steering LAND ROVER DISCOVERY 2002 User Guide

IDENTIFICATION NUMBERS
05-2
Vehicle identification number - except NAS and
Canada
Example: SALLTGM87WA600172Vehicle identification number - NAS and Canada
Example: SALTY124OWA600180
Paint and trim colour codes
Paint code (F): a 3 digit code identifying the original
paint colour is stamped on the VIN plate. Refer to
Parts Catalogue for full list of colour codes.
Trim code (G): a code identifying the original trim
type and colour is stamped on the VIN plate. Refer to
the relevant Parts Catalogue for coding details
SALManufacturer's identifier (Land Rover UK)
LTMarque/Model
LT = Discovery
GClass
A = Japan
G = 100 inch
MBody Style
B = 5 door models
8Engine
1 = 4.0 V8 LC Cat
2 = 4.0 V8 HC Cat
3 = 4.0 LC Non Cat
8 = TD5 engine EGR/Cat
9 = TD5 engine EGR/ Non Cat
7Transmission and Steering
3 = RHD automatic gearbox
4 = LHD automatic gearbox
7 = RHD manual gearbox
8 = LHD manual gearbox
WModel Year
W = 1998 Model year
X = 1999 Model year
Y = 2000 Model year
1 = 2001 Model year
2 = 2002 Model year
3 = 2003 Model year
AAssembly plant
A = Solihull
F = KD build
6 figures= Serial number
SALManufacturer's identifier (Land Rover UK)
TMarque/Model
T = Discovery
YClass
Y = 100 inch USA/Canada
N = 100 inch California
1Body Style
1 = 4 door Station Wagon
2Engine
2 = 4.0 V8 HC Cat
4Transmission and Steering
4 = LHD automatic gearbox
OCheck digit
WModel Year
W = 1998 Model year
X = 1999 Model year
Y = 2000 Model year
1 = 2001 Model year
2 = 2002 Model year
3 = 2003 Model year
AAssembly plant
A = Solihull
6 figures= Serial number

TORQUE WRENCH SETTINGS
06-10
Steering
TORQUE DESCRIPTION METRIC IMPERIAL
Drag link to drop arm 80 Nm (59 lbf.ft)
Track rod to steering knuckle 125 Nm (92 lbf.ft)
Tension collet to steering knuckle 5 Nm (3.7 lbf.ft)
Steering damper125 Nm (92 lbf.ft)
Steering knuckle to axle yoke upper ball joint 110 Nm (81 lbf.ft)
High pressure pipe union 20 Nm (15 lbf.ft)
Drag link/track rod M8 bolts 22 Nm (16 lbf.ft)
Drag link/track rod M10 bolts 33 Nm (24 lbf.ft)
Steering box90 Nm (66 lbf.ft)
Universal joint to intermediate shaft 25 Nm (18 lbf.ft)
Panhard rod230 Nm (170 lbf.ft)
Steering box output shaft 88 Nm (65 lbf.ft)
Drop arm240 Nm (177 lbf.ft)
Auxiliary housing bolts 40 Nm (30 lbf.ft)
Auxiliary housing nut 10 Nm (7 lbf.ft)
PAS pump - V822 Nm (16 lbf.ft)
PAS pump pipe bracket bolt 22 Nm (16 lbf.ft)
Jockey pulley bolt 50 Nm (37 lbf.ft)
PAS pump adaptor pipe 10 Nm (7 lbf.ft)
PAS pump to coolant pump bolts - Td5 25 Nm (18 lbf.ft)
Steering column to fascia 25 Nm (18 lbf.ft)
Universal joint to steering box 25 Nm (18 lbf.ft)
Ball joint to swivel hub 77 Nm (57 lbf.ft)
PAS pump pulley22 Nm (16 lbf.ft)
Steering wheel nut 43 Nm (32 lbf.ft)

TORQUE WRENCH SETTINGS
06-14
Body
TORQUE DESCRIPTION METRIC IMPERIAL
Front and rear door hinges 30 Nm (22 lbf.ft)
Tail door hinge bolts 34 Nm (25 lbf.ft)
Door frames10 Nm (7 lbf.ft)
Regulator to glass 6 Nm (4.4 lbf.ft)
Chassis cross member 25 Nm (18 lbf.ft)
Bulkhead to chassis bolts 45 Nm (33 lbf.ft)
Body to chassis bolts 45 Nm (33 lbf.ft)
Quarter light glass to frame 10 Nm (7 lbf.ft)
Glass lift motor to regulator 5 Nm (3.7 lbf.ft)
Tail door hand rail 10 Nm (7 lbf.ft)
Latch and motor assembly 7 Nm (5.2 lbf.ft)
Door handle7 Nm (5.2 lbf.ft)
Damper to step17 Nm (13 lbf.ft)
Throttle pedal assembly 13 Nm (10 lbf.ft)
Step assembly to chassis 45 Nm (33 lbf.ft)
Wing to sill finisher bracket 17 Nm (13 lbf.ft)
Front wing to body 17 Nm (13 lbf.ft)
Door mirror4 Nm (3 lbf.ft)
Roof bars32 Nm (24 lbf.ft)
Bonnet release lever 10 Nm (7 lbf.ft)
Front bumper to crash cans 13 Nm (10 lbf.ft)
Front bumper to side mountings 13 Nm (10 lbf.ft)
Mudshield10 Nm (7 lbf.ft)
Rear bumper45 Nm (33 lbf.ft)
Grab handle to body 3 Nm (2.2 lbf.ft)
Fascia26 Nm (19 lbf.ft)
Fascia to steering column bracket 11 Nm (8 lbf.ft)
Front seat to floor 45 Nm (33 lbf.ft)
Second row seats to floor 45 Nm (33 lbf.ft)
Third row seats to lower rear quarter 22 Nm (16 lbf.ft)
Sunroof tray to frame 2 Nm (1.5 lbf.ft)
Solenoid securing cap 11 Nm (8 lbf.ft)
Support stay to alternator 25 Nm (18 lbf.ft)
Sunroof glass3 Nm (2.2 lbf.ft)
Motor to sunroof tray 2 Nm (1.5 lbf.ft)
Drive cable assembly to frame 2.5 Nm (1.8 lbf.ft)
Front and rear door striker bolts 26 Nm (19 lbf.ft)
Tail door striker bolts 26 Nm (19 lbf.ft)

LIFTING AND TOWING
08-1
LIFTING AND TOWING
LIFTING
The following instructions must be carried out before
raising the vehicle off the ground.
lUse a solid level ground surface.
lApply hand brake.
lSelect 'P' (Automatic gearbox) or 1st gear
(Manual gearbox) in main gearbox.
lSelect Low range in transfer gearbox.
To avoid damage occurring to the under body
components of the vehicle the following jacking
procedures must be adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS:
lBody structure
lBumpers
lFuel lines
lBrake lines
lFront radius arms
lPanhard rod
lSteering linkage
lRear trailing arms
lFuel tank
lEngine sump
lGearbox bell housing
Vehicle jack
The jack provided with the vehicle is only intended for
use in an emergency, for changing a tyre. DO NOT
use the jack for any other purpose. Refer to Owner's
Handbook for vehicle jack location points and
procedure. Never work under a vehicle supported
solely by the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used. Do not commence
work on the underside of the vehicle until
suitable axle stands have been positioned under
the axle.
WARNING: Always chock the wheels when
jacking. The hand brake acts on the
transmission, not the rear wheels, and may be
ineffective when the wheels are off the ground.Raising and supporting the vehicle
Position cup of hydraulic arm under differential
casing (1).The differential casing is not central to
the axle. Care should be taken when raising the
front road wheels off the ground as the rear axle
has less sway stiffness.
Raise vehicle to enable an axle stand to be installed
under left hand axle tube (2).
Position an axle stand under right hand axle tube (4).
Carefully lower jack until vehicle sits securely on both
axle stands, remove jack.
Alternatively, the axle stands can be positioned
under the chassis longitudinals at the front and/or
rear of the vehicle.
Before commencing work on underside of vehicle re-
check security of vehicle on stands.
WARNING: Always chock the wheels when
jacking. The hand brake acts on the the
transmission, not the rear wheels, and may be
ineffective when the wheels are off the ground.

LIFTING AND TOWING
08-2
Reverse procedure when removing vehicle from
stands.
Hydraulic ramps
Use only a 'drive on' type ramp which supports a
vehicle by it's own road wheels. If a 'wheel free'
condition is required, use a 'drive on' ramp
incorporating a 'wheel free' system that supports
under axle casings. Alternatively, place vehicle on a
firm, flat floor and support on axle stands.
TOWING
Towing
The vehicle has permanent four wheel drive. The
following towing instructions must be adhered
to:
Towing on 4 wheels with driver
Turn ignition key to position '1' to release steering
lock.
Select neutral in main gearbox and transfer gearbox.
Secure tow rope, chain or cable to towing eye.
Release the handbrake.
The brake servo and power assisted steering
system will not be functional without the engine
running. Greater pedal pressure will be required
to apply the brakes, the steering system will
require greater effort to turn the front road
wheels. The vehicle tow connection should be
used only in normal road conditions, 'snatch'
recovery should be avoided.Suspended tow
To prevent vehicle damage, front or rear
propeller shaft MUST BE removed, dependent
upon which axle is being trailed.
Mark propeller shaft drive flanges at transfer box and
axles with identification lines to enable the propeller
shaft to be refitted in its original position.
Remove the propeller shaft fixings, remove the shaft
from the vehicle.
If the front axle is to be trailed turn ignition key to
position '1' to release steering lock.
The steering wheel and/or linkage must be
secured in a straight ahead position. DO NOT use
the steering lock mechanism for this purpose.
Towing eyes
The towing eyes at the front and rear of the vehicle
are designed for vehicle recovery purposes only and
must NOT be used to tow a trailer or caravan.
Front:A single towing eye, set behind a removable
panel in the front spoiler. DO NOT use the front
lashing rings for towing.

CAPACITIES, FLUIDS AND LUBRICANTS
09-2
Refrigerant - A/C system
Fluids
Anti-freeze
Use Havoline Extended Life Coolant (XLC), or any
ethylene glycol based anti-freeze (containing no
methanol) with only Organic Acid Technology
corrosion inhibitors, to protect the cooling system
CAUTION: No other anti-freeze should be used
with Havoline Extended Life Coolant.
The cooling system should be drained, flushed and
refilled with the correct amount of anti-freeze solution
at the intervals given on the Service Maintenance
Check Sheet.
After filling with anti-freeze solution, attach a warning
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
system to ensure that the correct type is used for
topping-up.
Brake/Clutch fluid
Use only DOT 4 brake fluid.
PAS/ACE fluid
Use Texaco cold climate power assisted steering
fluid 14315.
Air conditioning
Use only refrigerant R134a.
Refrigerant oil
Use only NipponDenso ND-oil 8 or Unipart ND-oil 8.
Refrigerant oil absorbs water and must not be stored
for long periods. Do not pour unused oil back into the
container.
NOTE: The total quantity of refrigerant oil in the
system is 180 ml.
CAUTION: Do not use any other type of
refrigerant oil.

Refill3.4 pt

Fill from dry 3.6 pt
Cooling system - V8 Engine:

Refill24.2 pt

Fill from dry 26.2 ptComponent US Units

Front A/C 700 ± 25 g

Front/rear A/C 900 ± 25 g

MAINTENANCE
PROCEDURES 10-13
Check/top-up — Washer reservoir
1.Check fluid level in windscreen washer
reservoir.
2.Clean area around filler cap, remove cap.
3.Top-up if necessary to correct level on reservoir
using recommended fluid.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Fluids.
4.Fit filler cap.
Steering box
Check
1.Check steering box for fluid leaks.
Adjust
1.Check that there is no backlash in steering box
with road wheels in straight ahead position.
Adjust if required.

+ STEERING, ADJUSTMENTS,
Steering box - check and adjust.
Battery
Check
1.Check battery condition by checking colour of
condition indicator.
lGreen = O.K.
lBlack = Battery requires charging.
lClear/white = New battery required.
Clean
1.Clean and grease battery terminals with
petroleum jelly.

MAINTENANCE
PROCEDURES 10-23
Power steering, suspension
ACE pipes
1.Check for fluid leaks from power steering and
suspension systems.
2.Check ACE pipes and unions for chafing, leaks
and corrosion and that all pipes and hoses are
correctly routed and secure.
Engine, gearbox, transfer box and axles
Check
1.Check for oil leaks from engine, gearbox
(manual and automatic), transfer box and front
and rear axles; pay particular attention to areas
around oil seals.
Exhaust system
Check
1.Check for signs of exhaust system leaks,
damage and security.
Steering box and front suspension
Check/tighten steering box fixings
1.Check steering box fixings and tighten to 90
Nm (66 lbf.ft).
Check/tighten front axle suspension fixings

MAINTENANCE
PROCEDURES 10-25
1.Check and tighten if necessary all rear axle
suspension fixings.

+ TORQUE WRENCH SETTINGS, Rear
suspension.
Steering rod ball joints
Check
1.Check condition of ball joints and dust covers,
and security of fixings.

+ TORQUE WRENCH SETTINGS,
Steering.
Dampers and SLS height sensors
Check – Dampers
Front dampers
Rear dampers
1.Check dampers for security and signs of
leakage.

MAINTENANCE
10-28 PROCEDURES
4.Check condition of Engine - RH mounting
rubber
5.Check tightness of all mounting bolts.

+ TORQUE WRENCH SETTINGS,
Engine V8.
Road/roller test
WARNING: Roller test must be restricted to 3
mph (5 km/h). If 2 wheel rolling road is to be used,
disconnect propeller shaft from the transfer box
output shaft driving the axle which is NOT on the
rolling road.Testing
1. 2 wheel rolling road: Engage differential lock
using a 10 mm open ended spanner on flats
machined on differential lock selector
shaft.Switch on ignition and check that the
differential lock, electronic brake
distribution and hill descent warning lamps
are illuminated.
2.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
3.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
4.With vehicle stationary, turn steering from lock
to lock. Check for smooth operation and ensure
there is no undue noise from power steering
pump or drive belt.
5.Depress clutch and select all gears in turn,
check for smooth, notch free engagement.
6. Check all vehicle systems for correct
operation.
7.Check for unusual engine, gearbox and
suspension noises.
8.Check braking system operation.
9.Check for smooth gear engagement.
10.Check engine performance.
11.Check operation of all instruments and warning
devices where practicable.