2002 LAND ROVER DISCOVERY Workshop Manual

FRONT SUSPENSION
60-38 REPAIRS
5.Remove 4 nuts securing turret base to chassis.
6.Remove 2 bolts securing damper to axle.
7. ACE models: Remove bolt securing ACE pipe
clamp to chassis.
8. ACE models: Remove bolt securing ACE pipe
clamp to turret.
9.Release harness clip from turret.
10.Raise turret and remove through bolt.
11.Compress damper and manoeuvre turret from
engine bay.
12.Remove damper. Refit
1.Position damper and manoeuvre turret into
position. Raise damper and align to turret. Fit
through bolt but do not tighten at this stage.
2.Align damper assembly to spring seat.
3.Fit bolts securing damper to axle and tighten to
45 Nm (33 lbf.ft).
4.Fit nuts securing turret to chassis and tighten
to 23 Nm (17 lbf.ft).
5.Tighten through bolt to 125 Nm (92 lbf.ft).
6. ACE models: Position ACE pipe clamp to
chassis and secure with bolt.
7. ACE models: Position ACE pipe clamp to
turret and secure with bolt.
8.Secure harness to turret.
9. RH damper: Reposition coolant reservoir.
10.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
11.Remove stand(s) and lower vehicle.

FRONT SUSPENSION
REPAIRS 60-39
Bushes - radius arm
$% 60.35.18
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel.
3.Remove nut securing track rod to steering
knuckle. Use LRT-57-036 to break taper, then
release track rod and position aside.
4.Remove nut and bolt securing radius arm to
chassis. 5.Remove nuts securing radius arm to axle.
Remove rear bolt and lower the radius arm.
Remove front bolt and remove radius arm from
vehicle.
6.Press out bushes from axle end of radius arm
using a length of steel tubing.
7.Press out bush from rear of radius arm:
lUse LRT-60-011/1 and LRT-60-011/2 to
remove bush.

FRONT SUSPENSION
60-40 REPAIRS
Refit
1.Clean bush locations in radius arm.
2.Press bushes into radius arm:
lUse LRT-60-011/1, LRT-60-011/2 and
LRT-60-011/3 to fit bush at rear of radius
arm.
3.Position radius arm to vehicle. Fit securing
bolts and nuts but do not tighten at this stage.
4.Fit track rod to steering knuckle. Fit and tighten
nut to 125 Nm (92 lbf.ft).
5.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
6.Remove stand(s) and lower vehicle.
7.Tighten radius arm nuts and bolts to 230 Nm
(170 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.
ECU - ACE
$% 60.60.01
Remove
1.Remove BCU.

+ BODY CONTROL UNIT, REPAIRS,
Body control unit (BCU).
2.Remove 5 multiplugs from SLABS ECU.
3.Remove multiplug from ACE ECU.
4.Remove lower nut and loosen upper nut
securing SLABS and ACE ECU bracket to
body.
5.Remove ECU's and bracket assembly.

FRONT SUSPENSION
REPAIRS 60-41
6.Remove 3 nuts securing ACE ECU and remove
ACE ECU.
Refit
1.Fit ACE ECU to bracket and secure with nuts.
2.Fit ECU's and bracket assembly to body and
secure with nuts.
3.Connect multiplugs to ACE ECU and SLABS
ECU.
4.Fit BCU.

+ BODY CONTROL UNIT, REPAIRS,
Body control unit (BCU).
5.If a replacement ACE ECU has been fitted, use
TestBook to calibrate ACE system.
Accelerometer - ACE - upper
$% 60.60.02
CAUTION: The accelerometer is an extremely
delicate component and can easily be rendered
unserviceable. Never use an accelerometer
which has been dropped or subjected to
mistreatment of any type.
Remove
1.Remove front stowage pocket.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage pocket - front.
2.Disconnect multiplug from accelerometer.
3.Use LRT-60-014A to release clip and remove
accelerometer.
Refit
1.Using LRT-60-014A, fit accelerometer fully into
clip.
2.Connect accelerometer multiplug.
3.Fit front stowage pocket.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage pocket - front.
4.If a replacement accelerometer has been fitted,
use TestBook to calibrate ACE system.

FRONT SUSPENSION
60-42 REPAIRS
Accelerometer - ACE - lower
$% 60.60.03
CAUTION: The accelerometer is an extremely
delicate component and can easily be rendered
unserviceable. Never use an accelerometer
which has been dropped or subjected to
mistreatment of any type.
Remove
1.Raise vehicle on a ramp.
2.Disconnect multiplug from accelerometer.
3.Use LRT-60-014A to release clip and remove
accelerometer.
Refit
1.Use LRT-60-014A, fit accelerometer fully into
clip.
2.Connect accelerometer multiplug.
3.Lower vehicle.
4.If a replacement accelerometer has been fitted,
use TestBook to calibrate ACE system.
Pump - ACE - V8
$% 60.60.10
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Loosen 3 clips securing air intake hose.
Release air intake hose and position aside.
Note: Pre 03 MY air intake hose illustrated.

FRONT SUSPENSION
REPAIRS 60-43
3.Position container to catch spillage.
4.Release clip on pump suction hose and
disconnect hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove banjo bolt and disconnect pressure
pipe from ACE pump. Discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove 3 bolts securing ACE pump to
mounting and remove ACE pump.
7.Restrain pulley, remove 3 securing bolts and
remove pulley from ACE pump. Refit
1.Clean mating faces of pulley and ACE pump.
2.Position pulley to ACE pump and fit bolts.
Restrain pulley and tighten bolts to 25 Nm (18
lbf.ft).
3.Clean mating faces of ACE pump and
mounting.
4.Connect suction hose to ACE pump and secure
with clip.
5.Ensure there is sufficient fluid in ACE/PAS
reservoir to prime ACE pump.
6.Position ACE pump below level of ACE/PAS
reservoir, with suction hose uppermost, and
allow fluid from ACE/PAS reservoir to
completely fill ACE pump.
7.Position ACE pump to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
8.Rotate ACE pump clockwise (viewed from
pulley end) until a steady flow of fluid runs from
outlet port.
9.Connect pressure pipe to ACE pump with banjo
bolt and new sealing washers. Tighten banjo
bolt to 28 Nm (21 lbf.ft).
10.Position air intake hose and secure clips.
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
12.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.

FRONT SUSPENSION
60-44 REPAIRS
Pump - ACE - diesel
$% 60.60.10
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Disconnect multiplugs from mass air flow
sensor and ambient air pressure sensor.
3.Release clips and disconnect mass air flow
sensor from air cleaner.
4.Loosen hose clip, disconnect inlet air hose
from turbo charger and move hose aside. 5.Release ACE/PAS reservoir from bracket and
move aside.
6.Loosen clip and disconnect inlet hose from
intercooler.
7.Position container to catch spillage.

FRONT SUSPENSION
REPAIRS 60-45
8.Release clip and disconnect suction hose from
ACE pump.
9.Remove banjo bolt and disconnect pressure
pipe from ACE pump. Discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
10.Remove 3 bolts securing ACE pump to
mounting and remove ACE pump.
11.Restrain pulley, remove 3 securing bolts and
remove pulley from ACE pump.Refit
1.Clean mating faces of pulley and ACE pump.
2.Position pulley to ACE pump and fit bolts.
Restrain pulley and tighten bolts to 25 Nm (18
lbf.ft).
3.Clean mating faces of ACE pump and
mounting.
4.Connect suction hose to ACE pump and secure
with clip.
5.Ensure there is sufficient fluid in ACE/PAS
reservoir to prime ACE pump.
6.Position ACE pump below level of ACE/PAS
reservoir, with suction hose uppermost, and
allow fluid from ACE/PAS reservoir to
completely fill ACE pump.
7.Position ACE pump to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
8.Rotate ACE pump clockwise (viewed from
pulley end) until a steady flow of fluid runs from
outlet port.
9.Connect pressure pipe to ACE pump with banjo
bolt and new sealing washers. Tighten banjo
bolt to 28 Nm (21 lbf.ft).
10.Connect hose to intercooler and secure with
clip.
11.Fit ACE/PAS reservoir into mounting bracket.
12.Connect air hose to turbo charger and secure
with clip.
13.Fit mass air flow sensor to air filter and secure
with clips.
14.Connect multiplugs to mass air flow sensor and
ambient air pressure sensor.
15.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
16.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.