washer fluid LAND ROVER DISCOVERY 2002 Owner's Manual

FRONT AXLE
54-8 REPAIRS
6.Using a suitable lever, remove pinion oil seal.
Take care to avoid damage to oil seal
recess.
Refit
1.Clean pinion oil seal recess and pinion flange.
2.Lubricate pinion oil seal lip with clean
differential oil.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
3.Using LRT-51-010 , fit pinion oil seal. 4.Fit pinion flange and securing bolt and washer.
Using LRT- 51-003, restrain pinion flange and
tighten pinion flange bolt to 100 Nm (74 lbf.ft).
5.Position propeller shaft and align reference
marks. Fit nuts and bolts and tighten to 47 Nm
(35 lbf.ft).
6.Remove stand(s) and lower vehicle.
7.Check differential oil level.
+ MAINTENANCE, PROCEDURES,
Front and rear axle.

STEERING
57-8 DESCRIPTION AND OPERATION
Steering box
The steering box is located behind the first cross member of the chassis and is secured to the chassis rail with four
bolts. The steering box is of the worm and roller type and has a rotary control valve. The steering box is connected to
the steering knuckles of the front road wheels by the drop arm, drag link and track rod. The steering box is lubricated
by the hydraulic fluid in the housing. The input shaft is attached to the steering wheel via the intermediate shaft and
steering column. The drop arm is secured to the output shaft with a nut and tab washer. A ball joint allows movement
between drop arm and drag link, the ball joint is secured with a locknut. The steering box requries approximately 3.5
turns from lock to lock.
As a maintenance aid, an alignment bolt can be used to lock the drop arm at the steering box centre position. The bolt
fits in a groove in the rear face of the drop arm and screws in to a threaded hole on the bottom of the steering box
housing.
Cross section through steering box
1Relief valve stop 2 off
2Relief valve 2 off
3Piston
4Rack
5Housing
6Output shaft
7Roller
8Valve rotor9Torsion bar
10Input shaft
11Pin
12Valve sleeve
13Course spline
14Worm gear
15Spline (worm gear to torsion bar)

STEERING
REPAIRS 57-29
12. RH drive models with ACE: Position ACE
control arms to access steering box bolts.
13.With assistance remove 4 securing bolts and
remove steering box.
14.Remove centralising bolt from steering box. Refit
1.Fit centralising bolt to steering box.
2. With assistance, position steering box, fit bolts
and tighten to 90 Nm (66 lbf.ft).
3. RH drive models with ACE: Ensure washer is
in place on lower ball joint of anti-roll bar link,
then connect lower ball joint to axle. Tighten nut
to 100 Nm (74 lbf.ft).
4.Position drag link, fit nut and tighten to 80 Nm
(59 lbf.ft).
5.Position Panhard rod, fit bolt and nut and
tighten to 230 Nm (170 lbf.ft).
6.Clean PAS pipe ends and 'O' ring recess.
7.Lubricate new 'O' rings for PAS pipes with clean
PAS fluid.
8.Fit 'O' rings to PAS pipes and position pipes in
steering box. Fit PAS pipe bracket and tighten
bolt to 22 Nm (16 lbf.ft).
9. RHD models: Fit oil filter and housing:
lClean oil filter housing and engine mating
faces.
lLubricate new 'O' ring with clean engine oil
and fit to housing.
lPosition oil filter housing and tighten bolts to
9 Nm (7 lbf.ft).
10.Ensure steering wheel is centralised. Fit
universal joint between steering box and
intermediate shaft and tighten bolts to 25 Nm
(18 lbf.ft).
11.Remove centralising bolt from steering box.
12.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft)..
13.Remove stand(s) and lower vehicle.
14.Check and top up engine oil.
15.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
16.Centralise steering linkage

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.

STEERING
REPAIRS 57-33
21.With assistance remove 2 nuts and bolts
securing RH engine mounting to chassis.
22.Support the engine weight on a jack.
CAUTION: To prevent damage to
components, cushion the jack pad with a
block of wood or hard rubber.
23.Raise the engine sufficiently to allow the
steering box to clear the sump.
24. Models with ACE: Position ACE control arms
to access steering box bolts. 25.With assistance remove 4 bolts securing
steering box and remove steering box.
26.Remove centralising bolt from steering box.
Refit
1.Fit centralising bolt to steering box.
2.With assistance, position steering box, fit bolts
and tighten to 90 Nm (66 lbf.ft).
3.Lower the engine onto its mountings. Fit engine
mounting bolts and tighten to 85 Nm (63 lbf.ft).
4. Models with ACE: Ensure washer is in place
on lower ball joint of anti-roll bar link, then
connect lower ball joint to axle. Tighten nut to
100 Nm (74 lbf.ft).
5.Position drag link, fit nut and tighten to 80 Nm
(59 lbf.ft).
6.Position Panhard rod, fit bolt and nut and
tighten to 230 Nm (170 lbf.ft).
7.Position coolant rail and secure with clips and
bolt.
8.Fit coolant hoses and secure with clips.
9. Models with ACE: Fit and tighten bolt
securing ACE pipes to chassis.
10.Clean PAS pipe ends and 'O' ring recess.
11.Lubricate new 'O' rings for PAS pipes with clean
PAS fluid.
12.Fit 'O' rings to PAS pipes and position pipes in
steering box. Fit PAS pipe bracket and tighten
bolt to 22 Nm (16 lbf.ft).
13.Ensure steering wheel is centralised. Fit
universal joint between steering box and
intermediate shaft and tighten bolts to 25 Nm
(18 lbf.ft).
14.Remove centralising bolt from steering box.
15.Fit intercooler to turbo hose and secure with
clips.
16.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
17.Remove stand(s) and lower vehicle.
18.Connect battery earth lead.
19.Fit battery cover.
20.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
21.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
22.Centralise steering linkage

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.

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.

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
REPAIRS 60-45
8.Release clip and disconnect suction hose from
ACE pump.
9.Remove banjo bolt and disconnect pressure
pipe from ACE pump. Discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
10.Remove 3 bolts securing ACE pump to
mounting and remove ACE pump.
11.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.Connect hose to intercooler and secure with
clip.
11.Fit ACE/PAS reservoir into mounting bracket.
12.Connect air hose to turbo charger and secure
with clip.
13.Fit mass air flow sensor to air filter and secure
with clips.
14.Connect multiplugs to mass air flow sensor and
ambient air pressure sensor.
15.Fit auxiliary drive belt.

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

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

FRONT SUSPENSION
REPAIRS 60-55
10.Loosen clip and disconnect air hose from
throttle body.
Note: Pre 03 MY air intake hose illustrated.
11.Position container to collect fluid loss.
12. Pump to valve block pipe:Remove banjo bolt
securing fluid hose to ACE pump and discard
sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.13. Valve block to reservoir pipe: Release clip,
disconnect hose from ACE fluid reservoir and
remove clip from hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
14.Remove bolts securing 2 pipe clamps to front
cross member and remove clamps.

FRONT SUSPENSION
REPAIRS 60-59
15.Release clips and disconnect 2 thermostat
housing hoses from coolant pipe.
16.Release clip and disconnect bottom hose from
radiator.
17.Remove thermostat housing with hoses.
18.Position container to collect ACE fluid loss.
19. Pump to valve block pipe: Remove banjo
bolt securing fluid hose to ACE pump and
discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.20. Valve block to reservoir pipe: Release clip,
disconnect hose from ACE fluid reservoir and
remove clip from hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
21.Remove bolts securing 2 pipe clamps to
chassis front cross member and remove
clamps.

FRONT SUSPENSION
60-60 REPAIRS
22. Valve block to reservoir pipe: Release fluid
return pipe from clip on LH chassis member.
23.Remove bolt securing pipe clamp to RH
chassis member and remove clamp.
24.Release harness clip from RH suspension
turret. 25.Remove nut securing pipe clamp to bracket on
RH suspension turret and remove clamp.
26.Release pipe from isolator above chassis RH
front outrigger.
27.Cut pipe at suitable point near suspension
turret.
28.Remove and discard front and rear sections of
pipe.
Refit
1.Fit both sections of new pipe to vehicle.
2.Ensure 'O' ring is fitted to union on front section
of pipe.
3.Push both sections of pipe together squarely
and tighten union nut to 16 Nm (12 lbf.ft).
4.Locate pipe in isolator above chassis RH front
outrigger. Fit cable tie around isolator to secure
pipe.
5. Valve block to reservoir pipe: Fit clip to
reservoir hose, connect hose to reservoir and
secure with clip.
6. Pump to valve block pipe: Ensure pipe banjo
and ACE pump connections are clean, fit new
sealing washers, align banjo to pump and
tighten bolt to 29 Nm (21 lbf.ft).