2002 LAND ROVER DISCOVERY ad blue

REAR AXLE
51-14 OVERHAUL
47.Tighten bearing cap bolts to 90 Nm (66.5 lbf.ft).
48.Secure adjusting nuts with new roll pins.
49.Apply Prussian Blue to crown wheel teeth to
check tooth contact.
50.Rotate pinion several times to obtain full tooth
contact.51.A = Normal pattern, the drive pattern should be
centred on the gear teeth. The coast pattern
should be centred on the gear teeth but may be
towards the toe. There should be some
clearance between the pattern and the top of
the gear teeth.
52.B = Backlash correct, thinner pinion shim
required.
53.C = Backlash correct, thicker pinion shim
required.
54.D = Pinion shim correct, decrease backlash.
55.E = Pinion shim correct, increase backlash.
56.Note assembly Torque to Turn when checking
tooth contact. Total Torque to Turn should not
exceed 10.85 Nm (8 lbf.ft).
Reassembly
1.Fit differential assembly.

FRONT SUSPENSION
60-6 DESCRIPTION AND OPERATION
Spring Data
The following table shows spring fitment applicablity.
Spring Fitment Applicability
The following table shows standard springs and uprated springs required when a front winch is fitted.
Winch Fitment Spring Applicability
Panhard rod
A Panhard rod is used to ensure that the axle remains centrally located. The Panhard rod has bushes pressed into
housings at each end which provide for the attachment to the axle and chassis. One end of the Panhard rod locates
in a fabricated bracket on the axle and is secured with a bolt and locknut. The opposite end is attached to a fabricated
bracket on the chassis and is also secured with a bolt and a locknut. The Panhard rod is shaped at one end to allow
clearance for the axle casing.
The attachment bolts for the Panhard rod are coated with a clear, dry wax which reduces friction on the bolt and allows
the correct torque to be applied to the clamping of the bushes. The bolts can be re-used, but if bolt replacement is
necessary the correct bolt with the wax coating must be used.
On models from 03 Model Year, the Panhard rod is shortened by 30 mm (1.18 in). This modification was introduced
to enhance the suspension bump steer characteristics in line with other suspension improvements introduced
simultaneously. The change to the Panhard rod also required the relocation of the attachment brackets on the axle
casing and the chassis.
Colour Code Total No. of Coils Free Length
Red/Purple 7.4 371 mm (14.6 in)
Yellow/Purple 7.4 378.4 mm (14.9 in)
Blue/Purple 7.4 365 mm (14.4 in)
Grey/Purple 7.4 387 mm (15.2 in)
Purple/Purple 7.4 373.8 mm (14.7 in)
Yellow/Orange 7.4 394.6 mm (15.5 in)
Green/Orange 7.4 382.6 mm (15 in)
Pink/Brown 7.6 405.6 mm (15.9 in)
Left Hand Drive Right Hand Drive
RH side LH side RH side LH side
Red/Purple Red/Purple Yellow/Purple Blue/Purple
Yellow/Purple Yellow/Purple Grey/Purple Purple/Purple
Grey/Purple Grey/Purple Yellow/Orange Green/Orange
Standard Spring Winch Fitted Spring
RH Side LH Side Both Sides
Red/Purple Red/Purple Grey/Purple
Yellow/Purple Blue/Purple Yellow/Orange
Yellow/Purple Yellow/Purple Yellow/Orange
Grey/Purple Purple/Purple Green/Orange
Grey/Purple Grey/Purple Green/Orange
Yellow/Orange Green/Orange Pink/Brown

REAR SUSPENSION
DESCRIPTION AND OPERATION 64-7
Coil springs (vehicles without SLS)
On vehicles without SLS fitted, coil springs are fitted between the rear axle and the chassis in place of the SLS air
springs. Each spring is located at its base by the lower spring seat which is secured to a fabricated platform on the
rear axle with two bolts. The top of each spring is located in the upper spring seat. The upper spring seat comprises
a pressed metal plate with an outer coating of natural rubber bonded to the plate. The upper spring seat is retained
in position by the compression of the spring.
Coil Spring Specifications – Models up to 03 Model Year
The rear coil springs are of the variable rate type and are manufactured from silicon manganese 16.5 mm (0.65 in.)
diameter bar. Each spring has 9 coils and a free length of 385 mm (15.1 in.). The variable rate of the spring is achieved
by the active coils at one end being closer together. The rear coil spring is identified by a purple stripe painted on a
number of coils.
Coil Spring Specifications – Models From 03 Model Year
The introduction of the 03MY vehicle introduced a range of additional rear coil spring fitments. These were introduced
as a package to optimise vehicle trim heights.
The coil springs are manufactured from silicon manganese 16.35 mm (0.64 in.) diameter bar for springs on five seater
models and 16.57 mm (0.65 in.) diameter bar on seven seater models. The following spring data table shows the
colour codes, number of coils and spring free length.
Spring Data
The following table shows spring fitment applicability.
Spring Fitment Applicability
Watts linkage
A Watts linkage is used to ensure that the rear axle remains centrally located. The Watts linkage comprises two
transverse links and a pivot housing. The transverse links and pivot housing allow the rear axle to move vertically
without any transverse movement.
The transverse links are made from fabricated and welded steel. Each transverse link has a bush press fitted into a
housing at one end. The opposite end has a forked bracket with two cross holes.
The pivot housing is made from cast iron. Three bushes are press fitted in the housing, one in the centre and one at
each end.
Colour Code Total No. of Coils Free Length Model
Brown/Orange 8.73 384.7 mm (15.14 in) 5 Seat
Grey/Orange 8.73 392 mm (15.43 in) 5 Seat
Yellow/Grey 8.73 376.6 mm (14.82 in) 5 Seat
Pink/Grey 8.73 400.3 mm (15.75 in) 5 Seat
Blue/Grey 9.10 387.8 mm (15.26 in) 7 Seat
Green/Grey 9.10 395.2 mm (15.55 in) 7 Seat
White/Grey 9.10 380.6 mm (14.98 in) 7 Seat
Left Hand Drive Right Hand Drive
Both Sides RH Side LH Side
Brown/Orange Grey/Orange Yellow/Grey
Grey Orange Pink/Grey Brown/Orange
Blue/Grey Green/Grey White/Grey

REAR SUSPENSION
DESCRIPTION AND OPERATION 64-13
Air supply unit
1Compressor electrical connector
2Electric motor
3Air intake hose
4Compressor
5Air dryer
6Pressure limiting valve
7Exhaust hose
8Exhaust valve electrical connector (black
harness connector)
9Exhaust valve10LH air valve electrical connector (blue harness
connector)
11LH air valve
12LH air spring supply pipe
13Air supply/exhaust pipe
14RH air spring supply pipe
15RH air valve
16RH air valve electrical connector (natural
harness connector)
17Housing
The air supply unit is located in a central position on the outside of the left hand chassis longitudinal. The unit is
contained in a plastic housing attached to the chassis. The housing has a removable lid which is secured with Dzus
fasteners for access to the unit.

RESTRAINT SYSTEMS
75-22 REPAIRS
4.Release rotary coupler multiplug from bracket
and disconnect from harness.
5.Disconnect rotary coupler multiplug from
harness.
6.Remove rotary coupler.
Refit
1.Fit rotary coupler to steering column and
connect multiplug to harness.
2.Connect rotary coupler multiplug to harness
and secure to bracket.
3.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
steering column.
4.Fit steering wheel.

+ STEERING, REPAIRS, Steering
wheel.
Airbag deployment tool - self test
$% 76.74.99
Test
1.Insert BLUE and YELLOW connectors of tool
lead into corresponding sockets on face of tool.
2.Connect crocodile clips of second tool lead to
battery, RED to positive and BLACK to
negative.
3.RED "READY" light should illuminate.
4.Press and hold both operating buttons.
5.GREEN "DEFECTIVE" light should illuminate.
6.Release both operating buttons.
7.RED "READY" light should illuminate.
8.Disconnect tool from battery.
9.Disconnect blue and yellow connectors from
tool face sockets.
10.Self test now complete.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-11
18. Models with A/C: Disconnect multiplug from
heater controls.
19. Models without A/C: Release temperature
and air distribution control outer cables from
clips on heater casing and disconnect inner
cables from levers.20.Separate blue section from ICE multiplug.
21.Release coaxial cables from fascia panel.
22.Disconnect multiplug from passenger air bag.
23.Disconnect multiplug from blower motor.
24.Working through glove box aperture remove 2
bolts, or 4 bolts if passenger airbag module is
fitted, securing fascia to body.

INTERIOR TRIM COMPONENTS
76-3-12 REPAIRS
25.Remove 4 bolts securing lower edge of fascia
to mounting brackets on transmission tunnel.
26.Remove 4 bolts securing lower edge of fascia
to brackets on 'A' post.
27.With assistance carefully remove fascia from
vehicle.
28.If renewing fascia, transfer components to new
fascia as necessary.
Refit
1.With assistance carefully fit fascia and tighten
bolts securing lower edge of fascia to 26 Nm
(19 lbf.ft).
2.Tighten bolts securing fascia to body to 26 Nm
(19 lbf.ft).
3.Fit nuts securingfascia to steering column
bracket to 11 Nm (8 lbf.ft).
4.Secure coaxial cables to fascia and secure blue
multiplug to main ICE multiplug.
5. Models with A/C: Connect heater control
multiplug.
6. Models without A/C: Connect temperature
and air distribution inner cables to heater
control levers. Set temperature control knobs to
fully hot, distribution knob to demist position
and, with flap levers fully closed, secure outer
cables to clips on heater casing.
7.Connect multiplugs to blower motor and
passenger air bag (where fitted).
8.Fit glove box and secure with bolts.
9.Connect fascia harness multiplugs to main
harness and fuse box.
10.Position instrument pack and connect
multiplugs.11.Fit instrument pack to fascia and secure with
screws.
12.Position instrument cowl and connect
multiplugs to switches.
13.Fit cowl to clips on fascia and secure with
screws.
14.Fit fascia access panel.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Panel - fascia access - driver's
side.
15.Fit fascia lower closing panels and secure with
clips.
16.Fit fascia mats.
17.Fit 'A' post trim panels.
18.Fit centre console
lFor models with automatic gearbox:

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
lFor models with manual gearbox:

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
19.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
steering column.
20.Fit steering wheel.

+ STEERING, REPAIRS, Steering
wheel.
21.Fit radio cassette player.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio cassette player.
22.Connect battery.

WIPERS AND WASHERS
84-12 DESCRIPTION AND OPERATION
Rear wiper motor
The DC motor contains two permanent magnets and a park switch. An earth braid attached between the motor casing
and the brush pack is utilised to minimise radio interference during wiper functions.
The rear wiper switch provides an earth signal to the BCU, which determines the delay interval, if appropriate. The
BCU then signals the IDM to activate the rear wiper motor relay, which provides power to the rear wiper motor.
To allow the rear wiper to park when the rear wiper is switched off, power flows through the park switch until a cam
in the wiper motor assembly breaks the contact of the park switch. Triggering the park switch grounds the positive
side of the wiper motor causing it to stop abruptly
Washers
The washer system comprises a reservoir, washer pumps, hoses and washer jets. The front washers are controlled
from a stalk switch on the steering column and the rear washers are operated by a non-latching pushbutton switch on
the fascia adjacent to the instrument pack.
Reservoir
The reservoir is located behind the front bumper in the inner wheel arch and has a capacity of 6.0 litres (12.5 US pints).
A filler neck tube is connected to the reservoir with a seal and extends into the engine compartment on the front left
hand side. The filler neck tube contains a removable filter to prevent particle contamination and a yellow float to show
reservoir contents. The washer filler neck tube is sealed with a cap which is coloured blue for identification.
Two electric washer pumps are located on the rear face of the reservoir and supply washer fluid to the front
windscreen and the tail door window. Each pump is sealed to the reservoir with a rubber sealing grommet.
On vehicles with headlamp powerwash fitted, a third pump is fitted with a sealing grommet to the front face of the
reservoir.
The reservoir and filler neck tube are manufactured from moulded opaque nylon. The reservoir has moulded lugs for
attachment to the vehicle body. A bracket is attached to the top of the filler neck tube and locates in a hole in the body
to secure the top of the tube.