washer fluid LAND ROVER DISCOVERY 2002 Owner's Guide

FRONT SUSPENSION
60-62 REPAIRS
4.Remove 2 nuts securing rear anti-roll bar links
to axle.
5.Release links from axle and pull long arm down
for access to actuator pipe unions.
6.Position container under actuator to collect
fluid spillage.
7.Remove 2 cap nuts securing pipes to ACE rear
actuator. Disconnect pipes, remove and
discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
8.Remove 2 nuts securing rear pipe clamping
plate. Release clamping plate and pipes from
valve block.
CAUTION: Always fit plugs to open
connections to prevent contamination.
9.Remove pipe assembly.
10.Remove collets and clamping plate from rear
pipes. Refit
1.Ensure valve block and pipe connections are
clean.
2.Install clamping plate and collets on rear pipes.
3.Position pipe assembly to vehicle and connect
pipes and clamping plate to valve block. To
avoid damage to seals, keep pipes square
to valve block. Fit and tighten nuts securing
clamping plate to valve block to 21 Nm (15
lbf.ft).
CAUTION: Ensure pipes are installed in
their correct ports or serious system
damage will occur.
4.Fit bolts securing rear pipe clips to chassis and
tighten to 6 Nm (4.4 lbf.ft).
5.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.
6.Ensure washer is in place on lower ball joint of
each anti-roll bar link, then connect lower ball
joints to axle and tighten nuts to 100 Nm (74
lbf.ft).
7.Renew ACE high pressure filter.

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

+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.
9.Lower vehicle.

FRONT SUSPENSION
REPAIRS 60-63
Actuator - front - ACE
$% 60.60.40
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.
Remove
1.Raise vehicle on a ramp.
2.Remove RH front road wheel.
3.Position container to collect fluid spillage.
4.Remove cap nuts securing fluid pipes to
actuator. Disconnect pipes and discard sealing
washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.5.Remove 2 nuts securing anti-roll bar links to
axle. Release links from axle.
6.With assistance, remove 2 bolts and remove
both clamp plates from torsion bar.
7.Remove mounting rubbers from torsion bar.
8.Remove torsion bar and actuator assembly.
CAUTION: While removed from the vehicle,
ensure torsion bar is stored without any
load on the anti-roll bar links, or the ball
joints and/or link rods could be damaged.

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
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.

BRAKES
REPAIRS 70-35
Master cylinder - brake
$% 70.30.08
Remove
1.Disconnect multiplug from fluid level switch.
2.Position cloth under master cylinder to absorb
spilled fluid.
CAUTION: Brake fluid will damage paint
finished surfaces. If spilled, immediately
remove fluid and clean area with water.
3.Disconnect secondary system pipe union from
master cylinder.
4.Disconnect primary system pipe union from
master cylinder.
5. Manual gearbox only: Release clip and
disconnect clutch fluid supply hose from
reservoir.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove 2 nuts and washers securing master
cylinder to servo.
7.Remove master cylinder. Refit
1.Clean master cylinder and servo mating
surfaces.
2.Align push rod and position master cylinder to
servo.
3.Fit nuts and washers securing master cylinder
to servo and tighten to 25 Nm (18 lbf.ft).
4.Connect primary and secondary brake pipes,
and tighten unions to 25 Nm (18 lbf.ft).
5. Manual gearbox only: Connect clutch fluid
hose to reservoir, secure with clip.
6.Connect fluid level switch multiplug.
7.Bleed brake system using TestBook/T4.

+ BRAKES, ADJUSTMENTS, Brake
system bleeding.

BRAKES
70-40 REPAIRS
3.Remove 2 washers, springs and pins retaining
brake shoes to back plate.
4.Release return springs and remove brake
shoe.
5.Remove retaining spring securing abutment
lever to back plate.
6.Release remaining brake shoe from brake
cable, remove brake shoe and collect return
springs.
7.Remove adjuster plungers.
8.Remove 'C' clip securing cable lever to brake
shoe. Remove flat washer, lever, 2 Belleville
washers and pivot pin. Refit
1.Clean components with brake cleaning fluid.
WARNING: Do not use compressed air to
clean brake components. Dust from friction
materials can be harmful if inhaled.
2.Lubricate cable lever pivot pin.
3.Fit pivot pin to shoe, fit cable lever washers and
secure with 'C' clip.
4.Fit adjuster plungers.
5.Fit shoe to brake cable, align to back plate and
adjuster. Secure shoe to back plate with pin,
spring and washer.
6.Fit abutment plate to brake shoe.
7.Fit return springs with remaining shoe. Secure
shoe to back plate with pin, spring and washer.
8.Fit abutment plate retaining spring.
9.Clean brake drum and mating face.
10.Position brake drum and tighten retaining
screw.
11.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
12.Adjust handbrake.

+ BRAKES, ADJUSTMENTS,
Handbrake.

BRAKES
REPAIRS 70-43
Refit
1.Clean mating faces of alternator and vacuum
pump.
2.Fit vacuum pump to alternator and tighten
bolts to 8 Nm (6 lbf.ft).
3.Position alternator to engine and connect
multiplug.
4.Connect vacuum hose and oil drain hose to
vacuum pump and secure clips.
5.With assistance align alternator to mounting
bracket and fit but do not tighten bolt.
6.Fit bolt securing support stay to alternator and
tighten to 25 Nm (18 lbf.ft) .
7.Tighten bolt securing alternator to mounting
bracket to 45 Nm (33 lbf.ft).
8.Using new 'O' ring, connect oil supply pipe to
cylinder head and tighten to 10 Nm (7 lbf.ft).
9.Connect lead to alternator and tighten nut to 6
Nm (4.4 lbf.ft).
10.Fit auxiliary drive belt tensioner and tighten bolt
to 50 Nm (37 lbf.ft).
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
Housing - caliper - front
$% 70.55.24
Remove
1.Raise front of vehicle, one side.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel(s).
3.Clamp brake hose to prevent fluid loss.
4.Remove brake hose banjo bolt and discard
sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove 2 guide pin bolts and remove caliper
housing from carrier.
6.Remove 2 brake pads from caliper carrier.

BRAKES
70-44 REPAIRS
Refit
1.Rotate disc by hand and scrape all scale and
rust from around edge of disc. Clean location
surfaces on caliper bracket.
2.Clean dust from brake parts using brake
cleaning fluid.
WARNING: Do not use compressed air to
clean brake components. Dust from friction
materials can be harmful if inhaled.
3.Fit brake pads to caliper carrier.
4.Position caliper housing to carrier, align flats on
guide pins with caliper housing.
5.Fit guide pin bolts and tighten to 30 Nm (22
lbf.ft).
6.Clean banjo bolt and fit new sealing washers.
7.Position hose to caliper and tighten banjo bolt
to 32 Nm (24 lbf.ft).
8.Remove clamp from brake hose.
9.Bleed brake system.

+ BRAKES, ADJUSTMENTS, Brake
system bleeding.
10.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
11.Remove stand(s) and lower vehicle.
Housing - caliper - rear
$% 70.55.25
Remove
1.Raise rear of vehicle, one side.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel(s).
3.Clamp brake hose to prevent fluid loss.
4.Remove brake hose banjo bolt and discard
sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove 2 guide pin bolts and remove caliper
housing from carrier.
6.Remove 2 brake pads from caliper carrier.

BRAKES
REPAIRS 70-45
Refit
1.Rotate disc by hand and scrape all scale and
rust from around edge of disc. Clean location
surfaces on caliper bracket.
2.Clean dust from brake parts using brake
cleaning fluid.
WARNING: Do not use compressed air to
clean brake components. Dust from friction
materials can be harmful if inhaled.
3.Fit brake pads to caliper carrier.
4.Position caliper housing to carrier, align flats on
guide pins with caliper housing.
5.Fit guide pin bolts and tighten to 30 Nm (22
lbf.ft).
6.Clean banjo bolt and fit new sealing washers.
7.Position hose to caliper and tighten banjo bolt
to 32 Nm (24 lbf.ft).
8.Remove clamp from brake hose.
9.Bleed brakes.

+ BRAKES, ADJUSTMENTS, Brake
system bleeding.
10.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
11.Remove stand(s) and lower vehicle.
ECU - Self levelling and anti locking
brakes (SLABS)
$% 70.65.01
Remove
1.Remove BCU.

+ BODY CONTROL UNIT, REPAIRS,
Body control unit (BCU).
2.Remove 5 multiplugs from SLABS ECU.
3.Remove multiplug from ACE ECU.
4.Remove lower nut and loosen upper nut
securing SLABS and ACE ECU bracket to
body.
5.Remove ECU's and bracket assembly.

EXTERIOR FITTINGS
76-2-12 REPAIRS
3.Remove 2 nuts securing bumper valance side
mountings to body.
4.Remove 4 nuts securing bumper to crush cans
and remove bumper from body.
5.Remove 3 screws securing bumper to front
cross bar.
6. Models with headlamp wash: Position
container to collect screen washer fluid and
disconnect hose from headlamp washer pump.
Refit
1. Models with headlamp wash: Connect hose
to headlamp washer pump. Refill washer
reservoir with fluid.
2.With assistance position bumper to body.
3.Fit and tighten 3 screws securing bumper to
front cross bar.
4.Tighten nuts securing bumper to crush cans to
13 Nm (10 lbf.ft).
5.Tighten nuts securing bumper to side
mountings to 13 Nm (10 lbf.ft).
6.Connect multiplugs to fog lamps.
7.Fit wheel arch liner extensions and secure with
screws.
Bumper assembly - rear - from 03MY
$% 76.22.15
Remove
1.Remove both rear tail lamps.

+ LIGHTING, REPAIRS, Lamp - tail/
flasher - bumper.
2.Disconnect park distance control harness
multiplug.
3.Release rear lamp harness clips.
M76 4566