Pay particular attention to headlamp
lenses for signs of stone chips or damage.
6.Check horn for loud, clear sound.
7.Switch on headlamps (with ignition switch at 'O'
position) and check light reminder warning
operates when door is opened.
8.Check operation of interior courtesy lights.
9.Check operation of all instrument pack warning
and indicator lights.
Wipers and washers
Check
1. Operate screen washer and switch on wipers.
Ensure washer jets are correctly aimed and
check for smooth, smear free operation of
wiper blades across screen at all speeds
including intermittent.
2.Repeat operation for rear screen washers/
wipers.

ENGINE - TD5
DESCRIPTION AND OPERATION 12-1-19
Oil Pressure switch
The oil pressure switch is located in a port on the outlet side of the oil cooler housing. It detects when a safe operating
pressure has been reached during engine starting and initiates the illumination of a warning light in the instrument
pack if the pressure drops below a given value.
Crankshaft, sump and oil pump components
The crankshaft, sump and oil pump components are described below:
Sump
The sump is a wet-type, of aluminium construction and is sealed to the engine block by means of a rubber gasket and
twenty fixing bolts. The four bolts at the gearbox end of the sump are longer than the other sixteen bolts.
The sump gasket incorporates compression limiters (integrated metal sleeves) at the bolt holes, which are included
to prevent distortion of the gasket when the sump to cylinder block bolts are being tightened.
The oil drain plug is fitted at the bottom of the oil sump reservoir. An oil return drain pipe is also attached to the oil
sump which returns oil from the centrifugal filter.
Stiffener Plate
The stiffener plate assembly provides lower engine block rigidity and utilises dowels to align it to the bottom of the
cylinder block. A rotary oil pump is integral with the stiffener plate and an oil pick-up and strainer assembly is fitted
to the underside of the stiffener plate. The stiffener and oil pump assembly is secured to the cylinder block by 22 bolts.

ENGINE - TD5
OVERHAUL 12-1-89
Reassembly
1.Clean drive plate, spacer, starter ring gear and
crankshaft mating faces.
2.Position starter ring gear on crankshaft, fit
spacer and drive plate.
3.Fit new bolts to retain assembly and tighten by
diagonal selection to:
lStage 1 - 40 Nm (30 lbf.ft)
lStage 2 - Further 90
°
CAUTION: Do not carry out stages 1 and 2 in
one operation.
4.Remove tool LRT-51-003, fit damper and
tighten bolts to 80 Nm (59 lbf.ft).
Starter ring gear
$% 12.53.19
Disassembly
1. Manual models: Remove flywheel.

+ ENGINE - Td5, OVERHAUL,
Flywheel.
2. Automatic models: Remove drive plate.

+ ENGINE - Td5, OVERHAUL, Drive
plate.
3.Drill a 3 mm (0.12 in) diameter hole at root of 2
teeth.
4.Apply a cold chisel to root of teeth, break ring
gear and remove from flywheel.
WARNING: SUITABLE EYE PROTECTION
MUST BE WORN.
Reassembly
1.Heat ring gear evenly to 350
° C, indicated by
light blue colour.
2.Locate ring gear on to flywheel and press on to
flange.
3.Allow ring gear to air cool.
4. Manual models: Fit flywheel.

+ ENGINE - Td5, OVERHAUL,
Flywheel.
5. Automatic models: Fit drive plate.

+ ENGINE - Td5, OVERHAUL, Drive
plate.

ENGINE - V8
DESCRIPTION AND OPERATION 12-2-9
element. Oil from the filter passes into the main oil gallery and through internal drillings to the crankshaft where it is
directed to each main bearing and to the big-end bearings via numbers 1, 3 and 5 main bearings. An internal drilling
in the cylinder block directs oil to the camshaft where it passes through further internal drillings to the hydraulic
tappets, camshaft bearing journals and rocker shafts. Lubrication to the pistons, small ends and cylinder bores is by
oil grooves machined in the connecting rods and by splash.
Oil pressure switch
The oil pressure warning light switch registers low oil pressure in the main oil gallery on the outflow side of the filter.
Whilst the engine is running and oil pressure is correct, the switch is open. When the ignition is switched on or if oil
pressure drops below the pressure setting of the switch, the switch closes and the low oil pressure warning lamp
located in the instrument pack will illuminate.
Hydraulic tappets
1Clip
2Pushrod seat
3Inner sleeve
4Upper chamber5Non-return ball valve
6Spring
7Outer sleeve
8Lower chamber
The hydraulic tappet provides maintenance free, quiet operation of the valves. This is achieved by utilizing engine oil
pressure to eliminate the clearance between the rocker arms and valve stems. When the valve is closed, engine oil
pressure present in the upper chamber, passes through the non-return ball valve and into the lower chamber. When
the cam begins to lift the outer sleeve, the resistance of the valve spring, felt through the push rod and seat, causes
the tappet inner sleeve to move downwards inside the outer sleeve. This downwards movement closes the non-return
ball valve and increases the pressure in the lower chamber sufficiently to ensure that the valve is fully opened by the
push rod. As the tappet moves off the peak of the cam, the non-return ball valve opens thereby allowing the pressure
in both chambers to equalize. This ensures that the valve will be fully closed when the tappet is on the back of the
cam.
Crankcase ventilation
A positive crankcase ventilation system is used to vent crankcase gases to the air induction system. Gases are drawn
from the left hand rocker cover to a tapping in the throttle body. An oil separator is incorporated in the hose connection
stub pipe in the right hand rocker cover, gases from this connection are drawn to a tapping in the inlet manifold.

+ EMISSION CONTROL - V8, DESCRIPTION AND OPERATION, Crankcase emission control system.

ENGINE - V8
REPAIRS 12-2-33
6.Remove 4 bolts securing drive plate clamp ring
and remove ring.
7.Remove drive plate from hub.
8.Remove 6 Allen screws securing hub, remove
hub and collect spacer.
On early engines, balance weights are on
engine side of drive plate; replacement drive
plates will have balance weights on torque
converter side of drive plate.
Refit
1.Clean hub and mating face, spacer and clamp
ring.
2.Clean drive plate and ensure free from cracks
and distortion.
3.Fit spacer and hub to crankshaft, tighten Allen
screws to 78 Nm (58 lbf.ft).
4.Fit drive plate and clamp ring, tighten bolts to
45 Nm (33 lbf.ft).
5.Clean CKP sensor and mating face.
6.Fit crankshaft sensor and tighten nuts to 6 Nm
(5 lbf.ft).
7.Fit CKP sensor cover and tighten bolts to 6 Nm
(5 lbf.ft).
8.Fit CKP sensor multiplug to bracket.
9.Fit automatic gearbox.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gearbox - convertor and
transfer gearbox - V8.
Ring gear - starter
$% 12.53.19
Remove
1.Remove flywheel.

+ ENGINE - V8, REPAIRS, Flywheel.
2.Drill a 3 mm (0.12 in) diameter hole at root of 2
teeth.
3.Apply a cold chisel in root of one of ring gear
teeth, strike chisel with hammer to break ring
gear.
WARNING: SUITABLE EYE PROTECTION
MUST BE WORN.
4.Remove starter ring gear.
Refit
1.Clean flywheel and starter ring gear.
2.Heat new starter ring gear evenly to 350
°C
(660
°F), indicated when the ring is a light blue
colour.
3.Locate ring gear on flywheel and press ring
gear hard against flange on flywheel.