2002 LAND ROVER DISCOVERY weight

CONTENTS
CONTENTS 1
INTRODUCTION ...................................................................................... 01-1
How To Use This Manual................................................................................................................ 01-1
Repairs and Replacements ............................................................................................................. 01-1
Specifications .................................................................................................................................. 01-2
Abbreviations and Symbols ............................................................................................................ 01-3
GENERAL INFORMATION ...................................................................... 03-1
General Precautions ....................................................................................................................... 03-1
Safety Instructions .......................................................................................................................... 03-2
Environmental Precautions ............................................................................................................. 03-3
General Fitting Instructions ............................................................................................................. 03-6
Ball and Roller Bearings ................................................................................................................. 03-7
Oil Seals.......................................................................................................................................... 03-8
Joints and Joint Faces .................................................................................................................... 03-9
Locking Devices .............................................................................................................................. 03-9
Screw Threads ................................................................................................................................ 03-10
Bolt and Nut Identification ............................................................................................................... 03-11
Flexible Pipes and Hoses ............................................................................................................... 03-13
Rolling Road Testing....................................................................................................................... 03-15
Fuel Handling Precautions .............................................................................................................. 03-16
Electrical Precautions ..................................................................................................................... 03-17
Supplementary Restraint System Precautions ............................................................................... 03-18
SRS Component Replacement Policy ............................................................................................ 03-23
Air Conditioning System Precautions .............................................................................................. 03-24
Air Conditioning Compressor Replacement .................................................................................... 03-26
Body Repairs .................................................................................................................................. 03-26
GENERAL DATA ..................................................................................... 04-1
Engine - Td5 ................................................................................................................................... 04-1
Engine - V8 ..................................................................................................................................... 04-4
Fuel system - Td5 ........................................................................................................................... 04-8
Fuel system - V8 ............................................................................................................................. 04-9
Cooling system - Td5 ...................................................................................................................... 04-9
Cooling system - V8 ........................................................................................................................ 04-10
Clutch - Td5 .................................................................................................................................... 04-10
Clutch - V8 ...................................................................................................................................... 04-11
Manual gearbox - R380 .................................................................................................................. 04-12
Transfer box - LT230SE .................................................................................................................. 04-13
Automatic gearbox - ZF4HP22/24 .................................................................................................. 04-13
Rear axle......................................................................................................................................... 04-13
Front axle ........................................................................................................................................ 04-13
Steering........................................................................................................................................... 04-14
Suspension ..................................................................................................................................... 04-15
Brakes ............................................................................................................................................. 04-16
Wheels and tyres ............................................................................................................................ 04-16
Air conditioning ............................................................................................................................... 04-17
Electrical - Td5 ................................................................................................................................ 04-17
Electrical - V8 .................................................................................................................................. 04-17
Dimensions ..................................................................................................................................... 04-18
Weights ........................................................................................................................................... 04-18

INTRODUCTION
01-3
Abbreviations and Symbols
A Amperes
AAP Ambient Air Pressure
AAT Ambient Air Temperature
ABDC After Bottom Dead Centre
ABS Anti-Lock Brake System
ABS / TC Anti-lock Brake System / Traction
Control
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
AUX Auxiliary
AVC Automatic Volume Control
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
BWD Backward
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
2Square centimetre
cm3Cubic centimetre
CMP Camshaft Position
CPP Clutch Pedal Position
CO Carbon Monoxide
CO
2Carbon Dioxide
COB Clear Over Base
CR Common Rail
CVS Canister Vent Solenoid
dB Decibels
DDM Driver's Door Module
deg. Degree, angle or temperature
DI Direct Injection
dia. DiameterDIN Deutsche Industrie Normen
(German Industrial Standards)
dc Direct current
DCV Directional Control Valve
DOHC Double Overhead Camshaft
DSP Digital Signal Processing
DTI Dial Test Indicator
DMF 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
ELR Emergency Locking Retractor
EN European Norm
EOBD European On Board Diagnostics
EON Enhanced Other Network
ERL Electrical Reference Library
ETC Electronic Traction Control
EUI Electronic Unit Injector
EVAP Evaporative Emission
EVR Electronic Vacuum Regulator
F Fahrenheit
ft. Feet
FBH Fuel Burning Heater
FET Field Effect Transistor
FIP Fuel Injection Pump
FTC Fast Throttle Control
FWD Forward
> Greater than
g Gramme or Gravity
gal. Gallons
GMT Greenwich Mean Time
GPS Global Positioning System
hHour
hc High compression
HC Hydro Carbons
HDC Hill Descent Control
HDOP Height Dilation Of Precision
HDPE High Density Polyethylene
HFS Heated Front Screen
Hg Mercury
HO
2S Heated Oxygen Sensor
HMW High Molecular Weight

GENERAL INFORMATION
03-2
Safety Instructions
Whenever possible, use a lift or pit when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
Jacking
Always use the recommended jacking points.
Always ensure that any lifting apparatus has
sufficient load capacity for the weight to be lifted.
Ensure the vehicle is standing on level ground prior
to lifting or jacking.
Apply the handbrake and chock the wheels.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
Do not leave tools, lifting equipment, spilt oil, etc.
around or on the work bench area. Always keep a
clean and tidy work area.
Brake shoes and pads
Always fit the correct grade and specification of
brake linings. When renewing brake pads and brake
shoes, always replace as complete axle sets.Brake hydraulics
Observe the following recommendations when
working on the brake system:
lAlways use two spanners when loosening or
tightening brake pipe or hose connections.
lEnsure that hoses run in a natural curve and are
not kinked or twisted.
lFit brake pipes securely in their retaining clips
and ensure that the pipe cannot contact a
potential chafing point.
lContainers used for brake fluid must be kept
absolutely clean.
lDo not store brake fluid in an unsealed
container, it will absorb water and in this
condition would be dangerous to use due to a
lowering of its boiling point.
lDo not allow brake fluid to be contaminated with
mineral oil, or put new brake fluid in a container
which has previously contained mineral oil.
lDo not re-use brake fluid removed from the
system.
lAlways use clean brake fluid or a recommended
alternative to clean hydraulic components.
lAfter disconnection of brake pipes and hoses,
immediately fit suitable blanking caps or plugs to
prevent the ingress of dirt.
lOnly use the correct brake fittings with
compatible threads.
lObserve absolute cleanliness when working
with hydraulic components.
Cooling system caps and plugs
Extreme care is necessary when removing
expansion tank caps and coolant drain or bleed
screws when the engine is hot, especially if it is
overheated. To avoid the possibility of scalding,
allow the engine to cool before attempting removal.

GENERAL INFORMATION
03-8
Oil Seals
General
Always renew oil seals which have been removed
from their working location (whether as an individual
component or as part of an assembly). NEVER use
a seal which has been improperly stored or handled,
such as hung on a hook or nail.
lCarefully examine seal before fitting to ensure
that it is clean and undamaged.
lEnsure the surface on which the new seal is to
run is free of burrs or scratches. Renew the
component if the original sealing surface cannot
be completely restored.
lProtect the seal from any surface which it has to
pass when being fitted. Use a protective sleeve
or tape to cover the relevant surface.
lLubricate the sealing lips with a recommended
lubricant before use to prevent damage during
initial use. On dual lipped seals, smear the area
between the lips with grease.
lIf a seal spring is provided, ensure that it is fitted
correctly. Place lip of seal towards fluid to be
sealed and slide into position on shaft. Use
fitting sleeve where possible to protect sealing
lip from damage by sharp corners, threads or
splines. If a fitting sleeve is not available, use
plastic tube or tape to prevent damage to the
sealing lip.
lGrease outside diameter of seal, place square
to housing recess and press into position using
great care, and if possible a 'bell piece' to
ensure that seal is not tilted. In some cases it
may be preferable to fit seal to housing before
fitting to shaft. Never let weight of unsupported
shaft rest in seal.lUse the recommended service tool to fit an oil
seal. If the correct service tool is not available,
use a suitable tube approximately 0.4 mm
(0.015 in.) smaller than the outside diameter of
the seal. Use a hammer VERY GENTLY on drift
if a suitable press is not available.
lPress or drift the seal in to the depth of its
housing with the sealing lip facing the lubricant
to be retained if the housing is shouldered, or
flush with the face of the housing where no
shoulder is provided. Ensure that the seal does
not enter the housing in a tilted position.

GENERAL INFORMATION
03-25
lComponents must not remain uncapped for
longer than 15 minutes. In the event of a delay,
the caps must be fitted.
lWhen disconnecting, immediately cap all air
conditioning pipes to prevent ingress of dirt and
moisture into the system.
lThe receiver/drier contains desiccant which
absorbs moisture. It must be positively sealed at
all times. A receiver/drier that has been left
uncapped must not be used, fit a new unit.
lThe receiver/drier should be the last component
connected to the system to ensure optimum
dehydration and maximum moisture protection
of the system.
lWhenever the refrigerant system is opened, the
receiver/drier must be renewed immediately
before evacuating and recharging the system.
lUse alcohol and a clean lint-free cloth to clean
dirty connections.
lEnsure that all new parts fitted are marked for
use with R134a.
When a major repair has been completed, a leak test
should be conducted; refer to the Air Conditioning
section of this manual for the correct procedure.
Refrigerant oil
Refrigerant oil easily absorbs water and must not
be stored for long periods. Do not pour unused
refrigerant oil back into the container. Always
use an approved refrigerant oil.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
When replacing components in the A/C system,
drain the refrigerant oil from the component being
replaced into a graduated container. On assembly,
add the quantity of refrigerant oil drained to the new
component.
Compressor
A new compressor is sealed and pressurised with
Nitrogen gas. When fitting a new compressor, slowly
release the sealing cap; gas pressure should be
heard to vent as the seal is broken.
CAUTION: A new compressor should always be
sealed and could be pressurised with nitrogen
gas. To avoid possible oil loss, release the
sealing cap(s) slowly. Do not remove the cap(s)
until immediately prior to connecting the air
conditioning pipes to the compressor.Rapid refrigerant discharge
If the air conditioning system is involved in accident
damage and the system is punctured, the refrigerant
will discharge rapidly. The rapid discharge of
refrigerant will also result in the loss of most of the oil
from the system. The compressor must be removed
and all the remaining oil in the compressor drained
and refilled as instructed in the air conditioning
section of this manual.
Precautions for refrigerant recovery, recycling
and recharging
When the air conditioning system is recharged, any
existing refrigerant is first recovered from the system
and recycled. The system is then charged with the
required weight of refrigerant and volume of
refrigerant oil.
WARNING: Refrigerant must always be recycled
before re-use to ensure that the purity of the
refrigerant is high enough for safe use in the air
conditioning system.
Recycling should always be carried out with
equipment which is design certified by
Underwriter Laboratory Inc. for compliance with
SAE J1991. Other equipment may not recycle
refrigerant to the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and
commercial sources must not be used in motor
vehicle air conditioning systems.
CAUTION: The system must be evacuated
immediately before recharging commences.
Delay between evacuation and recharging is not
permitted.

GENERAL DATA
04-4
Engine - V8
General
Cylinder arrangement 90° V8, numbered from the front of the engine:

Left bank cylinders 1, 3, 5 and 7

Right bank cylinders 2, 4, 6 and 8
Bore 94.00 mm (3.70 in)
Stroke:

4.0 litre

4.6 litre71.04 mm (2.80 in)
81.92 mm (3.22 in)
Capacity:

4.0 litre

4.6 litre3950 cm
3 (241 in3)
4554 cm3 (278 in3)
Firing order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2
Compression ratio:

Low - 4.0 litre 8.23:1

High - 4.0 and 4.6 litre 9.35:1
Direction of rotation Clockwise viewed from the front of the engine
Maximum power - 4.0 litre:

Low compression ratio 132 kW (177 bhp) at 4750 rev/min

High compression ratio - UK/Japan/ROW 136 kW (182 bhp) at 4750 rev/min

High compression ratio - NAS 140 kW (187 bhp) at 4750 rev/min
Maximum power - 4.6 litre 162 kW (217 bhp) at 4750 rev/min
Maximum engine speed:

Continuous5000 rev/min

Intermittent 5250 rev/min
Weight (fully dressed, wet)

Manual 194 Kg (435 lb)

Automatic 179 Kg (402 lb)
Dimensions:

Length - Manual 767 mm (30.2 in) (Including fan)

Length - Automatic 777 mm (30.5 in) (Including fan and drive plate)

Width 652 mm (25.7 in)

Height 746 mm (29.4 in)
Spark plugs:

Make/Type - 4.0 litre Champion RC11 PYP B4

Make/type - 4.6 litre Champion RN11 YCC

Gap - 4.0 and 4.6 litre 1.00 ± 0.05 mm (0.040 ± 0.002 in) Non-adjustable
Coils:

Make Bosch 0221 503 407

Type Twin coils
Fuel injection system:

Make Bosch Motronic 5.2.1 Type 4146

Type Multiport fuel injection, electronically controlled with electro-
mechanical injectors

GENERAL DATA
04-14
Steering
Note: Measurements taken at EEC kerb weight.
Type Hydraulically assisted worm and roller
Steering wheel turns lock to lock 3.5
Steering wheel diameter 400 mm (15.7 in)
Turning circle, kerb to kerb 11.9 metres (39.1 feet)
PAS pump Hobourn Automotive Ltd. Series 500, belt driven
PAS pump pressure - engine at idle with steering at
full lock21 to 62 bar (305 to 900 lbf/in
2
Delivery pressure (nominal) 100 bar (1450 lbf.in2) 8.5 litres/min (15.1 pints/min) (18.1 US pints/
min)
Steering geometry:

Camber angle - Front, up to VIN 2A 754807 -
unladen condition

Camber angle - Front, from VIN 2A 754808 -
unladen condition

Camber angle - Rear - unladen condition–10' ± 30'
+20' ± 30'
–10' ± 30'

Cross camber - Front and rear 1° (Maximum)

Castor angle - unladen condition 3° 45' ± 45'

Cross castor 1° (Maximum)

Toe out - Front

Toe in - Rear– 0° 10' ± 0° 10' (total)
+ 0° 5' ± 0° 15' (total)
Thrust angle 20' (Maximum)

Swivel pin inclination 13° 11'

GENERAL DATA
04-15
Suspension
* Measurement taken with vehicle at unladen weight.
Type - Front Beam axle with coil springs, longitudinal radius arms,
Panhard rod, twin tube dampers and either anti-roll
bar or active cornering enhancement (ACE)
Nominal height from hub centre to wheel arch (not liner)* 500 ± 15 mm (19.7 ± 0.6 in)
Front road spring colour codes:

V8 LHS Pink/orange

V8 RHS - LHD Pink/orange

V8 RHS - RHD White/purple

Td5 LHS White/purple

Td5 RHS - LHD White/purple

Td5 RHS - RHD White/purple
Rear road spring colour codes:
5 seat, LHS Purple
5 seat, RHS - LHD Purple
5 seat, RHS - RHD Purple/purple
7 seat, LHS - LHD Grey/blue
7 seat, LHS - RHD Grey/green
7 seat, RHS - LHD Grey/blue
7 seat, RHS - RHD Grey/white
Bump stop height (top of bump stop to axle bracket) 44.5 mm (1.75 in)
Anti-roll bar diameter - front

With ACE fitted 35 mm (1.38 in)

Without ACE 30 mm (1.18 in)
Type - Rear Beam axle with coil or air springs, longitudinal radius
arms, Watts linkage, twin tube dampers and either
anti-roll bar or active cornering enhancement (ACE)
Nominal height from hub centre to wheel arch (not liner):*

Coil spring 483 ± 15 mm (19.0 ± 0.6 in)

Air spring 473 ± 15 mm (18.6 ± 0.6 in)
Road spring colour code Purple (all models)
Bump stop height (top of bump stop to axle bracket):

Coil spring 71.5 mm (2.8 in)

Air spring 61.5 mm (2.4 in)
Anti-roll bar diameter - rear

With ACE fitted 35 mm (1.38 in)

Without ACE - SLS fitted 29 mm (1.14 in)

Without ACE - SLS not fitted 5 seats = 19 mm (0.75 in)
7 seats = 16 mm (0.63 in)