brakes LAND ROVER DISCOVERY 2002 Manual Online

PANEL REPAIRS
77-2-32 REPAIRS
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit harness to valance.
2.Fit and secure expansion tank to fixings.
3.Fit fuse box.
4.Fit battery tray.
5.Fit battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
6.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
Front valance assembly - RH
Remove
1.Disconnect battery eath lead.
2.Remove front bulkhead assembly.

+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
3.Remove engine compartment fusebox and
related wiring.
4.Remove radiator expansion tank from
mountings and position aside.
5. Petrol models: Remove cruise control
actuator mounting bracket.
6. Diesel models: Remove EGR modulator
mounting bracket.
7. RHD models: Remove brake servo.

+ BRAKES, REPAIRS, Servo - brake.
8.Remove brake pipes from valance assembly.
9.Remove RH road wheel.
10.Remove RH front mud flap.
11.Remove insulation pad from engine bulkhead.
12.Remove windscreen side finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit windscreen side finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
2.Fit insulation pad to engine bulkhead.
3.Fit front mud flap.
4.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
5.Fit brake pipes to valance assembly.
M77 1693A
M77 1749
M77 1694A

PANEL REPAIRS
REPAIRS 77-2-33
6. RHD models: Fit brake servo.
7. Diesel models: Fit EGR modulator mounting
bracket.
8. Petrol models: Fit cruise control actuator
mounting bracket.
9.Fit radiator expansion tank.
10.Fit fusebox and secure wiring.
11.Fit front bulkhead assembly.

+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
12.Connect battery leads, negative lead last.
Front valance assembly - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front bulkhead assembly.

+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
4.Remove ABS modulator unit.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
5. LHD models: Remove brake servo.

+ BRAKES, REPAIRS, Servo - brake.
6.Remove brake pipes from valance assembly.
7.Remove PAS/ACE reservoir.
8. Models with A/C: Remove A/C pipes from
valance assembly.
9.Remove wiring harness from valance
assembly.
10.Remove LH front road wheel.
11.Remove LH front mud flap.
12.Remove insulation pad from engine bulkhead.
13.Remove windscreen side finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
M77 1742

PANEL REPAIRS
77-2-34 REPAIRS
Refit
1.Fit windscreen side finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
2.Fit insulation pad to engine bulkhead.
3.Fit front mud flap.
4.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
5.Fit wiring harness to valance assembly.
6. Models with A/C: Fit A/C pipes to valance
assembly.
7.Fit PAS/ACE reservoir.
8.Fit brake pipes to valance assembly.
9. LHD models: Fit brake servo.

+ BRAKES, REPAIRS, Servo - brake.
10.Fit ABS modulator unit.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
11.Fit front bulkhead assembly.

+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
12.Connect leads/multiplug to alternator.
13.Connect battery leads, negative lead last.
'A' post assembly
In this procedure, the front wing and the valance
outer reinforcement (rear section) are replaced in
conjunction with the 'A' post assembly. The dash side
assembly can also be replaced in this procedure if
required.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove bonnet.
4.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
5.Remove RH or LH front door.

+ DOORS, REPAIRS, Door - front.
6.Remove RH or LH sill finisher.
7.Remove windscreen.

+ SCREENS, REPAIRS, Windscreen.
8. Diesel models: Remove ECM.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Engine control module
(ECM).
9.Remove RH or LH 'A' post inner finishers and
disconnect speaker multiplug (if fitted).
10.Release sunroof drain tube and position aside.
11.Remove RH or LH front seat.

+ SEATS, REPAIRS, Seat - front.
12. RH side: Remove CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
13.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
14. Driver's side: Remove steering column
support bracket.
15.Remove relevant wiring from 'A' post.
16.Remove tread plate from front door aperture.
17.Release front carpet and position aside.
18.Remove front door aperture seal.
19.Remove engine bulkhead insulation.

CORROSION PREVENTION AND SEALING
77-4-6 CORROSION PREVENTION
Corrosion prevention
Factory treatments
During production, vehicle bodies are treated with the following anti-corrosion materials:
lA PVC-based underbody sealer which is sprayed onto the underside of the main floor, rear floor, front and rear
wheelarches and the front valance assembly;
lAn application of cavity wax which is sprayed into the sill panels, 'A' post, 'B-C' post, fuel filler aperture, body rear
panel and the lower areas of the door panels;
lA coating of underbody wax which is applied to the entire underbody inboard of the sill vertical flanges, and
covers all moving and flexible components EXCEPT for wheels, tyres, brakes and exhaust;
lA coat of protective wax applied to the engine bay area.
Whenever body repairs are carried out, ensure the anti-corrosion materials in the affected area are repaired or
renewed as necessary using the approved materials.

+ BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.
Precautions during body repairs and handling
Take care when handling the vehicle in the workshop. Underbody sealers, seam sealers, underbody wax and body
panels may be damaged if the vehicle is carelessly lifted.

+ LIFTING AND TOWING, LIFTING.
Proprietary anti-corrosion treatments
The application of proprietary anti-corrosion treatments, in addition to the factory-applied treatment, could invalidate
the Corrosion Warranty and should be discouraged. This does not apply to Rover approved, compatible, preservative
waxes which may be applied on top of existing coatings.
Fitting approved accessories
When fitting accessories ensure that the vehicle's corrosion protection is not affected, either by breaking the protective
coating or by introducing a moisture trap.
Do not screw self-tapping screws directly into body panels. Fit suitable plastic inserts to the panel beforehand. Always
ensure that the edges of holes drilled into panels, chassis members and other body parts are protected with a suitable
zinc rich or acid etch primer, and follow with a protective wax coating brushed onto the surrounding area.
Do not attach painted metal surfaces of any accessory directly to the vehicle's bodywork unless suitably protected.
Where metal faces are bolted together always interpose a suitable interface material such as weldable zinc rich
primer, extruded strip, or zinc tape.
Steam cleaning and dewaxing
Due to the high temperatures generated by steam cleaning equipment, there is a risk that certain trim components
could be damaged and some adhesives and corrosion prevention materials softened or liquified.
Adjust the equipment so that the nozzle temperature does not exceed 90
° C (194° F). Take care not to allow the steam
jet to dwell on one area, and keep the nozzle at least 300 mm (11.811 in) from panel surfaces.
DO NOT remove wax or lacquer from underbody or underbonnet areas during repairs. Should it be necessary to
steam clean these areas, apply a new coating of wax or underbody protection as soon as possible.
Inspections during maintenance servicing
It is a requirement of the Corrosion Warranty that the vehicle body is checked for corrosion by an authorised Land
Rover Dealer at least once a year, to ensure that the factory-applied protection remains effective.
Service Job Sheets include the following operations to check bodywork for corrosion:
lWith the vehicle on a lift, carry out visual check of underbody sealer for damage;
lWith the vehicle lowered, inspect exterior paintwork for damage and body panels for corrosion.
It will be necessary for the vehicle to be washed by the Dealer prior to inspection of bodywork if the customer has
offered the vehicle in a dirty condition.

CORROSION PREVENTION AND SEALING
SEALING 77-4-9
SEALING
Body Sealing
Underbody sealer treatment areas
Underfloor areas and sill outer panels are treated with a Plastisol PVC underbody sealer. This material is not suitable
for re-treatment. When repairing areas of underbody sealer, strip the factory-applied underbody sealer back to a
suitable break point. Ensure that a clean metal surface is exposed and that the edge of the existing sealer adheres
soundly to the panel.
Apply new underbody sealer between primer and surfacer paint operations. Apply seam sealer as necessary before
application of underbody sealer. Ensure that blanking plugs and grommets in the floor pan (except those used for wax
injection) are fitted before underbody sealer application. Refit any heat-fusible plugs which have been disturbed in
repair with the aid of a hot air blower, or replace with rubber grommets.
CAUTION: Ensure that suspension units, wheels, tyres, power unit, propeller shafts, exhaust and brakes
(including all mounting points) are shielded prior to application of fresh underbody sealer.

BODY CONTROL UNIT
86-3-18 DESCRIPTION AND OPERATION
Self levelling suspension and ABS
The BCU communicates with the SLABS ECU for several functions:
lAn output is provided from the SLABS ECU to the BCU to provide the logic conditions for issuing the SLS audible
warning.
lThe BCU receives an input from the SLABS ECU relating to the raise/ lower command from the remote handset.

+ REAR SUSPENSION, DESCRIPTION AND OPERATION, Description - SLS.
Hill descent control
The BCU provides an output signal to the SLABS ECU for automatic transmission in neutral for HDC control. The
BCU checks the status of the ignition and 'gearbox state' inputs and provides a 'Neutral selected' output. If the ignition
is on and 'gearbox state' is Neutral, the 'Neutral selected' output is on, otherwise 'Neutral selected' is off.

+ BRAKES, DESCRIPTION AND OPERATION, Description.
Heated screens
The Heated Front Screen (HFS) is fitted for some market destinations and is operated from a non-latching switch
located on the instrument pack cowl. The BCU will only allow the heated front screen to operate when the engine is
running and controls the time-out period for switching the circuit off.
The heated front screen operation can also be controlled from the Automatic Temperature Control (ATC) ECU on
vehicles fitted with air conditioning.
The heated rear window will only function when the engine is running, and is operated by a non-latching switch on the
instrument pack cowl. The heated rear window can also be operated by the ATC ECU on vehicles fitted with air
conditioning.
Interior courtesy lamps
The BCU controls the operation of the interior courtesy lamps. The courtesy lamps are situated in the front, mid and
rear areas of the headlining.
Fuel flap actuator
The BCU provides an earth path to the fuel flap release solenoid to allow the fuel filler flap to be opened. This is only
allowed if the alarm system is not set and all other conditions have been satisfied. The fuel flap release switch is
located in the fascia switch pack and it receives a voltage supply from the passenger compartment fuse box.
Audible warnings
The BCU can request the instrument pack to generate an audible warning in response to conditions it has detected
and which need to be drawn to the driver's attention. One of six different audible warnings can be requested by the
BCU.
Sound request number Sound functions Priority (1 = lowest, 6 = highest)
0Off 1
1 Seat belt warning 6
2 Key-in warning 3
3 SLABS/ HDC warning 4
4 Transfer box in neutral warning 5
5 Lights on warning 2

IN CAR ENTERTAINMENT
DESCRIPTION AND OPERATION 86-6-11
If one headphone amplifier unit has control of the tape player, CD or radio, the other headphone amplifier will be able
to listen and be able to change tape tracks or radio bands. Other buttons allow a search seek function of radio band
or compact disk track, reversal of the tape, radio station and volume adjustment depending on the current operating
mode. If one radio headphone amplifier has control of the radio, tape or CD autochanger the other radio headphone
amplifier is able to change the track or radio band selected. A headphone socket with a glow ring is located on the
control panel. When a headphone is turned on , a 'headphone-module active' signal is sent to the radio cassette
player. The design incorporates panel illumination and a glow-ring to locate the socket in low light conditions. To
control the audio output from the radio headphone amplifiers, signals are sent to and received from the radio cassette
player.
Automatic volume control (High line system only)
An automatic base and treble volume control feature compensates for increases in interior road/transmission noise.
A road speed signal is monitored by the power amplifier, the signal is supplied by the SLABS ECU.

+ BRAKES, DESCRIPTION AND OPERATION, Description.The power amplifier boosts the levels of base
and treble as road speed increases. This system ensures that the apparent volume of sound remains constant and is
not affected by increases in the background noise in the vehicle.
Speakers
Some vehicles will not have all the speakers, the type and location of speakers fitted depends on the trim level and
ICE options specified for the vehicle.
A-post speakers LH/RH (if fitted)
The A-post speakers are located in the A-post trim on each side of the windscreen, and are each protected by a metal
grille. The speakers are held from the rear by a bayonet clip that clamps the speaker on to the A-post trim. The A-post
speakers are a high range type and have a power rating of:
lMid line system A-post speakers have a power rating of 15 watts and an impedance of 4
Ω.
lHigh line system A-post speakers have a power rating of 30 watts and an impedance of 4
Ω.
Upper front and rear door speakers LH/RH (high line system only)
The upper door speakers are located in the upper door trim, the speaker is protected by an integral metal grille. The
speaker is held in by a threaded ring that clamps the speaker from the rear onto the door trim. The upper door speaker
is a mid-range type and has a power rating of 30 watts and an impedance of 4
Ω.
Lower front door speakers LH/RH
The lower front door speaker is located in the front end of the lower (pocket) trim and is secured by three self tapping
screws. The speaker is protected by a clip on circular metal grille. The type of lower front door speakers fitted depends
on trim level and market:
lThe base and mid line systems are fitted with full-range door speakers with a power rating of 15 watts and an
impedance of 4
Ω
lThe high line system is fitted with a low-range door speaker with a power rating of 30 watts and an impedance
of 4
Ω.
Lower rear door speaker LH/RH
The lower rear door speaker is located in the lower door trim and is secured by three self tapping screws. The speaker
is protected by a clip on metal grille. The type of lower rear door speaker fitted depends on trim level and market:
lThe base and mid line systems are fitted with full-range door speakers with a power rating of 15 watts and an
impedance of 4
Ω
lThe high line system is fitted with a low-range door speaker with a power rating of 30 watts and an impedance
of 4
Ω.
Low range tail door speakers (high line system only)
The low range tail door speaker are located in a plastic casing in the lower door trim. Each of the two speakers is
secured to the casing with four self tapping screws. The casing is secured to the lower door structure with eight bolts.
The tail door trim surrounds the casing, the front of the casing is covered by a metal grill that is secured with six
screws. The low range tail door speakers have a power rating of 30 watts and has an impedance of 4
Ω.