Discovery 2. Manual — part 1

INTRODUCTION

01-1

INTRODUCTION

How To Use This Manual

Introduction
This Manual is designed to assist skilled technicians
in the efficient repair and maintenance of Discovery
vehicles.

Individuals who undertake their own repairs should
have some skill and training, and limit repairs to
components which could not affect the safety of the
vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes,
suspension or supplementary restraint system
should be carried out by a Land Rover Dealer.
Repairs to such items should NEVER be attempted
by untrained individuals.

General
To assist in the use of this Manual, it is divided into
sections and sub-sections. The section title is given
at the top of each page and the relevant sub-section
is given at the bottom.

There is a single contents section at the front of the
Manual, which is divided by section and sub-section.
Each section is numbered from page 1.

The individual items comprising repair operations are
to be followed in the sequence in which they appear.
Items numbers in the illustration are referred to in the
text.

Adjustment and Repair operations include reference
to Service tool numbers and the associated
illustration depicts the tool in use. Adjustment and
repair operations also include reference to wear
limits, relevant data, torque figures, and specialist
information and useful assembly details. Each
adjustment or repair operation is given its Service
Repair Operation number.

WARNINGS, CAUTIONS and NOTES have the
following meanings:

WARNING: Procedures which must be followed
precisely to avoid the possibility of injury.

CAUTION: Calls attention to procedures which
must be followed to avoid damage to
components.

NOTE: Gives helpful information.

References
References to the LH or RH side given in this Manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
crankshaft pulley end of the engine is referred to as
the front.

Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.

Dimensions
The dimensions quoted are to design engineering
specification with Service limits where applicable.

INTRODUCTION

01-2

Repairs and Replacements

When replacement parts are required it is essential
that only Land Rover recommended parts are used.

Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement
parts and accessories.

Safety features and corrosion prevention treatments
embodied in the vehicle may be impaired if other
than Land Rover recommended parts are fitted. In
certain territories, legislation prohibits the fitting of
parts not to the manufacturer's specification. Torque
wrench setting figures given in this Manual must be
used. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be renewed.

Owners purchasing accessories while travelling
abroad should ensure that the accessory and its
fitted location on the car conform to legal
requirements.

The Terms of the vehicle Warranty may be
invalidated by the fitting of parts other than Land
Rover recommended parts.

All Land Rover recommended parts have the full
backing of the vehicle Warranty.

Land Rover Dealers are obliged to supply only Land
Rover recommended parts.

Specifications

Land Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.

This Manual does not constitute an offer for sale of
any particular vehicle. Land Rover Dealers are not
agents of Land Rover and have no authority to bind
the manufacturer by any expressed or implied
undertaking or representation.

INTRODUCTION

01-3

Abbreviations and Symbols

A

Amperes

AAP

Ambient Air Pressure

ABDC

After Bottom Dead Centre

ABS

Anti-Lock Brake System

ac

Alternating current

A/C

Air Conditioning

ACE

Active Cornering Enhancement

ACEA

Association of Constructors of
European Automobiles

AFR

Air Fuel Ratio

AP

Ambient Pressure

ASC

Anti-shunt Control

ATC

Air Temperature Control

ATDC

After Top Dead Centre

BBDC

Before Bottom Dead Centre

BBUS

Battery Backed Up Sounder

BCU

Body Control Unit

BDC

Bottom Dead Centre

bhp

Brake Horse Power

BP

Boost Pressure

BPP

Brake Pedal Position

BS

British Standard

BTDC

Before Top Dead Centre

C

Celsius

CAN

Controller Area Network

CD

Compact Disc

CDC

Centre Differential Control

CDL

Central Door Locking

CD - ROM

Compact Disc - Read Only
Memory

CFC

Chlorofluorocarbon

CHMSL

Centre High Mounted Stop Lamp

CKP

Crankshaft Position

CLV

Calculated Load Value

cm

Centimetre

cm

2

Square centimetre

cm

3

Cubic centimetre

CMP

Camshaft Position

CPP

Clutch Pedal Position

CO Carbon

Monoxide

CO

2

Carbon Dioxide

CR

Common Rail

CVS

Canister Vent Solenoid

deg.

Degree, angle or temperature

dia.

Diameter

DIN

Deutsche Industrie Normen
(German Industrial Standards)

dc

Direct current

DCV

Directional Control Valve

DOHC

Double Overhead Camshaft

DTI

Dial Test Indicator

DFM

Dual Mass Flywheel

DVD

Digital Versatile Disc

EACV

Electronic Air Control Valve

EAT

Electronic Automatic
Transmission

EBD

Electronic Brake pressure
Distribution

ECD

European Community Directive

ECM

Engine Control Module

ECT

Engine Coolant Temperature

ECU

Electronic Control Unit

EDC

Electronic Diesel Control

EEPROM

Electronic Erasable
Programmable Read Only
Memory

EGR

Exhaust Gas Recirculation

EKA

Emergency Key Access

EN

European Norm

EOBD

European On Board Diagnostics

ETC

Electronic Traction Control

EUI

Electronic Unit Injector

EVAP

Evaporative Emission

EVR

Electronic Vacuum Regulator

F

Fahrenheit

FBH

Fuel Burning Heater

FIP

Fuel Injection Pump

FTC Fast

Throttle

Control

g

Gramme or Gravity

h

Hour

hc

High compression

HC

Hydro Carbons

HDC

Hill Descent Control

HDPE

High Density Polyethylene

HFS

Heated Front Screen

Hg

Mercury

HO2S

Heated Oxygen Sensor

HMW

High Molecular Weight

HRW

Heated Rear Window

ht/HT

High tension

IACV

Idle Air Control Valve

IAT

Intake Air Temperature

ICE

In-Car Entertainment

i.dia.

Internal diameter

IDM

Intelligent Driver Module

in

3

Cubic inch

ILT

Inlet Throttle

ISO

International Organisation for
Standardisation

k

Thousand

kg

Kilogramme

km

Kilometre

km/h

Kilometres per hour

kPa

KiloPascal

KS

Knock Sensor

l

Litre

lbf.in

Pounds force inches

lbf/in

2

Pounds per square inch

lbf.ft

Pounds force feet

INTRODUCTION

01-4

λ

Lambda

lc

Low compression

LCD

Liquid Crystal Display

LED

Light Emitting Diode

LH

Left-Hand

LHD

Left-Hand Drive

LVS

Liquid Vapour Separator

m

Metre

µ

Micro

MAF

Mass Air Flow

MAP

Manifold Absolute Pressure

MFU

Multi-Function Unit

MFL

Multi-Function Logic

max.

Maximum

MEMS

Modular Engine Management
System

MIL

Malfunction Indicator Lamp

min.

Minimum

MPa

MegaPascal

-

Minus (tolerance)

'

Minute (angle)

mm

Millimetre

mph

Miles per hour

MPi

Multi-Point injection

MY

Model Year

NAS

North American Specification

(-)

Negative (electrical)

Nm

Newton metre

No.

Number

NO

2

Nitrogen Dioxide

NO

x

Oxides of Nitrogen

NTC

Negative Temperature
Coefficient

OBD

On Board Diagnostics

o.dia.

Outside diameter

ORM

Off-road Mode

Ω

Ohm

PAS

Power Assisted Steering

PCV

Positive Crankcase Ventilation

PDC

Parking Distance Control

%

Percentage

+

Plus (tolerance) or Positive
(electrical)

±

Plus or minus (tolerance)

PTC

Positive Temperature Coefficient

PTFE

Polytetrafluorethylene

PWM

Pulse Width Modulation

r

Radius

:

Ratio

ref

Reference

RES

Rover Engineering Standards

rev/min

Revolutions per minute

RF

Radio Frequency

RH

Right-Hand

RHD

Right-Hand Drive

ROM

Read Only Memory

RON

Research Octane Number

ROV

Roll Over Valve

ROW

Rest Of World

SAE

Society of Automotive Engineers

"

Second (angle)

SLABS

Self Levelling and Anti-Lock
Brake System

SLS

Self Levelling Suspension

SOHC

Single Overhead Camshaft

sp.gr

Specific gravity

SRS

Supplementary Restraint System

std.

Standard

synchro

Synchronizer or synchromesh

TDC

Top Dead Centre

TMAP

Temperature, Manifold Absolute
Pressure

TP Throttle

Position

TPS

Throttle Position Sensor

TV

Torsional Vibration

TXV

Thermostatic Expansion Valve

UK

United Kingdom

US

United States

V Volt
Var.

Variable

VIN

Vehicle Identification Number

VIS

Variable Intake System

VRS

Variable Reluctance Sensor

VSS

Vehicle Speed Signal

W

Watt