2002 LAND ROVER DISCOVERY suspension

PANEL REPAIRS
REPAIRS 77-2-37
Sill outer assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove RH or LH front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
4.Remove RH or LH front door.

+ DOORS, REPAIRS, Door - front.
5.Remove RH or LH rear door.

+ DOORS, REPAIRS, Door - rear.
6.Remove RH or LH sill finisher.
7.Remove RH or LH 'A' post inner lower
finishers.
8.Remove RH or LH front seat.

+ SEATS, REPAIRS, Seat - front.
9. LH side: Remove power amplifier and EAT
ECU.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
10. RH side: Remove CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
11.Remove rear seats.

+ SEATS, REPAIRS, Seat - rear.
12.Remove RH or LH front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
13.Remove tread plates from front and rear door
apertures.
14.Release carpet and position aside.
15.Remove front and rear door aperture seals.
16.Release relevant wiring from 'A' post, 'B/C' post
and sill areas, and position aside.
17.Remove loadspace lower trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
18. RH side: Remove lower ACE accelerometer.

+ FRONT SUSPENSION, REPAIRS,
Accelerometer - ACE - lower.
19. LH side: Remove SLS air compressor unit.

+ REAR SUSPENSION, REPAIRS,
Compressor unit - air - SLS.
20. Models with rear A/C: Recover refrigerant
from A/C system and remove A/C pipes from
LH sill.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
21.Remove 2 bolts securing body to chassis.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit 2 bolts securing body to chassis and tighten
to 45 Nm (33 lbf.ft).
2. Models with rear A/C: Fit A/C pipes to sill and
recharge A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3. LH side: Fit SLS air compressor unit.

+ REAR SUSPENSION, REPAIRS,
Compressor unit - air - SLS.
4. RH side: Fit lower ACE accelerometer.

+ FRONT SUSPENSION, REPAIRS,
Accelerometer - ACE - lower.
5.Fit loadspace lower trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
6.Fit relevant wiring to 'A' post, 'B/C' post and sill
areas.
7.Fit front and rear door door aperture seals.
8.Fit carpet and secure into position.
9.Fit tread plates to front and rear door apertures.
10.Fit front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
11.Fit rear seats.

+ SEATS, REPAIRS, Seat - rear.
12. LH side: Fit CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
13. RH side: Fit power amplifier and EAT ECU.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
14.Fit front seat.

+ SEATS, REPAIRS, Seat - front.
15.Fit 'A' post inner lower finishers.
M77 1716A

CORROSION PREVENTION AND SEALING
CORROSION PREVENTION 77-4-7
The checks described above are intended to be visual only. It is not intended that the operator should remove trim
panels, finishers, rubbing strips or sound-deadening materials when checking the vehicle for corrosion and paint
damage.
With the vehicle on a lift, and using an inspection or spot lamp, visually check for the following:
lCorrosion damage and damaged paintwork, condition of underbody sealer on front and rear lower panels, sills
and wheel arches;
lDamage to underbody sealer. Corrosion in areas adjacent to suspension mountings and fuel tank fixings.
NOTE: The presence of small blisters in the underbody sealer is acceptable, providing they do not expose bare metal.
Pay special attention to signs of damage caused to panels or corrosion protection material by incorrect jack
positioning.
WARNING: It is essential to follow the correct jacking and lifting procedures.
With the vehicle lowered, visually check for evidence of damage and corrosion on all visible painted areas, in
particular the following:
lFront edge of bonnet;
lVisible flanges in engine compartment;
lLower body and door panels.
Rectify any bodywork damage or evidence of corrosion found during inspection as soon as is practicable, both to
minimise the extent of the damage and to ensure the long term effectiveness of the factory-applied corrosion
prevention treatment. Where the cost of rectification work is the owner's responsibility, the Dealer must advise the
owner and endorse the relevant documentation accordingly.
Where corrosion has become evident and is emanating from beneath a removable component (e.g. trim panel,
window glass, seat etc.), remove the component as required to permit effective rectification.
Underbody protection repairs
Whenever body repairs are carried out, ensure that full sealing and corrosion protection treatments are reinstated.
This applies both to the damaged areas and also to areas where protection has been indirectly impaired, as a result
either of accident damage or repair operations.
Remove corrosion protection from the damaged area before straightening or panel beating. This applies in particular
to panels coated with wax, PVC underbody sealer, sound deadening pads etc.
WARNING: DO NOT use oxy-acetylene gas equipment to remove corrosion prevention materials. Large
volumes of fumes and gases are liberated by these materials when they burn.
NOTE: Equipment for the removal of tough anti-corrosion sealers offers varying degrees of speed and effectiveness.
The compressed air-operated scraper (NOT an air chisel) offers a relatively quiet mechanical method using an
extremely rapid reciprocating action. Move the operating end of the tool along the work surface to remove the material.
The most common method of removal is by means of a hot air blower with integral scraper.
Another tool, and one of the most efficient methods, is the rapid-cutting 'hot knife'. This tool uses a wide blade and is
quick and versatile, able to be used easily in profiled sections where access is otherwise difficult.
Use the following procedure when repairing underbody coatings:
1Remove existing underbody coatings
2After panel repair, clean the affected area with a solvent wipe, and treat bare metal with an etch phosphate
material
3Re-prime the affected area
CAUTION: DO NOT, under any circumstances, apply underbody sealer directly to bare metal surfaces.
4Replace all heat-fusible plugs which have been disturbed. Where such plugs are not available use rubber
grommets of equivalent size, ensuring that they are embedded in sealer
5Mask off all mounting faces from which mechanical components, hoses and pipe clips, have been removed.
Underbody sealer must be applied before such components are refitted
6Brush sealer into all exposed seams
7Spray the affected area with an approved service underbody sealer
8Remove masking from component mounting faces, and touch-in where necessary. Allow adequate drying time
before applying underbody wax

CORROSION PREVENTION AND SEALING
SEALING 77-4-9
SEALING
Body Sealing
Underbody sealer treatment areas
Underfloor areas and sill outer panels are treated with a Plastisol PVC underbody sealer. This material is not suitable
for re-treatment. When repairing areas of underbody sealer, strip the factory-applied underbody sealer back to a
suitable break point. Ensure that a clean metal surface is exposed and that the edge of the existing sealer adheres
soundly to the panel.
Apply new underbody sealer between primer and surfacer paint operations. Apply seam sealer as necessary before
application of underbody sealer. Ensure that blanking plugs and grommets in the floor pan (except those used for wax
injection) are fitted before underbody sealer application. Refit any heat-fusible plugs which have been disturbed in
repair with the aid of a hot air blower, or replace with rubber grommets.
CAUTION: Ensure that suspension units, wheels, tyres, power unit, propeller shafts, exhaust and brakes
(including all mounting points) are shielded prior to application of fresh underbody sealer.

BODY CONTROL UNIT
86-3-10 DESCRIPTION AND OPERATION
Diagnostic socket
RHD illustrated
The BCU has a serial connection to the diagnostic socket to allow unit interrogation using TestBook.
In addition to fault diagnosis, the BCU can be programmed with the following information:
lPlip codes.
lOptions.
lVIN code.
lEKA code.
lEEPROM locking.
The following manufacturing details are programmed into the BCU which can be accessed using TestBook:
lDate of manufacture.
lHardware version number.
lUnit serial number.
lOdometer reading.
It is not possible to use the diagnostic bus to communicate with the BCU via TestBook when the security system is
active (except for passive immobilisation). This is a security measure to ensure that no key programming or market
configuration can take place if the operator is not in possession of a valid remote transmitter or the vehicle keys.
The BCU is normally programmed to accept two remote transmitters, but a further two remote handsets can be
programmed into the BCU and one optional Self Levelling Suspension (SLS) transmitter. All remote transmitters need
to be available if TestBook is to be used to re-configure the BCU.
M86 4705

BODY CONTROL UNIT
86-3-18 DESCRIPTION AND OPERATION
Self levelling suspension and ABS
The BCU communicates with the SLABS ECU for several functions:
lAn output is provided from the SLABS ECU to the BCU to provide the logic conditions for issuing the SLS audible
warning.
lThe BCU receives an input from the SLABS ECU relating to the raise/ lower command from the remote handset.

+ REAR SUSPENSION, DESCRIPTION AND OPERATION, Description - SLS.
Hill descent control
The BCU provides an output signal to the SLABS ECU for automatic transmission in neutral for HDC control. The
BCU checks the status of the ignition and 'gearbox state' inputs and provides a 'Neutral selected' output. If the ignition
is on and 'gearbox state' is Neutral, the 'Neutral selected' output is on, otherwise 'Neutral selected' is off.

+ BRAKES, DESCRIPTION AND OPERATION, Description.
Heated screens
The Heated Front Screen (HFS) is fitted for some market destinations and is operated from a non-latching switch
located on the instrument pack cowl. The BCU will only allow the heated front screen to operate when the engine is
running and controls the time-out period for switching the circuit off.
The heated front screen operation can also be controlled from the Automatic Temperature Control (ATC) ECU on
vehicles fitted with air conditioning.
The heated rear window will only function when the engine is running, and is operated by a non-latching switch on the
instrument pack cowl. The heated rear window can also be operated by the ATC ECU on vehicles fitted with air
conditioning.
Interior courtesy lamps
The BCU controls the operation of the interior courtesy lamps. The courtesy lamps are situated in the front, mid and
rear areas of the headlining.
Fuel flap actuator
The BCU provides an earth path to the fuel flap release solenoid to allow the fuel filler flap to be opened. This is only
allowed if the alarm system is not set and all other conditions have been satisfied. The fuel flap release switch is
located in the fascia switch pack and it receives a voltage supply from the passenger compartment fuse box.
Audible warnings
The BCU can request the instrument pack to generate an audible warning in response to conditions it has detected
and which need to be drawn to the driver's attention. One of six different audible warnings can be requested by the
BCU.
Sound request number Sound functions Priority (1 = lowest, 6 = highest)
0Off 1
1 Seat belt warning 6
2 Key-in warning 3
3 SLABS/ HDC warning 4
4 Transfer box in neutral warning 5
5 Lights on warning 2

INSTRUMENTS
88-6 DESCRIPTION AND OPERATION
The third warning lamp pack is located in the top right-hand side of the instrument pack and contains the following
warning lamps:
lSRS warning lamp.
lSLS off road mode warning lamp.
lTrailer warning lamp.
lGlow plug warning lamp.
lWater in fuel filter warning lamp.
lSeat belt warning lamp.
lTransmission high temperature warning lamp.
The fourth warning lamp pack is located underneath the tachometer of the instrument pack contains the following
warning lamps:
lOil pressure warning lamp.
lAlternator charge warning lamp.
lHDC fault warning lamp.
lSelf Levelling Suspension (SLS) warning lamp.
lActive Cornering Enhancement (ACE) warning lamp.
lGearbox manual/sport mode warning lamps.
The serial communication link is used to allow information to travel to and from the instrument pack, and it provides
the ability to configure the instrument pack to a specific market. It also allows the instrument pack to be controlled by
TestBook for diagnostics.
There are five market specific variants of the instrument pack:
lUnited Kingdom (UK).
lNorth American Specification (NAS).
lCanada.
lAustralia.
lRest Of the World (ROW), Gulf and Japan.
The main difference between the five markets is that the speedometer will indicate road speed in mph as major figures
and km/h as minor figures, km/h as major figures and mph as minor figures or km/h only.
When TestBook is used to diagnose the instrument pack it demands each of the dials and warning lamps to operate
in-turn so a visual check of their operation can be made.
CAUTION: The instrument pack must not be stored on its face side at any time. This is because the dials have
damping fluid within them to ensure smooth operation of the dials' indicator needles. This fluid will leak out.
Speedometer
The speedometer informs the driver of the current vehicle road speed. It has a Liquid Crystal Display (LCD) to show
odometer, trip meter and, on automatic gearbox models, the selected gear. The speedometer will not show speeds
of less than 1.5 mph (2.5 km/h).
There are three different market configurations:
lNAS and UK = mph as major figures km/h as minor figures.
lCanada = km/h as major figures mph as minor figures.
lROW and Australia = km/h only.
The Self Levelling and Anti-Lock Brake System (SLABS) ECU provides the signal input for the road speed. The signal
is at 8000 pulses per mile (1.6 kilometres).

INSTRUMENTS
88-26 DESCRIPTION AND OPERATION
Off road mode warning lamp
The off road mode warning lamp is available on vehicles equipped with self levelling suspension. The off road mode
warning lamp within the instrument pack utilises an amber LED and a clear legend. On vehicles fitted with self levelling
suspension the driver can enable the function using the off road mode fascia switch.
The SLABS ECU illuminates the LED, providing the driver with a visible warning.
When the ignition is switched on the SLABS ECU illuminates the LED to provide a self-check, providing there is no
fault it will remain illuminated for 3 seconds or until the ignition is switched off.
The off road mode is only enabled if the transfer box is in low range.
The off road mode warning lamp will flash at the rate of 2 Hz during the transition phase (up and down), and is
illuminated continuously when at full height.
The vehicle may be parked in off road mode the driver is reminded when the ignition is switched on that off road mode
is still active by the warning lamp flashing twice at a ratio 2 Hz then illuminates continuously.
The warning lamp will flash at 2 Hz in belly out mode. Belly out mode is if the vehicle grounds out, then the suspension
will raise to try and clear the underside of the vehicle.
If a new SLABS ECU is fitted the warning lamp remains illuminated until the ECU has been calibrated using TestBook.
The warning lamp will illuminate continuously if the voltage supply is less than 10 volts for 1 second.
The power input for the LED is supplied by the instrument pack via fuse 27. The warning lamp is switched on
according to the voltage present in the SLABS ECU to instrument pack earth path as follows:
l< 1.8 volts = warning lamp on.
l> 7.7 volts = warning lamp off.

INSTRUMENTS
88-36 DESCRIPTION AND OPERATION
Self Levelling Suspension (SLS) warning lamp
The SLS warning lamp within the instrument pack utilises an amber LED and a clear legend. The SLABS ECU
illuminates the LED continuously if a fault within the SLS is detected, providing the driver with a visible warning.
When the ignition is switched on the SLABS ECU illuminates the LED to provide a self-check, providing there is no
fault it will remain illuminated for 3 seconds or until the ignition is switched off.
On vehicles equipped with coil springs the SLS warning lamp is extinguished after 850 milliseconds if the SLABS ECU
configuration of the vehicle is correct.
The SLS warning lamp flashes at 2 Hz when the remote handset control is used to raise or lower the ride height.
If a new SLABS ECU is installed the SLS warning lamp will remain illuminated until the ECU has been calibrated by
TestBook.
The warning lamp will illuminate continuously when battery voltage is less than 10 volts for greater than 1 second.
When the vehicle is in transportation mode the SLS warning lamp is illuminated continuously with ignition on, and will
flash at 2 Hz frequency as the vehicle rises from bump stop level to transport level on engine start.
The power input for the LED is supplied by the instrument pack via fuse 27. The SLABS ECU provides the earth path
to illuminate the warning lamp.
The voltage on the earth path from the SLABS ECU to the instrument pack has the following functions:
l< 1.8 volts = warning lamp on.
l> 7.7 volts = warning lamp off.