bonnet LAND ROVER DISCOVERY 2002 Workshop Manual

CONTENTS
2CONTENTS
IDENTIFICATION NUMBERS .................................................................. 05-1
Vehicle Identification Number ......................................................................................................... 05-1
Identification Number Locations ..................................................................................................... 05-3
TORQUE WRENCH SETTINGS .............................................................. 06-1
Maintenance ................................................................................................................................... 06-1
Engine Td5 ..................................................................................................................................... 06-2
Engine V8 ....................................................................................................................................... 06-4
Emission control - Td5 .................................................................................................................... 06-5
Emission control - V8 ...................................................................................................................... 06-5
Engine management system - Td5 ................................................................................................. 06-5
Engine management system - V8................................................................................................... 06-6
Cooling system ............................................................................................................................... 06-6
Manifolds and exhaust systems - Td5 ............................................................................................ 06-6
Manifolds and exhaust systems - V8 .............................................................................................. 06-7
Clutch.............................................................................................................................................. 06-7
Manual gearbox - R380 .................................................................................................................. 06-8
Transfer box - LT230SE ................................................................................................................. 06-8
Automatic gearbox - ZF4HP22/24 .................................................................................................. 06-9
Propeller shafts ............................................................................................................................... 06-9
Axles ............................................................................................................................................... 06-9
Steering .......................................................................................................................................... 06-10
Front suspension ............................................................................................................................ 06-11
Rear suspension ............................................................................................................................. 06-12
Brakes............................................................................................................................................. 06-12
Restraint systems ........................................................................................................................... 06-13
Body................................................................................................................................................ 06-14
Heating and air conditioning ........................................................................................................... 06-15
Wipers and washers ....................................................................................................................... 06-15
Electrical ......................................................................................................................................... 06-15
LIFTING AND TOWING ........................................................................... 08-1
LIFTING .......................................................................................................................................... 08-1
TOWING ......................................................................................................................................... 08-2
TRANSPORTING ........................................................................................................................... 08-3
CAPACITIES, FLUIDS AND LUBRICANTS ............................................ 09-1
Capacities ....................................................................................................................................... 09-1
Fluids .............................................................................................................................................. 09-2
Anti-Freeze Concentration .............................................................................................................. 09-3
Lubrication ...................................................................................................................................... 09-3
MAINTENANCE ........................................................................................ 10-1
PROCEDURES
V8 engine underbonnet view .......................................................................................................... 10-1
Diesel underbonnet view ................................................................................................................ 10-2
Seats and seat belts ...................................................................................................................... 10-3
Lamps, horns and warning indicators ........................................................................................... 10-5
Wipers and washers ...................................................................................................................... 10-5
Handbrake .................................................................................................................................. 10-6

CONTENTS
CONTENTS 3
Alarm handset battery ..................................................................................................................... 10-6
Road wheels ................................................................................................................................... 10-7
Tyres .............................................................................................................................................. 10-7
Brake pads, discs and calipers ....................................................................................................... 10-7
Road wheel speed sensors ............................................................................................................. 10-7
Brake fluid ....................................................................................................................................... 10-8
Fuel filter - diesel engine ................................................................................................................. 10-8
Fuel filter sedimenter ...................................................................................................................... 10-8
Road wheels ................................................................................................................................... 10-8
Radiator/Intercooler ........................................................................................................................ 10-8
Ambient air Temperature and pressure sensor .............................................................................. 10-8
Doors, bonnet and fuel filler flap ..................................................................................................... 10-9
Air suspension intake filter .............................................................................................................. 10-9
Anti-freeze....................................................................................................................................... 10-9
Cooling system ............................................................................................................................... 10-9
Spark plugs - V8 engine.................................................................................................................. 10-10
Air cleaner - V8 engine ................................................................................................................... 10-11
Air cleaner and dump valve - diesel engine .................................................................................... 10-11
Auxiliary drive belt ........................................................................................................................... 10-11
Auxiliary drive belt - V8 engine ....................................................................................................... 10-12
Auxiliary drive belt - diesel engine .................................................................................................. 10-12
Fluid reservoirs ............................................................................................................................... 10-12
Steering box .................................................................................................................................... 10-13
Battery ............................................................................................................................................. 10-13
Intercooler - diesel engine............................................................................................................... 10-14
Engine oil - V8 engine ..................................................................................................................... 10-14
Engine oil - diesel engine ................................................................................................................ 10-14
Centrifuge rotor – diesel engine ...................................................................................................... 10-15
Engine oil filter - diesel engine ........................................................................................................ 10-15
Engine oil filter – V8 engine ............................................................................................................ 10-15
Manual gearbox .............................................................................................................................. 10-16
Automatic gearbox ......................................................................................................................... 10-17
Transfer box .................................................................................................................................... 10-18
Front and rear axle .......................................................................................................................... 10-19
Propeller shafts ............................................................................................................................... 10-19
Anti-roll bar links ............................................................................................................................. 10-20
ACE actuators ................................................................................................................................. 10-21
ACE filter ......................................................................................................................................... 10-21
Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ 10-22
Engine, gearbox, transfer box and axles ........................................................................................ 10-23
Exhaust system............................................................................................................................... 10-23
Steering box and front suspension ................................................................................................. 10-23
Steering rod ball joints ................................................................................................................... 10-25
Dampers and SLS height sensors .................................................................................................. 10-25
Front and rear axle suspension links .............................................................................................. 10-26
Towing bracket................................................................................................................................ 10-27
Engine mountings - V8 engine ........................................................................................................ 10-27
Road/roller test................................................................................................................................ 10-28
ENGINE - Td5 ........................................................................................... 12-1-1
DESCRIPTION AND OPERATION
Td5 Engine...................................................................................................................................... 12-1-1
Cylinder block components ............................................................................................................. 12-1-2

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
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 23
Headlamps beam alignment - from 03MY ...................................................................................... 86-2-2
REPAIRS
Lamp - front repeater .................................................................................................................... 86-2-3
Headlamp - up to 03MY .................................................................................................................. 86-2-4
Headlamp - from 03MY .................................................................................................................. 86-2-5
Lamp - tail ..................................................................................................................................... 86-2-6
Lamp - front fog up to 03MY ........................................................................................................... 86-2-6
Lamp - front fog from 03MY ............................................................................................................ 86-2-7
Housing - number plate lamp ......................................................................................................... 86-2-8
Motor - headlamp levelling ............................................................................................................ 86-2-9
Lamp - stop - centre high mounted (CHMSL) .............................................................................. 86-2-10
Lamp - tail/flasher - bumper ............................................................................................................ 86-2-10
Lamp - interior - front .................................................................................................................... 86-2-11
Lamp - interior - rear ..................................................................................................................... 86-2-11
Rheostat - panel lights dimmer ...................................................................................................... 86-2-12
Switch - hazard warning ................................................................................................................. 86-2-13
Switch - indicator and exterior lighting - combined.......................................................................... 86-2-13
Socket - accessory ......................................................................................................................... 86-2-14
Switch - front/rear fog lamps ......................................................................................................... 86-2-14
BODY CONTROL UNIT ............................................................................ 86-3-1
DESCRIPTION AND OPERATION
Description ...................................................................................................................................... 86-3-1
Operation ........................................................................................................................................ 86-3-19
REPAIRS
Body control unit (BCU) .................................................................................................................. 86-3-39
ALARM SYSTEM AND HORN ................................................................. 86-4-1
DESCRIPTION AND OPERATION
Alarm system component layout ..................................................................................................... 86-4-2
Alarm system block diagram ........................................................................................................... 86-4-4
Description ...................................................................................................................................... 86-4-5
Operation ........................................................................................................................................ 86-4-16
REPAIR
Switch - central door locking ......................................................................................................... 86-4-25
Switches - horn ............................................................................................................................. 86-4-25
Vehicle horn .................................................................................................................................. 86-4-26
Sounder - alarm ............................................................................................................................ 86-4-26
Sounder - battery backed-up (BBUS) ............................................................................................. 86-4-27
Switch - bonnet ............................................................................................................................. 86-4-27
Receiver - alarm system - models with sunroof ............................................................................. 86-4-28
Receiver - alarm system - models without sunroof ......................................................................... 86-4-28
Coil - passive immobilisation ......................................................................................................... 86-4-29
WINDOWS ................................................................................................ 86-5-1
DESCRIPTION AND OPERATION

GENERAL INFORMATION
03-18
Connectors should never be subjected to forced
removal or refit, especially inter-board connectors.
Damaged contacts can cause short-circuit and open-
circuit fault conditions.
Prior to commencing test, and periodically during a
test, touch a good vehicle body earth to discharge
static charge. Some electronic components are
vulnerable to the static electricity that may be
generated by the operator.
Grease for electrical connectors
Some under bonnet and under body connectors may
be protected against corrosion by the application of a
special grease during vehicle production. Should
connectors be disturbed in service, repaired or
replaced, additional grease should be applied: Part
No. BAU 5811, available in 150 gm tubs.
NOTE: The use of greases other than BAU 5811
must be avoided as they can migrate into relays,
switches etc. contaminating the contacts and leading
to intermittent operation or failure.
Supplementary Restraint System
Precautions
General
The Supplementary Restraint System (SRS)
provides active protection for vehicle occupants in
the event of a serious collision. The system
components include airbags and pretensioner seat
belts which are automatically deployed when a
severe frontal crash condition is detected.
In order to assure system integrity, it is essential that
the SRS system is regularly checked and maintained
so that it is ready for operation in the event of an
accident.
The SRS system contains components which could
be potentially hazardous to the service engineer if
not serviced and handled correctly. The following
guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the
importance of ensuring integrity of the SRS
components fitted to the vehicle.
Where necessary, additional specific precautions are
detailed in the Restraint Systems section of this
Manual which should be referred to prior to
commencing repair operations.
It should be noted that these precautions are not
restricted to operations performed when servicing
the SRS system. The same care should be exercised
when working on ancillary systems and components
located in the vicinity of SRS components; these
include but are not limited to steering system (driver's
airbag), body and trim components (passenger's
airbag and seat belt pretensioners) and electrical
system components (SRS harnesses etc.).

GENERAL INFORMATION
03-27
Body repairs often involve the removal of mechanical
and electrical units and associated wiring. Where
necessary, refer to the relevant section of the
Workshop Manual for removal and refitting
instructions.
Taking into consideration the differences in body
styles, suspension systems and engine and
transmission layouts, the location of the following
components as applicable to a particular vehicle is
critical:
lFront suspension upper damper mountings on
RH and LH chassis longitudinals.
lFront suspension or sub frame mountings.
lEngine mountings on RH and LH chassis
longitudinals.
lRear suspension upper damper mountings on
RH and LH chassis longitudinals.
lRear suspension mountings or lower pivots.
Additional points which can be used to check
alignment and assembly are:
lInner holes in cross member - side - main floor.
lHoles in front bulkhead.
lHoles in rear longitudinals.
lHoles in rear lower panels.
Apertures for windscreen, rear screen, bonnet and
doors can be measured and checked using the
dimensional information provided and also by
offering up an undamaged component as a gauge.
Straightening
Whenever possible, structural members should be
cold straightened under tension. Do not attempt to
straighten with a single pull but rework the damaged
area using a series of pulls, releasing tension
between each stage and using the opportunity to
check alignment.
Body jig
Unless damage is limited to cosmetic panels, all
repair work to body members must be carried out on
a body jig, to ensure that impact damage has not
spread into more remote parts of the structure.
Mounting on a jig will also ensure that the
straightening and panel replacement procedures do
not cause further distortion.
If original dimensions cannot be satisfactorily
restored by these methods, damaged structural
members should be replaced. Damaged areas
should be cut away using a high speed saw, NOT an
oxy-acetylene torch.
As a rule, body dimensions are symmetrical about
the centre line. A good initial check for distortion is
therefore to measure diagonally and to investigate
apparent differences in dimensions.Inspection
Every accident produces individual variations in
damage. Each repair is influenced by the extent of
the damage and the facilities and equipment
available for its rectification.
Most accident damage can be visually inspected and
the approximate extent of damage assessed.
Sometimes deformation will extend beyond the
directly damaged area, and the severity of this must
be accurately established so that steps can be taken
to restore critical body components to their original
dimensions. An initial check can be carried out by
means of drop checks or, preferably, trammels.
Gauges are available which will accurately check for
body twist.

IDENTIFICATION NUMBERS
05-1
IDE NTIFICATION NUMBERS
Vehicle Identification Number
Location
The Vehicle Identification Number (VIN) plate is
stamped on a plate attached to the bonnet locking
platform. The VIN is also stamped in the following
locations:
lOn a plate behind the LH lower corner of the
windscreen.
lOn the chassis RH longitudinal behind the rear
wheel.
Bonnet locking platform VIN
Windscreen VINChassis VIN
VIN plate content
The VIN plate contains the following information.
aVehicle Identification Number (VIN)
bGross vehicle weight
cGross train weight
dMaximum front axle load
eMaximum rear axle load
fPaint code
gTrim code

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)

CAPACITIES, FLUIDS AND LUBRICANTS
09-4
Engine oil - V8 - high compression engine
Use a 5W/30 oil meeting specification ACEA: A1,
(API SJ or ILSAC GF2 for USA).
NOTE: ACEA: A2 can be used.
Engine oil - Td5
Use oil meeting specification ACEA: A1, B1 or B2.
Gearbox oil
Use of gearbox oils other than those specified may
result in serious damage to the gearbox,
Manual Gearbox
Use Texaco MTF 94 oil for refill and topping-up. If
MTF 94 is not available, ATF Dexron IID or ATF
Dexron III may be used.
Automatic Gearbox
Use ATF Dexron IID or Dexron III oil for refill or
topping-up.
Transfer box
Use Texaco Multi-Gear 75W/90R.
Front and rear axles
Use Texaco Multi-Gear 75W/90R.
Air Conditioning
Use lubricating oil Nippon Denso ND-8.
General Greasing
Use Multipurpose Lithium Base Grease N.L.G.I.
consistency No. 2.
Bonnet latch
Lubricate cable and latch with oil.
Locks, Latches and Hinges
Use Door Lock and Latch Lubricant, Part No. VWN
10075.