2002 LAND ROVER DISCOVERY Workshop Manual

CONTENTS
14 CONTENTS
Steering system component layout................................................................................................. 57-1
Steering column assembly and intermediate shaft ......................................................................... 57-2
Steering box.................................................................................................................................... 57-4
Description ...................................................................................................................................... 57-5
Operation ........................................................................................................................................ 57-15
ADJUSTMENTS
Steering box - check and adjust ..................................................................................................... 57-17
Hydraulic system - bleed ................................................................................................................ 57-18
Steering linkage - centralise ......................................................................................................... 57-18
Wheel alignment - front ................................................................................................................. 57-19
Power steering pressure check - diesel models ............................................................................. 57-20
Power steering pressure check - V8 LHD models .......................................................................... 57-22
Power steering pressure check - V8 RHD models ......................................................................... 57-24
REPAIRS
Power steering box - V8 ................................................................................................................. 57-27
Power steering box - LHD - diesel .................................................................................................. 57-30
Steering box - RHD - diesel ............................................................................................................ 57-34
Seal - input shaft - steering box ..................................................................................................... 57-37
Seal - output shaft - steering box ................................................................................................... 57-38
Pump - power steering - V8 ............................................................................................................ 57-39
Pump - power steering - diesel ....................................................................................................... 57-41
Steering column assembly and lock ............................................................................................... 57-42
Shaft - intermediate and universal joint - steering column ............................................................ 57-44
Nacelle - steering column ............................................................................................................... 57-47
Drop arm - steering box ................................................................................................................ 57-47
Ball joint - track rod ....................................................................................................................... 57-48
Ball joint - drag link ....................................................................................................................... 57-49
Drag link ........................................................................................................................................ 57-50
Damper - steering ......................................................................................................................... 57-51
Steering wheel ............................................................................................................................... 57-51
FRONT SUSPENSION .............................................................................. 60-1
DESCRIPTION AND OPERATION
Front suspension component layout (ACE torsion bar shown)....................................................... 60-1
Front suspension components (ACE torsion bar shown) ............................................................... 60-2
Description ...................................................................................................................................... 60-4
DESCRIPTION AND OPERATION
ACE system component layout....................................................................................................... 60-9
ACE system control diagram .......................................................................................................... 60-10
Description - ACE ........................................................................................................................... 60-11
Operation ........................................................................................................................................ 60-25
ADJUSTMENTS
ACE hydraulic system bleeding ..................................................................................................... 60-27
Fluid level check - ACE system ...................................................................................................... 60-27
REPAIRS
Bushes - Panhard rod ................................................................................................................... 60-29
Ball joint - upper - steering knuckle ............................................................................................... 60-30
Ball joint - lower - steering knuckle ................................................................................................. 60-31
Steering knuckle ........................................................................................................................... 60-32
Road spring - front ........................................................................................................................ 60-34
Wheel hub....................................................................................................................................... 60-35
Damper - front ............................................................................................................................... 60-37

CONTENTS
CONTENTS 15
Bushes - radius arm ...................................................................................................................... 60-39
ECU - ACE ..................................................................................................................................... 60-40
Accelerometer - ACE - upper ........................................................................................................ 60-41
Accelerometer - ACE - lower ........................................................................................................ 60-42
Pump - ACE - V8 ............................................................................................................................ 60-42
Pump - ACE - diesel ....................................................................................................................... 60-44
Valve block - ACE ......................................................................................................................... 60-46
Filter - high pressure - ACE .......................................................................................................... 60-48
Pressure transducer - ACE ........................................................................................................... 60-49
Solenoid - pressure control valve - ACE ....................................................................................... 60-50
Solenoid - directional control valve - ACE ..................................................................................... 60-51
Pipe assembly - valve block to front actuator - ACE ...................................................................... 60-51
Pipe assembly - pump or reservoir to valve block - ACE - V8 ....................................................... 60-54
Pipe assembly - pump or reservoir to valve block - ACE - diesel .................................................. 60-57
Pipe assembly - valve block to rear actuator - ACE ........................................................................ 60-61
Actuator - front - ACE .................................................................................................................... 60-63
Bushes - front long arm - ACE ........................................................................................................ 60-65
REAR SUSPENSION ................................................................................ 64-1
DESCRIPTION AND OPERATION
Rear suspension component layout (vehicles with SLS) ............................................................... 64-2
Rear suspension component layout (vehicles without SLS) .......................................................... 64-3
Rear suspension components ........................................................................................................ 64-4
Description ...................................................................................................................................... 64-6
DESCRIPTION AND OPERATION
SLS component layout .................................................................................................................... 64-9
SLS system control diagram ........................................................................................................... 64-10
Description - SLS ............................................................................................................................ 64-12
Operation ........................................................................................................................................ 64-20
ADJUSTMENTS
SLS calibration blocks..................................................................................................................... 64-23
REPAIRS
Wheel hub ....................................................................................................................................... 64-25
Road spring - rear ........................................................................................................................... 64-27
Air spring - SLS ............................................................................................................................... 64-28
Damper - rear ................................................................................................................................ 64-29
Bushes - radius arm ...................................................................................................................... 64-29
Bushes - Watts linkage ................................................................................................................. 64-31
Sensor - height - SLS...................................................................................................................... 64-32
Compressor unit - air - SLS ............................................................................................................ 64-32
Filter - intake - SLS ......................................................................................................................... 64-34
Switch - ride height ......................................................................................................................... 64-34
Air valve - SLS ................................................................................................................................ 64-35
Actuator - rear - ACE ...................................................................................................................... 64-36
Bushes - rear long arm - ACE ......................................................................................................... 64-38
BRAKES ................................................................................................... 70-1
DESCRIPTION AND OPERATION

CONTENTS
16 CONTENTS
Brake system control component layout ......................................................................................... 70-1
Brake system control diagram ........................................................................................................ 70-2
Brake system hydraulic component layout ..................................................................................... 70-4
Description ...................................................................................................................................... 70-5
Operation ........................................................................................................................................ 70-20
DESCRIPTION AND OPERATION
Handbrake component layout ......................................................................................................... 70-25
Description ...................................................................................................................................... 70-26
ADJUSTMENTS
Handbrake .................................................................................................................................... 70-29
Brake system bleeding .................................................................................................................. 70-30
REPAIRS
Brake disc - front .......................................................................................................................... 70-33
Brake disc - rear ........................................................................................................................... 70-34
Master cylinder - brake ................................................................................................................. 70-35
Cable - handbrake ........................................................................................................................ 70-36
Switch - brake light ....................................................................................................................... 70-37
Brake pads - front ......................................................................................................................... 70-37
Brake pads - rear .......................................................................................................................... 70-38
Brake shoes - handbrake................................................................................................................ 70-39
Servo - brake .................................................................................................................................. 70-41
Vacuum pump - servo..................................................................................................................... 70-42
Housing - caliper - front ................................................................................................................ 70-43
Housing - caliper - rear ................................................................................................................. 70-44
ECU - Self levelling and anti locking brakes (SLABS) ................................................................. 70-45
Sensor – ABS – front ..................................................................................................................... 70-46
Sensor – ABS – rear ....................................................................................................................... 70-47
Modulator unit - ABS ...................................................................................................................... 70-47
Switch - Hill descent control............................................................................................................ 70-48
Switch - handbrake ....................................................................................................................... 70-49
RESTRAINT SYSTEMS ............................................................................ 75-1
DESCRIPTION AND OPERATION
SRS component layout ................................................................................................................... 75-1
SRS block diagram ......................................................................................................................... 75-2
Description - SRS ........................................................................................................................... 75-3
Operation - SRS ............................................................................................................................. 75-9
DESCRIPTION AND OPERATION
Description - seat belts ................................................................................................................... 75-11
REPAIRS
Seat belt - front .............................................................................................................................. 75-13
Seat belt - rear - centre ................................................................................................................. 75-13
Seat belt - rear - side .................................................................................................................... 75-15
Mounting - seat belt - 'B' post ...................................................................................................... 75-16
Seat belts - third row ....................................................................................................................... 75-17
Pre-tensioner - front seat belt ....................................................................................................... 75-18
Airbag module - drivers .................................................................................................................. 75-18
Airbag module - passenger ........................................................................................................... 75-19
DCU ................................................................................................................................................ 75-20
Rotary coupler ................................................................................................................................ 75-21
Airbag deployment tool - self test ................................................................................................... 75-22
Airbag module - drivers - deployment ............................................................................................. 75-23

CONTENTS
CONTENTS 17
Airbag module - passenger - deployment ...................................................................................... 75-25
Pre-tensioner - deployment ............................................................................................................. 75-27
DOORS ..................................................................................................... 76-1-1
REPAIRS
Door - front .................................................................................................................................... 76-1-1
Door - rear ..................................................................................................................................... 76-1-2
Door - tail ........................................................................................................................................ 76-1-3
Glass - front or rear door ............................................................................................................... 76-1-4
Quarter light ................................................................................................................................... 76-1-5
Regulator and motor - front and rear door glass .......................................................................... 76-1-6
Trim casing - front door .................................................................................................................. 76-1-7
Trim casing - rear door ................................................................................................................... 76-1-8
Trim casing - tail door .................................................................................................................... 76-1-9
Latch and motor - front door .......................................................................................................... 76-1-9
Latch and motor - rear door ........................................................................................................... 76-1-10
Latch and motor - tail door ............................................................................................................ 76-1-11
Handle - exterior - rear door .......................................................................................................... 76-1-12
Handle - exterior - tail door ........................................................................................................... 76-1-12
Handle - exterior - front door .......................................................................................................... 76-1-13
EXTERIOR FITTINGS ............................................................................... 76-2-1
REPAIRS
Wing - front - up to 03MY ................................................................................................................ 76-2-1
Wing - front - from 03MY ................................................................................................................. 76-2-2
Rear folding step ............................................................................................................................ 76-2-4
Liner - wheel arch - front ................................................................................................................. 76-2-5
Liner - wheel arch - rear ................................................................................................................. 76-2-5
Panel - underbelly .......................................................................................................................... 76-2-6
Mirror - exterior - electric ................................................................................................................ 76-2-7
Roof bars ....................................................................................................................................... 76-2-7
Bonnet ........................................................................................................................................... 76-2-8
Cable - bonnet release - up to 03MY .............................................................................................. 76-2-9
Cable - bonnet release - from 03MY ............................................................................................... 76-2-10
Bumper assembly - front ............................................................................................................... 76-2-11
Bumper assembly - rear - from 03MY ............................................................................................. 76-2-12
Trim finisher - bumper - front - from 03MY ...................................................................................... 76-2-14
Bumper assembly - rear - up to 03MY ............................................................................................ 76-2-14
Side finisher - windscreen .............................................................................................................. 76-2-15
Grille - front - up to 03MY................................................................................................................ 76-2-16
Grille - front - from 03MY ................................................................................................................ 76-2-16
INTERIOR TRIM COMPONENTS ............................................................. 76-3-1
REPAIRS
Trim casing - tail door speaker ...................................................................................................... 76-3-1
Trim casing - side - loadspace ....................................................................................................... 76-3-1
Trim casing - upper - 'B' post ......................................................................................................... 76-3-2
Trim casing - lower - 'B' post ......................................................................................................... 76-3-3

CONTENTS
18 CONTENTS
Trim casing - 'D' post ..................................................................................................................... 76-3-3
Console - centre - automatic models .............................................................................................. 76-3-4
Console - centre - manual models .................................................................................................. 76-3-7
Fascia ............................................................................................................................................. 76-3-9
Panel - auxiliary switch ................................................................................................................... 76-3-13
Panel - fascia access - driver's side ............................................................................................. 76-3-14
Drink tray assembly - centre fascia................................................................................................. 76-3-14
Louvre panel assembly - centre fascia ........................................................................................... 76-3-15
Carpet - front................................................................................................................................... 76-3-17
Carpet - rear ................................................................................................................................. 76-3-18
Carpet - loadspace ........................................................................................................................ 76-3-19
Headlining ...................................................................................................................................... 76-3-20
Stowage pocket - front .................................................................................................................. 76-3-23
SCREENS ................................................................................................. 76-4-1
REPAIRS
Glass/sealing rubber - tail door ..................................................................................................... 76-4-1
Windscreen ................................................................................................................................... 76-4-2
Glass - body side - rear ................................................................................................................ 76-4-4
Glass - alpine light ........................................................................................................................ 76-4-6
SEATS ....................................................................................................... 76-5-1
DESCRIPTION AND OPERATION
Electric seat component location .................................................................................................... 76-5-1
Electric seat block diagram ............................................................................................................. 76-5-2
Description - electric seats.............................................................................................................. 76-5-4
Operation - electric seats ................................................................................................................ 76-5-7
DESCRIPTION AND OPERATION
Heated seat component location .................................................................................................... 76-5-9
Heated seat block diagram (electric seats).................................................................................... 76-5-10
Description - heated seats .............................................................................................................. 76-5-11
Operation - heated seats ................................................................................................................ 76-5-13
REPAIRS
Seat - front ..................................................................................................................................... 76-5-15
Seat - third row ............................................................................................................................... 76-5-16
Seat - rear ....................................................................................................................................... 76-5-18
Cover - cushion - front seat .......................................................................................................... 76-5-18
Heating element - cushion - front seat .......................................................................................... 76-5-20
Cover - cushion - rear seat ........................................................................................................... 76-5-20
Bladder - lumbar support .............................................................................................................. 76-5-21
Motor - fore and aft - front seat ..................................................................................................... 76-5-22
Motor - rise and fall - front seat ..................................................................................................... 76-5-23
Motor - tilt - front seat .................................................................................................................... 76-5-23
Motor - recline ................................................................................................................................. 76-5-24
Switch - electric seats .................................................................................................................... 76-5-24
Cover - squab - front seat ............................................................................................................. 76-5-25
Cover - squab - RH rear seat ........................................................................................................ 76-5-28
Heating element - squab - front seat ............................................................................................ 76-5-29
Head restraint - third row seat ....................................................................................................... 76-5-30

CONTENTS
CONTENTS 19
SUNROOF................................................................................................. 76-6-1
DESCRIPTION AND OPERATION
Electric sunroof component location ............................................................................................... 76-6-1
Sunroof components ....................................................................................................................... 76-6-2
System block diagram..................................................................................................................... 76-6-4
Description ...................................................................................................................................... 76-6-5
Operation ........................................................................................................................................ 76-6-12
REPAIRS
Sunroof - front ................................................................................................................................. 76-6-13
Sunroof - rear ................................................................................................................................ 76-6-14
Glass panel - sunroof ...................................................................................................................... 76-6-15
Motor - sunroof ............................................................................................................................... 76-6-15
Drive cable assembly ..................................................................................................................... 76-6-16
Switch pack - sunroof ..................................................................................................................... 76-6-17
ECU - sunroof ................................................................................................................................ 76-6-18
CHASSIS AND BODY DIMENSIONS....................................................... 77-1-1
CHASSIS DIMENSIONS
Chassis body mounting points - front end....................................................................................... 77-1-1
Chassis body mounting points - rear end ....................................................................................... 77-1-2
Chassis dimensions - front end ....................................................................................................... 77-1-3
Chassis dimensions - rear end ....................................................................................................... 77-1-4
BODY DIMENSIONS
Body Dimensions ............................................................................................................................ 77-1-5
Gaps and profiles ............................................................................................................................ 77-1-13
PANEL REPAIRS ..................................................................................... 77-2-1
REPLACEMENT PANELS
Replacement panels ....................................................................................................................... 77-2-1
Front end inner panels .................................................................................................................... 77-2-2
Valance panels .............................................................................................................................. 77-2-3
Body side panels............................................................................................................................. 77-2-4
Body side assembly ........................................................................................................................ 77-2-5
'D'-post assembly ............................................................................................................................ 77-2-6
Rear floor assembly. ....................................................................................................................... 77-2-7
Rear end panels ............................................................................................................................. 77-2-8
Front and rear doors ....................................................................................................................... 77-2-9
Taildoor ........................................................................................................................................... 77-2-10
Roof panels ..................................................................................................................................... 77-2-11
Replacement panels ....................................................................................................................... 77-2-12
PROCEDURES
General welding precautions .......................................................................................................... 77-2-13
Electronic control units .................................................................................................................... 77-2-14
PROCEDURES
Panel replacement procedure ......................................................................................................... 77-2-15
REPAIRS

CONTENTS
20 CONTENTS
Front bulkhead assembly................................................................................................................ 77-2-21
Bonnet locking platform .................................................................................................................. 77-2-22
Front cross member........................................................................................................................ 77-2-23
Headlamp mounting panel - RH ..................................................................................................... 77-2-24
Headlamp mounting panel - LH ...................................................................................................... 77-2-26
Valance upper assembly - LH......................................................................................................... 77-2-27
Valance upper assembly - RH ........................................................................................................ 77-2-29
Valance upper assembly (front section) - LH.................................................................................. 77-2-30
Valance upper assembly (front section) - RH ................................................................................. 77-2-31
Front valance assembly - RH ......................................................................................................... 77-2-32
Front valance assembly - LH ......................................................................................................... 77-2-33
'A' post assembly ............................................................................................................................ 77-2-34
Dash side assembly........................................................................................................................ 77-2-36
Sill outer assembly.......................................................................................................................... 77-2-37
Sill inner assembly .......................................................................................................................... 77-2-38
'B/C' post assembly ........................................................................................................................ 77-2-39
Panel body side assembly .............................................................................................................. 77-2-40
Body side inner rear assembly ....................................................................................................... 77-2-42
'D' post outer assembly................................................................................................................... 77-2-43
Wheelarch rear outer assembly ...................................................................................................... 77-2-44
'E' post assembly ............................................................................................................................ 77-2-45
'E' post closing assembly ................................................................................................................ 77-2-46
Cross member outer rear panel ...................................................................................................... 77-2-46
Cross member outer rear panel (centre section) ............................................................................ 77-2-47
Cross member outer rear panel (RH/LH section) ........................................................................... 77-2-48
Cross member closing rear panel ................................................................................................... 77-2-48
Cross member rear assembly......................................................................................................... 77-2-49
Cross member rear assembly (RH/LH section) .............................................................................. 77-2-49
Rear floor complete assembly ........................................................................................................ 77-2-50
Rear floor (rear section) .................................................................................................................. 77-2-51
Rear floor (RH/LH section) ............................................................................................................. 77-2-52
Roof assembly ............................................................................................................................... 77-2-52
TIMES
TIME SCHEDULES ........................................................................................................................ 77-2-55
BODY SEALING MATERIALS ................................................................. 77-3-1
MATERIALS AND APPLICATIONS
Materials applications ..................................................................................................................... 77-3-1
Approved materials ......................................................................................................................... 77-3-2
Application equipment .................................................................................................................... 77-3-4
CORROSION PREVENTION AND SEALING .......................................... 77-4-1
CORROSION PREVENTION
Cavity wax treatment areas and injection holes - 'A' post and sill .................................................. 77-4-1
Cavity wax treatment area and injection hole - fuel filler neck ........................................................ 77-4-2
Cavity wax treatment areas and injection holes - rear cross member ............................................ 77-4-3
Cavity wax treatment areas and injection holes - front door, rear door and tail door ..................... 77-4-4
Corrosion prevention ...................................................................................................................... 77-4-6
SEALING
Body Sealing................................................................................................................................... 77-4-9
Water leaks ..................................................................................................................................... 77-4-24

CONTENTS
CONTENTS 21
PAINTING ................................................................................................ 77-5-1
PROCEDURES
Panel preparation............................................................................................................................ 77-5-1
Paint preparation............................................................................................................................. 77-5-2
HEATING AND VENTILATION................................................................. 80-1
DESCRIPTION AND OPERATION
Heating and ventilation component layout ...................................................................................... 80-1
Fuel burning heater component layout ........................................................................................... 80-2
Description ...................................................................................................................................... 80-3
Operation ........................................................................................................................................ 80-13
REPAIRS
Heater control and fan switch ....................................................................................................... 80-15
Cables - heater control .................................................................................................................. 80-15
Servo - recirculation flap ............................................................................................................... 80-17
Switch - recirculation control ......................................................................................................... 80-18
Servo - air distribution control ........................................................................................................ 80-19
Servo - air temperature control ....................................................................................................... 80-20
Plenum Air Intake ........................................................................................................................... 80-20
Heater assembly - models without air conditioning ......................................................................... 80-21
Heater assembly - models with air conditioning .............................................................................. 80-23
Blower assembly ............................................................................................................................ 80-25
Motor - blower ............................................................................................................................. 80-26
Resistor pack - power resistor A/C ............................................................................................... 80-27
Heater matrix ................................................................................................................................ 80-28
Pipe - Heater - Feed ...................................................................................................................... 80-29
Pipe - Heater - Return .................................................................................................................... 80-29
Fuel burning heater - (FBH) - Td5................................................................................................... 80-30
AIR CONDITIONING ................................................................................. 82-1
DESCRIPTION AND OPERATION
A/C refrigerant system component layout ....................................................................................... 82-1
A/C control system component layout ............................................................................................ 82-2
Description ...................................................................................................................................... 82-3
Operation ........................................................................................................................................ 82-18
DESCRIPTION AND OPERATION
Rear A/C refrigerant system component layout .............................................................................. 82-23
Rear A/C distribution and control component layout ....................................................................... 82-24
Description ...................................................................................................................................... 82-25
Operation ........................................................................................................................................ 82-27
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Refrigerant recovery, recycling and recharging .............................................................................. 82-29
REPAIRS
Compressor - diesel ........................................................................................................................ 82-31
Compressor - V8 ............................................................................................................................. 82-32
Fan - condenser ............................................................................................................................ 82-33