height LAND ROVER DISCOVERY 2002 Workshop Manual

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 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

INTRODUCTION
01-3
Abbreviations and Symbols
A Amperes
AAP Ambient Air Pressure
AAT Ambient Air Temperature
ABDC After Bottom Dead Centre
ABS Anti-Lock Brake System
ABS / TC Anti-lock Brake System / Traction
Control
ac Alternating current
A/C Air Conditioning
ACE Active Cornering Enhancement
ACEA Association of Constructors of
European Automobiles
AFR Air Fuel Ratio
AP Ambient Pressure
ASC Anti-shunt Control
ATC Air Temperature Control
ATDC After Top Dead Centre
AUX Auxiliary
AVC Automatic Volume Control
BBDC Before Bottom Dead Centre
BBUS Battery Backed Up Sounder
BCU Body Control Unit
BDC Bottom Dead Centre
bhp Brake Horse Power
BP Boost Pressure
BPP Brake Pedal Position
BS British Standard
BTDC Before Top Dead Centre
BWD Backward
C Celsius
CAN Controller Area Network
CD Compact Disc
CDC Centre Differential Control
CDL Central Door Locking
CD - ROM Compact Disc - Read Only
Memory
CFC Chlorofluorocarbon
CHMSL Centre High Mounted Stop Lamp
CKP Crankshaft Position
CLV Calculated Load Value
cm Centimetre
cm
2Square centimetre
cm3Cubic centimetre
CMP Camshaft Position
CPP Clutch Pedal Position
CO Carbon Monoxide
CO
2Carbon Dioxide
COB Clear Over Base
CR Common Rail
CVS Canister Vent Solenoid
dB Decibels
DDM Driver's Door Module
deg. Degree, angle or temperature
DI Direct Injection
dia. DiameterDIN Deutsche Industrie Normen
(German Industrial Standards)
dc Direct current
DCV Directional Control Valve
DOHC Double Overhead Camshaft
DSP Digital Signal Processing
DTI Dial Test Indicator
DMF Dual Mass Flywheel
DVD Digital Versatile Disc
EACV Electronic Air Control Valve
EAT Electronic Automatic
Transmission
EBD Electronic Brake pressure
Distribution
ECD European Community Directive
ECM Engine Control Module
ECT Engine Coolant Temperature
ECU Electronic Control Unit
EDC Electronic Diesel Control
EEPROM Electronic Erasable
Programmable Read Only
Memory
EGR Exhaust Gas Recirculation
EKA Emergency Key Access
ELR Emergency Locking Retractor
EN European Norm
EOBD European On Board Diagnostics
EON Enhanced Other Network
ERL Electrical Reference Library
ETC Electronic Traction Control
EUI Electronic Unit Injector
EVAP Evaporative Emission
EVR Electronic Vacuum Regulator
F Fahrenheit
ft. Feet
FBH Fuel Burning Heater
FET Field Effect Transistor
FIP Fuel Injection Pump
FTC Fast Throttle Control
FWD Forward
> Greater than
g Gramme or Gravity
gal. Gallons
GMT Greenwich Mean Time
GPS Global Positioning System
hHour
hc High compression
HC Hydro Carbons
HDC Hill Descent Control
HDOP Height Dilation Of Precision
HDPE High Density Polyethylene
HFS Heated Front Screen
Hg Mercury
HO
2S Heated Oxygen Sensor
HMW High Molecular Weight

GENERAL DATA
04-1
GENERAL DATA
Engine - Td5
General
Type 2.5 litre in-line direct injection diesel, turbocharged and intercooled
Cylinder arrangement 5 in-line, No. 1 cylinder at front of engine
Bore 84.450 mm (3.3248 in)
Stroke 88.950 mm (3.5020 in)
Capacity 2498 cm
3 (152.5 in3)
Firing order 1 - 2 - 4 - 5 - 3
Compression ratio 19.5 : 1
Direction of rotation Clockwise viewed from the front of the engine
Dimensions:

Length 766 mm (30.1 in)

Width 708 mm (27.8 in)

Height 788 mm (31.0 in)
Injection timing Controlled by ECM
Injectors:

Make/Type Lucas EV1

Nominal operating pressure:

Pre EU3 models 1500 bar (21750 lbf.in
2)

EU3 models 1750 bar (25500 lbf.in
2)
Maximum governed speed 4850 rev/min
Maximum overrun speed 5460 rev/min
Idle speed:

Manual gearbox 740 ± 50 rev/min

Automatic gearbox 760 ± 50 rev/min
Glow plugs Beru 12 V. Four plugs in cylinders 1, 2, 3 and 4
Turbocharger Garrett GT 20
Emissions standard:

Pre EU3 models ECD 2

EU3 models ECD 3
Valve timing
Inlet valves:

Opens 14° BTDC

Closes 33° ABDC
Exhaust valves:

Opens 57° BBDC

Closes 14° ATDC

GENERAL DATA
04-4
Engine - V8
General
Cylinder arrangement 90° V8, numbered from the front of the engine:

Left bank cylinders 1, 3, 5 and 7

Right bank cylinders 2, 4, 6 and 8
Bore 94.00 mm (3.70 in)
Stroke:

4.0 litre

4.6 litre71.04 mm (2.80 in)
81.92 mm (3.22 in)
Capacity:

4.0 litre

4.6 litre3950 cm
3 (241 in3)
4554 cm3 (278 in3)
Firing order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2
Compression ratio:

Low - 4.0 litre 8.23:1

High - 4.0 and 4.6 litre 9.35:1
Direction of rotation Clockwise viewed from the front of the engine
Maximum power - 4.0 litre:

Low compression ratio 132 kW (177 bhp) at 4750 rev/min

High compression ratio - UK/Japan/ROW 136 kW (182 bhp) at 4750 rev/min

High compression ratio - NAS 140 kW (187 bhp) at 4750 rev/min
Maximum power - 4.6 litre 162 kW (217 bhp) at 4750 rev/min
Maximum engine speed:

Continuous5000 rev/min

Intermittent 5250 rev/min
Weight (fully dressed, wet)

Manual 194 Kg (435 lb)

Automatic 179 Kg (402 lb)
Dimensions:

Length - Manual 767 mm (30.2 in) (Including fan)

Length - Automatic 777 mm (30.5 in) (Including fan and drive plate)

Width 652 mm (25.7 in)

Height 746 mm (29.4 in)
Spark plugs:

Make/Type - 4.0 litre Champion RC11 PYP B4

Make/type - 4.6 litre Champion RN11 YCC

Gap - 4.0 and 4.6 litre 1.00 ± 0.05 mm (0.040 ± 0.002 in) Non-adjustable
Coils:

Make Bosch 0221 503 407

Type Twin coils
Fuel injection system:

Make Bosch Motronic 5.2.1 Type 4146

Type Multiport fuel injection, electronically controlled with electro-
mechanical injectors

GENERAL DATA
04-10
Cooling system - V8
Clutch - Td5
Type Pressurised, spill return, thermostatically controlled water and
antifreeze mixture. Vertical flow radiator with remote header tank
and pump assisted
Cooling fans 9 blade axial flow on viscous coupling and 11 blade axial flow
electric
Electric cooling fan switching points:
For A/C system:

On When vehicle speed is 50 mph (80 km/h) or less and ambient
temperature is 28 °C (82 °F) or more

Off When vehicle speed increases to (62.5 mph (100 km/h) or
ambient temperature decreases to 25 °C (77 °F)
For engine cooling during normal running:

On 100 °C (212 °F)

Off 94.5 °C (202 °F)
For engine cooling at ignition off (to counteract heat
soak):

On If, within 10 seconds of ignition off, intake air temperature is 60 °C
(140 °F) or more and engine coolant temperature is 110 °C (230
°F) or more

Off After 10 minutes or if engine coolant temperature decreases to
100 °C (212 °F)
Coolant pump Centrifugal impeller, belt driven from crankshaft
Coolant pump drive ratio 1.293 : 1
Coolant pump output at 1000 rev/min 10 litres/min (2.64 US galls/min) at 0.7 bar (10 lbf.in
2)
Thermostat Waxstat with pressure relief valve
Thermostat operating temperature:

Initial opening 82 °C (179 °F)

Fully open 96 °C (204 °F)
Expansion tank cap relief valve - system operating
pressure1.4 bar (20 lbf.in
2)
Type Diaphragm spring, hydraulically operated with self-centering,
preloaded release bearing
Drive plate diameter 267 mm (10.5118 in)
Pressure plate diameter 267 mm (10.5118 in)
Clutch plate friction material Verto F202
Diaphragm finger height when clamped on a 8.5 mm
(0.33 in) thick gauge plate42.5 to 48.5 mm (1.673 to 1.904 in)
Diaphragm finger clearance (service limit) 1.00 mm (0.040 in)
Clutch plate thickness under 6500 N (1461 lb) axial
load:

New 8.2 to 8.8 mm (0.33 to 0.34 in)

Service limit 7.0 mm (0.27 in)

GENERAL DATA
04-15
Suspension
* Measurement taken with vehicle at unladen weight.
Type - Front Beam axle with coil springs, longitudinal radius arms,
Panhard rod, twin tube dampers and either anti-roll
bar or active cornering enhancement (ACE)
Nominal height from hub centre to wheel arch (not liner)* 500 ± 15 mm (19.7 ± 0.6 in)
Front road spring colour codes:

V8 LHS Pink/orange

V8 RHS - LHD Pink/orange

V8 RHS - RHD White/purple

Td5 LHS White/purple

Td5 RHS - LHD White/purple

Td5 RHS - RHD White/purple
Rear road spring colour codes:
5 seat, LHS Purple
5 seat, RHS - LHD Purple
5 seat, RHS - RHD Purple/purple
7 seat, LHS - LHD Grey/blue
7 seat, LHS - RHD Grey/green
7 seat, RHS - LHD Grey/blue
7 seat, RHS - RHD Grey/white
Bump stop height (top of bump stop to axle bracket) 44.5 mm (1.75 in)
Anti-roll bar diameter - front

With ACE fitted 35 mm (1.38 in)

Without ACE 30 mm (1.18 in)
Type - Rear Beam axle with coil or air springs, longitudinal radius
arms, Watts linkage, twin tube dampers and either
anti-roll bar or active cornering enhancement (ACE)
Nominal height from hub centre to wheel arch (not liner):*

Coil spring 483 ± 15 mm (19.0 ± 0.6 in)

Air spring 473 ± 15 mm (18.6 ± 0.6 in)
Road spring colour code Purple (all models)
Bump stop height (top of bump stop to axle bracket):

Coil spring 71.5 mm (2.8 in)

Air spring 61.5 mm (2.4 in)
Anti-roll bar diameter - rear

With ACE fitted 35 mm (1.38 in)

Without ACE - SLS fitted 29 mm (1.14 in)

Without ACE - SLS not fitted 5 seats = 19 mm (0.75 in)
7 seats = 16 mm (0.63 in)

GENERAL DATA
04-18
Dimensions
* Measurement taken with vehicle at unladen weight.
Weights
NOTE: The rear axle load for vehicles with self levelling suspension can be increased to a maximum of 1928 kg (4249
lb) when towing, provided road speed is limited to 60 mph (100 km/h).
NOTE: Axle weights are non additive. The individual maximum weights and gross vehicle weight must not be
exceeded.
Overall length - including towing hitch 4715 mm (185.6 in)
Overall length - including spare wheel 4705 mm (185.24 in)
Overall width (excluding mirrors) 1885 mm (74.2 in)
Overall height - Open sunroof * 2015 mm (79.3 in)
Overall height (without roof bars) * 1940 mm (76.40 in)
Minimum ground clearance * 253.5 mm (10.0 in)
Wheelbase 2540 mm (100.00 in)
Turning circle (kerb to kerb) 11.9 metres (39.1 feet)
Track - front 1540 mm (60.63 in)
Track - rear 1560 mm (61.42 in)
kgs lbs
Unladen weight:

V8 models 2095 - 2235 4619 - 4928

Td5 model 2150 - 2280 4740 - 5027
Max.GVW:

All 5 seat vehicles (coil springs) 2750 6063

All 7 seat Diesel engine vehicles (coil springs)
2880 6347

All 7 seat Petrol engine vehicles (coil springs)
2825 6215

V8 models with self levelling suspension 2825 6228

Td5 models with self levelling suspension 2880 6349
Max. front axle load 1200 2646
Max. rear axle load:

With coil springs 1720 3792

With self levelling suspension 1800 3968

TORQUE WRENCH SETTINGS
06-12
Rear suspension
Brakes
TORQUE DESCRIPTION METRIC IMPERIAL
Wheel nuts140 Nm (103 lbf.ft)
Wheel hub to axle 100 Nm (74 lbf.ft)
Damper to axle125 Nm (92 lbf.ft)
SLS height sensor link to radius arm 25 Nm (18 lbf.ft)
Radius arm230 Nm (170 lbf.ft)
Transverse links to pivot housing 155 Nm (114 lbf.ft)
Pivot housing to axle bolts 230 Nm (170 lbf.ft)
Transverse link to chassis 140 Nm (103 lbf.ft)
SLS height sensor 6 Nm (4.4 lbf.ft)
SLS compressor25 Nm (18 lbf.ft)
ACE actuator to short arm 185 Nm (136 lbf.ft)
ACE actuator to long arm 48 Nm (35 lbf.ft)
ACE actuator pipe cap nuts 29 Nm (21 lbf.ft)
Anti-roll bar link - upper 50 Nm (37 lbf.ft)
Anti-roll bar link - lower 100 Nm (74 lbf.ft)
ACE long arm to torsion bar 180 Nm (133 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Brake caliper bleed screw 10 Nm (7 lbf.ft)
Brake disc to drive flange 13 Nm (10 lbf.ft)
Caliper bolts - Front 175 Nm (129 lbf.ft)
Caliper bolts - Rear 95 Nm (70 lbf.ft)
Master cylinder to servo 25 Nm (18 lbf.ft)
Master cylinder brake pipe, unions 25 Nm (18 lbf.ft)
Brake caliper pivot bolt 30 Nm (22 lbf.ft)
Vacuum pump8 Nm (6 lbf.ft)
Vacuum pump lubrication pipe union 10 Nm (7 lbf.ft)
Brake caliper guide pin bolts 30 Nm (22 lbf.ft)
Brake caliper banjo bolt 32 Nm (24 lbf.ft)
ABS modulator to mounting bracket nuts 9 Nm (7 lbf.ft)
ABS modulator - 13 mm unions 22 Nm (16 lbf.ft)
ABS modulator - 11 mm union 14 Nm (10 lbf.ft)
Handbrake lever to floor bolts 22 Nm (16 lbf.ft)

MAINTENANCE
10-4 PROCEDURES
5. Check security of seat belt upper mountings.
6. Check for correct operation of seat belt height
adjusters.
7.Check security of seat belt buckle mountings.
8.Connect each belt to the correct buckle, check
seat buckle and tongue are secure. Release
seat belt buckle and check for correct
operation.9.Check tightness of accessible seat belt fixings.
10.Check tightness of accessible seat belt
mountings.