2002 LAND ROVER DISCOVERY charging

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-26 REPAIRS
Refit
1.Clean shaft and seal housing.
2.Using a suitable adapter, fit new seal.
3.Position selector quadrant and connecting rod.
4.Position selector shaft and secure to quadrant
using new roll pin.
5.Fit valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
Gearbox - convertor and transfer
gearbox - Diesel
$% 44.20.04.99
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Raise vehicle on a ramp.
4.Remove starter motor

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
5.Remove 2 upper bolts securing gearbox
housing to engine.
6.Remove bolt securing closing plate to gearbox
housing.
7.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
8.Remove 3 nuts securing intermediate silencer
to tail pipe.
9.Release and remove silencer from rubber
mountings.
10.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-30 REPAIRS
14.Secure gearbox breather pipes to bulkhead
clip.
15.Connect multiplugs to high/low ratio switch and
neutral sensor. Connect Lucars to differential
lock switch.
16.Position cable tie and multi plug to transfer box
bracket.
17.Connect high/low ratio cable to transfer box
and secure with retaining clips.
18.Position hand brake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
19.Fit hand brake drum and tighten screw.
20.Remove bolts securing tool LRT-99-008A to
gearbox.
21.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
22.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
23.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
24.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
25.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
26.Position intermediate silencer and secure to
mounting rubbers.
27.Clean silencer and tail pipe mating faces.
28.Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
29.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
30.Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
31.Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
32.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
33.Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
34.Connect battery earth lead.
35.Fit battery cover and secure with fixings.
36.Check and adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.
Gearbox - convertor and transfer
gearbox - V8
$% 44.20.04.99
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Raise vehicle on a ramp.
4.Remove 8 bolts securing centre cross member
and remove cross member.
5.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
6.Remove 3 nuts securing intermediate silencer
to tail pipe.
7.Release and remove silencer from rubber
mountings.
8.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
9.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
10.Remove front propeller shaft

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.

STEERING
REPAIRS 57-39
Refit
1.Clean seal recess, output shaft, end cover and
mating face.
2.Lubricate new end cover 'O' ring with clean
PAS fluid. Fit 'O' ring to end cover.
3.Position output shaft, fit bolts and tighten to 88
Nm (65 lbf.ft).
4.Tighten rack adjuster one turn, align marks and
secure with Allen screw.
5.Lubricate new output shaft seal with clean PAS
fluid.
6.Fit seal using LRT-57-504.
7.Fit spacer, circlip and seal shield.
8.Clean drop arm and steering box splines.
9.Ensure steering box is in the central position.
Align and fit drop arm to output shaft and
secure with new lock washer and nut. Tighten
nut to 240 Nm (177 lbf.ft).
10.Secure lock washer to drop arm nut.
11.Fit steering box.
lFor V8 models:

+ STEERING, REPAIRS, Power
steering box - V8.
lFor LHD diesel models:

+ STEERING, REPAIRS, Power
steering box - LHD - diesel.
lFor RHD diesel models:

+ STEERING, REPAIRS, Steering
box - RHD - diesel.
Pump - power steering - V8
$% 57.20.14
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Remove cable tie securing harness to air intake
hose.
3.Loosen 3 clips securing air intake hose, release
and remove hose.
Note: Pre 03 MY air intake hose illustrated.
4. Models with ACE: Remove 3 bolts securing
ACE pump, release pump and position aside.

STEERING
REPAIRS 57-41
Refit
1.Position PAS pump to auxiliary housing and
locate housing to engine. Fit and tighten
auxiliary housing bolts to 40 Nm (30 lbf.ft).
2.Tighten auxiliary housing nut to 10 Nm (7 lbf.ft).
3.Fit bolts securing PAS pump and tighten to 22
Nm (16 lbf.ft).
4.Position PAS pump pipe bracket, fit and tighten
bolt to 22 Nm (16 lbf.ft).
5.Fit and tighten PAS pump pressure pipe.
6.Fit PAS pump inlet hose and secure with clip.
7.Position jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
8.Clean PAS pump pulley mating faces.
9.Position PAS pump pulley, fit bolts and tighten
to 22 Nm (16 lbf.ft).
10. Models with ACE: Clean ACE pump dowels
and dowel holes. Position ACE pump, fit bolts
and tighten to 25 Nm (18 lbf.ft).
11. Models with A/C: Clean A/C compressor
dowels and dowel holes. Position A/C
compressor, fit bolts and tighten to 22 Nm (16
lbf.ft).
12.Position air intake hose and secure with clips.
13.Secure harness to air intake hose with new
cable tie.
14.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive..
15.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
Pump - power steering - diesel
$% 57.20.14
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Remove 3 bolts securing PAS pump pulley and
remove pulley.
3.Position tray to catch spillage, release PAS
pump pressure pipe.
4.Remove clip and release PAS pump inlet hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove 4 bolts and remove PAS pump.
6.Remove bolt, and remove mounting bracket
from PAS pump.
7.Remove 2 bolts, remove low pressure adaptor
pipe and discard 'O' ring.

STEERING
57-42 REPAIRS
Refit
1.Clean PAS pump and adaptor pipe.
2.Fit new 'O' ring to adaptor pipe, fit pipe and
tighten bolts to 10 Nm (7 lbf.ft).
3.Position mounting bracket to PAS pump, fit but
do not tighten bolt.
4.Position PAS pump and align pump drive to
coolant pump. Fit and tighten bolts to 25 Nm
(18 lbf.ft).
5.Tighten mounting plate bolt to 25 Nm (18 lbf.ft).
6.Clean PAS pump and pipe union.
7.Fit and tighten PAS pump pressure pipe to 20
Nm (15 lbf.ft).
8.Fit PAS pump inlet hose and secure with clip.
9.Clean PAS pump and pulley mating faces.
10.Position PAS pump pulley, fit and tighten bolts
to 10 Nm (7 lbf.ft).
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
12.Bleed power steering system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
Steering column assembly and lock
$% 57.40.01
Remove
1.Remove steering column intermediate shaft.

+ STEERING, REPAIRS, Shaft -
intermediate and universal joint - steering
column.
2.Remove rotary coupler.

+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler.
3.Open fascia lower access panel.
4.Remove steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
steering column.
5.Disconnect multiplug and illumination bulb
from passive coil and remove passive coil.

FRONT SUSPENSION
60-42 REPAIRS
Accelerometer - ACE - lower
$% 60.60.03
CAUTION: The accelerometer is an extremely
delicate component and can easily be rendered
unserviceable. Never use an accelerometer
which has been dropped or subjected to
mistreatment of any type.
Remove
1.Raise vehicle on a ramp.
2.Disconnect multiplug from accelerometer.
3.Use LRT-60-014A to release clip and remove
accelerometer.
Refit
1.Use LRT-60-014A, fit accelerometer fully into
clip.
2.Connect accelerometer multiplug.
3.Lower vehicle.
4.If a replacement accelerometer has been fitted,
use TestBook to calibrate ACE system.
Pump - ACE - V8
$% 60.60.10
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.
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Loosen 3 clips securing air intake hose.
Release air intake hose and position aside.
Note: Pre 03 MY air intake hose illustrated.

FRONT SUSPENSION
REPAIRS 60-43
3.Position container to catch spillage.
4.Release clip on pump suction hose and
disconnect hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove banjo bolt and disconnect pressure
pipe from ACE pump. Discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove 3 bolts securing ACE pump to
mounting and remove ACE pump.
7.Restrain pulley, remove 3 securing bolts and
remove pulley from ACE pump. Refit
1.Clean mating faces of pulley and ACE pump.
2.Position pulley to ACE pump and fit bolts.
Restrain pulley and tighten bolts to 25 Nm (18
lbf.ft).
3.Clean mating faces of ACE pump and
mounting.
4.Connect suction hose to ACE pump and secure
with clip.
5.Ensure there is sufficient fluid in ACE/PAS
reservoir to prime ACE pump.
6.Position ACE pump below level of ACE/PAS
reservoir, with suction hose uppermost, and
allow fluid from ACE/PAS reservoir to
completely fill ACE pump.
7.Position ACE pump to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
8.Rotate ACE pump clockwise (viewed from
pulley end) until a steady flow of fluid runs from
outlet port.
9.Connect pressure pipe to ACE pump with banjo
bolt and new sealing washers. Tighten banjo
bolt to 28 Nm (21 lbf.ft).
10.Position air intake hose and secure clips.
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
12.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.

FRONT SUSPENSION
60-44 REPAIRS
Pump - ACE - diesel
$% 60.60.10
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.
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Disconnect multiplugs from mass air flow
sensor and ambient air pressure sensor.
3.Release clips and disconnect mass air flow
sensor from air cleaner.
4.Loosen hose clip, disconnect inlet air hose
from turbo charger and move hose aside. 5.Release ACE/PAS reservoir from bracket and
move aside.
6.Loosen clip and disconnect inlet hose from
intercooler.
7.Position container to catch spillage.