2002 LAND ROVER DISCOVERY roof

FRONT SUSPENSION
DESCRIPTION AND OPERATION 60-19
The right hand end of the torsion bar has a machined spigot which provides for the attachment of the forged steel
short and long arms. The spigot for the short arm is splined and mates with splines in the short arm. The short arm is
located in a specific position on the splines and clamped to the spigot with a Torx bolt and locknut. The short arm is
not a serviceable item other than the actuator attachment bush. The smaller spigot diameter locates the long arm.
The long arm is fitted with a slipper bush which is located on the spigot and secured with a large washer and a special
bolt. The slipper bush comprises two inner and two outer bushes which are installed from each side of the long arm.
The outer bushes have three lugs which locate in the long arm to prevent the bush from rotating. The long arm also
provides the attachment point for the actuator piston rod and the anti-roll bar link.
The actuator has a forked end which locates on the bush in the short arm and is secured with a bolt and nut. The
piston rod of the actuator locates through a hole in a cast boss on the long arm which is fitted with a special bush. A
shoulder on the piston rod seats in a hole in the bush and a locknut on the end of the piston rod secures the rod to
the long arm and bush.
The front torsion bar is attached to the front chassis cross member. Two rubber bushes are fitted to the torsion bar
and are located in clamp plates. The clamp plates are located in slots in the cross member and secured with bolts.
The rear torsion bar is attached to the tubular cross member at the rear section of the chassis. Two rubber bushes
are fitted to the torsion bar and are located in clamp plates. The clamp plates are located in fabricated brackets
attached to the tubular cross-member and secured with bolts.
Two anti-roll bar links are mounted on brackets on the front and rear axles. Each anti-roll bar link is fitted with a
spherical bearing at each end. One bearing is attached to the link at a 90
° angle. The threaded shank of the bearing
is located through a hole in a bracket on the axle and secured with a locknut; a washer is installed on the threaded
shank between the bearing and the bracket. The second spherical bearing is attached in-line with the link and locates
in the torsion bar on the left hand side and the long arm on the right hand side. The front anti-roll bar links are longer
than the rear links and are not interchangeable.
Accelerometers
Two accelerometers are used for the ACE system. The upper accelerometer is mounted on a bracket, behind the
headlining adjacent to the rear view mirror and the sunroof ECU. The lower accelerometer is located on a bracket on
the inner sill panel under the RH front floor.
The lower accelerometer is the primary sensor used to measure lateral acceleration of the vehicle for roll control. The
upper accelerometer is used by the ECU for roll correction and fault detection in conjunction with the lower
accelerometer.
Each accelerometer is a solid state capacitive acceleration sensor and operates on a 5 V supply from the ECU. The
upper and lower sensors can measure acceleration in the range of
± 1.10 g and return an output to the ECU of
between 0.5 and 4.5 V.
Failures of an accelerometer are recorded by the ECU and can be retrieved using TestBook. A special tool is required
to remove and replace a sensor in the bracket.

EXTERIOR FITTINGS
REPAIRS 76-2-7
Mirror - exterior - electric
$% 76.10.57
Remove
1.Release cheater panel from front door.
2.Remove anti-rattle foam pad from front door.
3.Release mirror multiplug from mounting plate.
4.Disconnect multiplug from mirror.
5.Remove 3 bolts securing mirror to door.
6.Remove mirror and collect mounting plate.
Refit
1.Fit mirror and mounting plate to door.
2.Fit bolts securing mirror to door and tighten to
4 Nm (3 lbf.ft).
3.Connect multiplug to mirror.
4.Secure multiplug to mounting plate.
5.Fit anti-rattle foam pad to front door.
6.Secure cheater panel to front door.
Roof bars
$% 76.11.31
Remove
1.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
2. Models with rear A/C: Drill out 4 rivets
securing rear centre duct to roof.
3. Models with rear A/C: Release and remove
rear centre duct.
4. Models with rear A/C: Drill out 2 rivets
securing each upper side duct to roof.
5. Models with rear A/C: Remove upper side
ducts.

EXTERIOR FITTINGS
76-2-8 REPAIRS
6.Remove 2 nuts securing each roof bar to roof.
7.Remove roof bars and collect foam pads from
each end.
Refit
1.Fit roof bars to roof, ensuring foam pads are
correctly located.
2.Fit nuts securing roof bars to roof and tighten
to 32 Nm (24 lbf.ft).
3. Models with rear A/C: Fit upper side ducts and
secure with rivets.
4. Models with rear A/C: Fit rear centre duct and
secure with rivets.
5.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
Bonnet
$% 76.16.01.99
Remove
1.Support bonnet in open position.
2.Fit protection covers to wings and mark hinge
outline on bonnet if bonnet is to be refitted.
3.Disconnect windscreen washer tube at elbow
joint.
4.With assistance, remove bolts securing hinges
to bonnet and remove bonnet.
Refit
1.With assistance, position bonnet to hinges. Fit
and lightly tighten bolts.
2.Connect windscreen washer tube.
3.Close bonnet. Check that bonnet is aligned to
both front wings and that gaps are equal. If
necessary, adjust bonnet alignment and/or
gaps.
4.Finally tighten hinge bolts to 25 Nm (18 lbf.ft).

INTERIOR TRIM COMPONENTS
76-3-20 REPAIRS
Headlining
$% 76.64.15.21
Remove
1.Remove both 'D' post trim casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - 'D' post.
2.Remove both 'B' post upper trim casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - upper - 'B' post.
3.Release clips securing both 'A' post trim
casings.
4. Models with premium ICE: Disconnect
multiplugs from 'A' post speakers.
5.Remove both 'A' post trim casings.
6.Remove 3 screws securing sun visor to
headlining.
7.Release sun visor from clip.
8.Disconnect multiplug from sun visor.
9.Remove sun visor.
10.Repeat process for second sun visor. 11.Remove access panel from front edge of front
stowage pocket.
12.Remove screw securing front stowage pocket
to headlining.
13.Remove lens from front interior lamp.
14.Remove 2 nuts securing front interior lamp to
headlining.
15.Disconnect multiplug from front interior lamp.
16.Remove front interior lamp.
17.Remove 10 screws securing front stowage
pocket to headlining.
18.Disconnect 3 multiplugs from sunroof switches.
19.Remove front stowage pocket.
20.Remove caps from sun visor clips.
21.Remove screws and release both sun visor
clips.
22.Remove tail door aperture upper trim casing.
23.Remove rear sunroof aperture trim.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-21
24.Remove front sunroof aperture trim.
25.Release end caps from all grab handles.
26.Remove 2 bolts securing each grab handle to
roof.
27.Remove all 4 grab handles.
28. Models with volumetric alarm: Release front
volumetric sensor from headlining and
disconnect multiplug.
29. Models with rear A/C:
aRelease rear A/C control panel from
headlining.
bDisconnect 2 multiplugs and 2 Lucar
connectors from rear A/C control panel.
cRemove rear A/C control panel.
30.Release rear interior lamp from headlining and
disconnect multiplug.
31.Remove rear interior lamp. 32.Remove 2 clips securing rear of headlining to
roof.
33.Release rear sunroof switch from headlining.
34.Disconnect multiplug and remove rear sunroof
switch.
35.Remove screw securing headlining to roof.
36.With assistance, remove headlining.
37. Models with rear A/C:
aRemove foam pads from air vents.
bRelease 2 rear air vents from headlining.
cRelease 3 central air vents from headlining.

INTERIOR TRIM COMPONENTS
76-3-22 REPAIRS
38.Remove 7 nuts securing each stowage pocket
to headlining and collect mounting plates.
39.Remove both pockets from headlining.
40.Remove 8 screws securing rear console to
headlining and collect 3 mounting plates.
41.Remove rear console from headlining.
Refit
1.Fit rear console and mounting plates to
headlining.
2.Fit and tighten nuts securing rear console to
headlining.
3.Fit both stowage pockets and mounting plates
to headlining.
4.Fit and tighten nuts securing stowage pockets
to headlining.
5. Models with rear A/C:
aFit 3 central air vents to headlining.
bFit 2 rear air vents to headlining.
cFit foam pads to air vents.
6.With assistance, position headlining in vehicle.
7.Fit and tighten screw securing centre of
headlining to roof.
8.Connect multiplug to rear sunroof switch.
9.Fit rear sunroof switch to rear console.
10.Fit clips securing rear edge of headlining to
sunroof. 11.Position rear interior lamp to headlining and
connect multiplug.
12.Fit rear interior lamp to headlining.
13. Models with rear A/C:
aPosition rear A/C control panel to headlining
and connect multiplugs and Lucar
connectors.
bFit rear A/C control panel to headlining.
14. Models with volumetric alarm: Connect
multiplug to front volumetric sensor and fit
sensor to headlining.
15.Fit grab handles to headlining and secure with
bolts.
16.Fit end caps to grab handles.
17.Fit front sunroof aperture trim.
18.Fit rear sunroof aperture trim.
19.Fit tail door aperture upper trim casing.
20.Fit sun visor clips to headlining and secure with
screws.
21.Fit caps to sun visor clips.
22.Position front stowage pocket to headlining and
connect multiplugs to sunroof switches.
23.Fit and tighten 10 screws securing front
stowage pocket to headlining.
24.Connect multiplug to front interior lamp.
25.Fit front interior lamp to headlining and secure
with nuts.
26.Fit lens to front interior lamp.
27.Fit and tighten screw securing front stowage
pocket to headlining.
28.Fit access panel to front edge of front stowage
pocket.
29.Position sun visor to headlining and secure to
clip.
30.Connect multiplug to sun visor.
31.Fit and tighten screws securing sun visor to
headlining.
32.Repeat process for second sun visor.
33. Models with premium ICE: Position both 'A'
post trim casings and connect multiplugs to
speakers.
34.Fit both trim casings to 'A' posts and secure
with clips.
35.Fit both 'B' post upper trim casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - upper - 'B' post.
36.Fit both 'D' post trim casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - 'D' post.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-23
Stowage pocket - front
$% 76.67.26
Remove
1.Remove access panel from front edge of front
stowage pocket.
2.Remove screw securing front stowage pocket
to headlining.
3.Remove lense from front interior lamp.
4.Remove 2 nuts securing front interior lamp to
headlining.
5.Disconnect multiplug from front interior lamp.
6.Remove front interior lamp.
7.Remove 10 screws securing front stowage
pocket to headlining.
8.Disconnect 3 multiplugs from sunroof
switches.
9.Remove front stowage pocket. 10.Release clips securing sunroof switch pack.
11.Remove switch pack.
Refit
1.Fit sunroof switch pack to front stowage pocket
and secure with clips.
2.Position front stowage pocket to headlining
and connect multiplugs to sunroof switches.
3.Fit and tighten 10 screws securing front
stowage pocket to headlining.
4.Connect multiplug to front interior lamp.
5.Fit front interior lamp to headlining and secure
with nuts.
6.Fit lense to front interior lamp.
7.Fit and tighten screw securing front of front
stowage pocket to headlining.
8.Fit access panel to front stowage pocket.

SUNROOF
DESCRIPTION AND OPERATION 76-6-1
SUNROOF DESCRIPTION AND OPERAT ION
Electric sunroof component location
RHD shown, LHD similar
1Sunroof front switches
2Front sunroof motor and microswitch
3Rear sunroof - rear switch
4Sunroof ECU
5BCU