LAND ROVER DISCOVERY 2002 Workshop Manual

REAR SUSPENSION
64-36 REPAIRS
Actuator - rear - ACE
$% 64.60.40
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.
Models with SLS:
WARNING: Ensure the air suspension system is
made safe before commencing work. Otherwise
the chassis may lower onto the bump stops
during repair.
Remove
1.Raise vehicle on ramp.
2.Remove nuts securing anti-roll bar links to
axle. Release links from axle.
3.Pull torsion bar down for access to actuator. 4.Remove nut securing anti-roll bar link to long
arm and remove link.
5.Position container to collect fluid spillage.
6.Remove cap nuts securing fluid pipes to
actuator. Disconnect pipes and remove and
discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.

REAR SUSPENSION
REPAIRS 64-37
7.Use LRT-60-009 to remove nut securing
actuator push rod to long arm.
8.Remove nut and bolt securing actuator to short
arm and remove actuator.
CAUTION: The short arm and torsion bar
are supplied as an assembly and must not
be separated.Refit
1.Position actuator and tighten nut and bolt
securing actuator to short arm to 180 Nm (133
lbf.ft).
2.Using LRT-60-009 , fit and tighten nut securing
actuator push rod to long arm to 48 Nm (35
lbf.ft).
3.Connect pipes to actuator with cap nuts and
new sealing washers. Tighten cap nuts to 29
Nm (21 lbf.ft). Ensure pipes are not under
tension or kinked.
4.Connect anti-roll bar link to long arm and
tighten nut to 50 Nm (37 lbf.ft).
5.Ensure washer is in place on lower ball joint of
each anti-roll bar link and connect lower ball
joints to axle. Tighten nuts to 100 Nm (74 lbf.ft).
6.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
7.Lower vehicle.
8.Bleed ACE hydraulic system.

+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.

REAR SUSPENSION
64-38 REPAIRS
Bushes - rear long arm - ACE
$% 64.60.46
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.
Models with SLS:
WARNING: Ensure the air suspension system is
made safe before commencing work. Otherwise
the chassis may lower onto the bump stops
during repair.
Remove
1.Raise vehicle on ramp.
2.Remove nuts securing anti-roll bar links to axle.
Release links from axle.
3.Pull torsion bar down for access to actuator.4.Remove securing nuts and remove anti-roll bar
links from torsion bar.
5.Position container to collect fluid spillage.
6.Remove cap nuts securing fluid pipes to
actuator. Disconnect pipes and remove and
discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
7.With assistance, remove bolts securing torsion
bar clamps. Remove clamps and remove
torsion bar and actuator.

REAR SUSPENSION
REPAIRS 64-39
8.Use LRT-60-009 to remove nut securing
actuator push rod to long arm.
9.Remove nut and bolt securing actuator to short
arm and remove actuator.
10.Restrain torsion bar and remove long arm
securing bolt and washer. Remove long arm
from torsion bar.
CAUTION: The short arm and torsion bar
are supplied as an assembly and must not
be separated.11.Use a suitable drift to remove both halves of
slipper bush from long arm.
12.Use suitable adaptors to press actuator rod end
bush from long arm.

REAR SUSPENSION
64-40 REPAIRS
Refit
1.Clean bush locations in long arm.
2.Use suitable adaptors to press new actuator
rod end bush into long arm. Ensure bush is
correctly aligned.
3.Align slots in new slipper bush halves with
those in long arm. Carefully press both halves
of slipper bush into long arm. Ensure the
sealing rings on the bush faces are not
damaged.
4.Clean long arm and mating face on torsion bar.
5.Fit long arm to torsion bar. Restrain torsion bar
and tighten bolt to 180 Nm (133 lbf.ft).
6.Ensure actuator and bushes are clean.
7.Fit actuator and tighten nut and bolt securing
actuator to short arm to 180 Nm (133 lbf.ft).
8.Using LRT-60-009 , fit and tighten nut securing
actuator push rod to long arm to 48 Nm (35
lbf.ft).
9.With assistance, position torsion bar and
actuator to vehicle and fit torsion bar clamps.
Tighten torsion bar clamp bolts to 45 Nm (33
lbf.ft).
10.Connect pipes to actuator with cap nuts and
new sealing washers. Tighten cap nuts to 29
Nm (21 lbf.ft). Ensure pipes are not under
tension or kinked.11.Fit anti-roll bar links to torsion bar and tighten
nuts to 50 Nm (37 lbf.ft).
12.Ensure washer is in place on lower ball joint of
each anti-roll bar link and connect lower ball
joints to axle. Tighten nuts to 100 Nm (74 lbf.ft).
13.Renew ACE high pressure filter.

+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
14.Lower vehicle.
15.Bleed ACE hydraulic system.

+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.

BRAKES
DESCRIPTION AND OPERATION 70-1
BRAKES DESCRIPTION AND OPERAT ION
Brake system control component layout
RH drive shown, LH drive similar
1Hill descent switch
2ABS sensor
3SLABS ECU

BRAKES
70-2 DESCRIPTION AND OPERATION
Brake system control diagram

BRAKES
DESCRIPTION AND OPERATION 70-3
1ABS sensor
2ABS modulator
3Return pump relay
4SLABS ECU
5Brake lamp relay
6Centre high mounted stop lamp
7LH brake lamp
8RH brake lamp
9Instrument pack
10Body control unit
11Reverse lamp switch (manual gearbox)
12Diagnostic socket
13HDC switch
14Transmission high/low switch
15Centre differential lock switch
16Engine control module
17Battery power supply
18Ignition power supply

BRAKES
70-4 DESCRIPTION AND OPERATION
Brake system hydraulic component
layout
RH drive shown, LH drive similar
1Rear brake
2ABS modulator
3Front brake
4Inlet manifold plenum (V8 models)
5Non return valve6Master cylinder assembly
7Brake fluid reservoir
8Brake servo assembly
9Vacuum pump (diesel models)

BRAKES
DESCRIPTION AND OPERATION 70-5
Description
General
The brakes consist of front and rear disc brakes operated by a diagonally split, dual circuit hydraulic system with
vacuum servo power assistance. The system incorporates the following control functions as standard on all models:
lAnti-lock Brakes (ABS), to prevent road wheels locking during brake application.
lElectronic Brake Distribution (EBD), to control distribution of hydraulic pressure between front and rear axles.
Replaces mechanical pressure limiting valve of previous systems.
lElectronic Traction Control (ETC), to maintain even torque distribution to the road wheels.
lHill Descent Control (HDC), to provide controlled descent ability in off road conditions.
Hydraulic system schematic
1Master cylinder/brake servo assembly
2Brake pedal
3ABS modulator
4Rear brake
5Front brake
6Hydraulic circuit
aPrimary
bSecondary
For normal brake operation, brake pedal movement is assisted by the brake servo assembly and transmitted to the
master cylinder assembly. The master cylinder assembly converts brake pedal movement to hydraulic pressure.
Primary and secondary brake pipe circuits supply the hydraulic pressure to the brakes via the ABS modulator: the
primary circuit supplies the front left and rear right brakes; the secondary circuit supplies the front right and rear left
brakes. Vacuum for the brake servo assembly is obtained from the engine inlet manifold (V8 models) or a vacuum
pump (diesel models), through a vacuum line and non return valve. To reduce operating noise, sleeving is installed
on some of the brake pipes in the engine compartment and the pipes are located in sprung pipe clips.