2002 LAND ROVER DISCOVERY suspension

REAR SUSPENSION
64-30 REPAIRS
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 rear bush.Refit
1.Clean bush locations in radius arms.
2.Press in new bushes:
lUse LRT-60-011/1, LRT-60-011/2 and
LRT-60-011/3 to fit rear bush.
3.Position radius arm to vehicle. Fit bolts and nuts
but do not tighten at this stage.
4. Models with SLS: Position height sensor link
to radius arm and tighten nut and bolt to 25 Nm
(18 lbf.ft).
5.Fit road wheel(s) 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.
8.Use TestBook to calibrate SLS height sensor.

REAR SUSPENSION
REPAIRS 64-31
Bushes - Watts linkage
$% 64.35.35
Models with SLS:
WARNING: Ensure the air suspension system is
made safe before commencing work. Otherwise
the chassis may lower onto the bump stops
during repair.
Remove
1.Raise rear 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 3 nuts and bolts securing Watts
linkage to axle and chassis and remove Watts
linkage.
3.Remove 2 nuts and bolts securing transverse
links to pivot housing and remove links from
pivot housing. 4.Use LRT-60-010/1 and LRT-60-010/3 to press
bushes from transverse links and pivot
housing.
Refit
1.Clean bush locations in transverse links and
pivot housing.
2.Using LRT-60-010/1 and LRT-60-010/2press
new bushes into transverse links and pivot
housing.
3.Position transverse links to pivot housing and
tighten bolts to 155 Nm (114 lbf.ft).
4.Position Watts linkage to axle and chassis. Fit
bolts but do not tighten at this stage.
5.Remove stand(s) and lower vehicle.
6.Tighten bolts securing pivot housing to axle to
230 Nm (170 lbf.ft). Tighten bolts securing
transverse links to chassis to 140 Nm (103
lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.

REAR SUSPENSION
64-32 REPAIRS
Sensor - height - SLS
$% 64.36.01
WARNING: Ensure the air suspension system is
made safe before commencing work. Otherwise
the chassis may lower onto the bump stops
during repair.
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Disconnect height sensor multiplug.
3.Remove bolt securing height sensor link to
radius arm.
4.Remove 2 bolts securing height sensor to
chassis and remove height sensor.
Refit
1.Position height sensor to chassis and tighten
bolts to 6 Nm (4.4 lbf.ft).
2.Position height sensor link to radius arm and
tighten bolt to 25 Nm (18 lbf.ft).
3.Connect height sensor multiplug.
4.Remove stand(s) and lower vehicle.
5.Use TestBook to calibrate height sensor.
Compressor unit - air - SLS
$% 64.50.10
WARNING: Ensure the air suspension system is
made safe before commencing work. Otherwise
the chassis may lower onto the bump stops
during repair.
Remove
1.Using TestBook, depressurise SLS air system.
After depressurisation, approximately 1 bar
(15 lbf.in
2) air pressure remains in the
system.
2.Release 2 fasteners and remove air
compressor unit cover.
3.Remove 2 bolts securing air compressor unit to
chassis. Release unit and lower onto blocks to
support the weight.
4.Noting their fitted position, disconnect pipes
from air valves.
CAUTION: Always fit plugs to open
connections to prevent contamination.

REAR SUSPENSION
REPAIRS 64-33
5.Disconnect inlet and exhaust pipes.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Disconnect multiplugs from air valves, exhaust
valve and compressor.
7.Release and disconnect compressor multiplug
from casing.
8.Remove air compressor unit from vehicle.
9.Release supply/exhaust pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
10.Remove 3 bolts securing compressor to
casing. Remove compressor and collect
mounting washers. Refit
1.Locate mounting washers and position
compressor in casing.
2.Apply Loctite 270 to compressor securing bolts.
Fit bolts and tighten to 7 Nm (5.2 lbf.ft).
3.Connect compressor multiplug to casing.
4.Connect supply/exhaust pipe.
5.Position air compressor unit on support block,
connect inlet and exhaust pipes.
6.Connect multiplugs to air valves, exhaust valve
and compressor.
7.Connect pipes to air valves.
8.Position air compressor unit to chassis and
engage casing in retaining lugs. Fit air
compressor unit securing bolts and tighten to
25 Nm (18 lbf.ft).
9.Ensure pipes are located in cut outs in casing.
10.Position air compressor unit cover and lock
fasteners.

REAR SUSPENSION
64-34 REPAIRS
Filter - intake - SLS
$% 64.50.12
Remove
1.Remove LH tail lamp.

+ LIGHTING, REPAIRS, Lamp - tail.
2.Disconnect filter from retaining peg.
3.Disconnect quick release connection and
remove filter assembly.
Refit
1.Position filter assembly and connect quick
release connection.
2.Secure filter retaining peg.
3.Fit LH tail lamp.

+ LIGHTING, REPAIRS, Lamp - tail.
Switch - ride height
$% 64.50.45
Remove
1.Carefully remove switch.
2.Disconnect multiplug from switch.
3.Remove switch.
Refit
1.Connect multiplug switch.
2.Position switch and push to secure.

REAR SUSPENSION
REPAIRS 64-35
Air valve - SLS
$% 64.50.47
WARNING: Ensure the air suspension system is
made safe before commencing work. Otherwise
the chassis may lower onto the bump stops
during repair.
Remove
1.Using TestBook, depressurise SLS air system.
After depressurisation, approximately 1 bar
(15 lbf.in
2) air pressure remains in the
system.
2.Release 2 fasteners and remove air
compressor unit cover.
3.Noting their fitted position, disconnect pipes
from air valves and discard 'O' rings.
4.Disconnect air valve multiplugs.
5.Remove 2 bolts securing air valves and
remove air valves. Refit
1.Position air valves and fit and tighten bolts.
2.Connect air valve multiplugs.
3.Connect air valve pipes.
4.Ensure pipes are located in cut outs in casing.
5.Position air compressor unit cover and lock
fasteners.

REAR SUSPENSION
64-36 REPAIRS
Actuator - rear - ACE
$% 64.60.40
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.
Models with SLS:
WARNING: Ensure the air suspension system is
made safe before commencing work. Otherwise
the chassis may lower onto the bump stops
during repair.
Remove
1.Raise vehicle on ramp.
2.Remove nuts securing anti-roll bar links to
axle. Release links from axle.
3.Pull torsion bar down for access to actuator. 4.Remove nut securing anti-roll bar link to long
arm and remove link.
5.Position container to collect fluid spillage.
6.Remove cap nuts securing fluid pipes to
actuator. Disconnect pipes and remove and
discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.

REAR SUSPENSION
REPAIRS 64-37
7.Use LRT-60-009 to remove nut securing
actuator push rod to long arm.
8.Remove nut and bolt securing actuator to short
arm and remove actuator.
CAUTION: The short arm and torsion bar
are supplied as an assembly and must not
be separated.Refit
1.Position actuator and tighten nut and bolt
securing actuator to short arm to 180 Nm (133
lbf.ft).
2.Using LRT-60-009 , fit and tighten nut securing
actuator push rod to long arm to 48 Nm (35
lbf.ft).
3.Connect pipes to actuator with cap nuts and
new sealing washers. Tighten cap nuts to 29
Nm (21 lbf.ft). Ensure pipes are not under
tension or kinked.
4.Connect anti-roll bar link to long arm and
tighten nut to 50 Nm (37 lbf.ft).
5.Ensure washer is in place on lower ball joint of
each anti-roll bar link and connect lower ball
joints to axle. Tighten nuts to 100 Nm (74 lbf.ft).
6.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
7.Lower vehicle.
8.Bleed ACE hydraulic system.

+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.