mirror LAND ROVER DISCOVERY 2002 Workshop Manual

CONTENTS
CONTENTS 17
Airbag module - passenger - deployment ...................................................................................... 75-25
Pre-tensioner - deployment ............................................................................................................. 75-27
DOORS ..................................................................................................... 76-1-1
REPAIRS
Door - front .................................................................................................................................... 76-1-1
Door - rear ..................................................................................................................................... 76-1-2
Door - tail ........................................................................................................................................ 76-1-3
Glass - front or rear door ............................................................................................................... 76-1-4
Quarter light ................................................................................................................................... 76-1-5
Regulator and motor - front and rear door glass .......................................................................... 76-1-6
Trim casing - front door .................................................................................................................. 76-1-7
Trim casing - rear door ................................................................................................................... 76-1-8
Trim casing - tail door .................................................................................................................... 76-1-9
Latch and motor - front door .......................................................................................................... 76-1-9
Latch and motor - rear door ........................................................................................................... 76-1-10
Latch and motor - tail door ............................................................................................................ 76-1-11
Handle - exterior - rear door .......................................................................................................... 76-1-12
Handle - exterior - tail door ........................................................................................................... 76-1-12
Handle - exterior - front door .......................................................................................................... 76-1-13
EXTERIOR FITTINGS ............................................................................... 76-2-1
REPAIRS
Wing - front - up to 03MY ................................................................................................................ 76-2-1
Wing - front - from 03MY ................................................................................................................. 76-2-2
Rear folding step ............................................................................................................................ 76-2-4
Liner - wheel arch - front ................................................................................................................. 76-2-5
Liner - wheel arch - rear ................................................................................................................. 76-2-5
Panel - underbelly .......................................................................................................................... 76-2-6
Mirror - exterior - electric ................................................................................................................ 76-2-7
Roof bars ....................................................................................................................................... 76-2-7
Bonnet ........................................................................................................................................... 76-2-8
Cable - bonnet release - up to 03MY .............................................................................................. 76-2-9
Cable - bonnet release - from 03MY ............................................................................................... 76-2-10
Bumper assembly - front ............................................................................................................... 76-2-11
Bumper assembly - rear - from 03MY ............................................................................................. 76-2-12
Trim finisher - bumper - front - from 03MY ...................................................................................... 76-2-14
Bumper assembly - rear - up to 03MY ............................................................................................ 76-2-14
Side finisher - windscreen .............................................................................................................. 76-2-15
Grille - front - up to 03MY................................................................................................................ 76-2-16
Grille - front - from 03MY ................................................................................................................ 76-2-16
INTERIOR TRIM COMPONENTS ............................................................. 76-3-1
REPAIRS
Trim casing - tail door speaker ...................................................................................................... 76-3-1
Trim casing - side - loadspace ....................................................................................................... 76-3-1
Trim casing - upper - 'B' post ......................................................................................................... 76-3-2
Trim casing - lower - 'B' post ......................................................................................................... 76-3-3

CONTENTS
CONTENTS 25
NAVIGATION SYSTEM ............................................................................ 87-1
DESCRIPTION AND OPERATION
Navigation System Component Location ........................................................................................ 87-1
Description ...................................................................................................................................... 87-2
REPAIRS
Interface electronic control unit (ECU) - remote control ................................................................. 87-11
Display unit .................................................................................................................................... 87-12
INSTRUMENTS......................................................................................... 88-1
DESCRIPTION AND OPERATION
Instrument pack .............................................................................................................................. 88-1
Instrument component location - Engine compartment / underneath vehicle ................................. 88-2
Instrument component location - Passenger compartment............................................................. 88-3
Instrument block diagram................................................................................................................ 88-4
Description ...................................................................................................................................... 88-5
Interior rear view mirror with compass (where fitted) ..................................................................... 88-42
REPAIRS
Clock ............................................................................................................................................... 88-45
Instrument pack ............................................................................................................................ 88-45

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
06-14
Body
TORQUE DESCRIPTION METRIC IMPERIAL
Front and rear door hinges 30 Nm (22 lbf.ft)
Tail door hinge bolts 34 Nm (25 lbf.ft)
Door frames10 Nm (7 lbf.ft)
Regulator to glass 6 Nm (4.4 lbf.ft)
Chassis cross member 25 Nm (18 lbf.ft)
Bulkhead to chassis bolts 45 Nm (33 lbf.ft)
Body to chassis bolts 45 Nm (33 lbf.ft)
Quarter light glass to frame 10 Nm (7 lbf.ft)
Glass lift motor to regulator 5 Nm (3.7 lbf.ft)
Tail door hand rail 10 Nm (7 lbf.ft)
Latch and motor assembly 7 Nm (5.2 lbf.ft)
Door handle7 Nm (5.2 lbf.ft)
Damper to step17 Nm (13 lbf.ft)
Throttle pedal assembly 13 Nm (10 lbf.ft)
Step assembly to chassis 45 Nm (33 lbf.ft)
Wing to sill finisher bracket 17 Nm (13 lbf.ft)
Front wing to body 17 Nm (13 lbf.ft)
Door mirror4 Nm (3 lbf.ft)
Roof bars32 Nm (24 lbf.ft)
Bonnet release lever 10 Nm (7 lbf.ft)
Front bumper to crash cans 13 Nm (10 lbf.ft)
Front bumper to side mountings 13 Nm (10 lbf.ft)
Mudshield10 Nm (7 lbf.ft)
Rear bumper45 Nm (33 lbf.ft)
Grab handle to body 3 Nm (2.2 lbf.ft)
Fascia26 Nm (19 lbf.ft)
Fascia to steering column bracket 11 Nm (8 lbf.ft)
Front seat to floor 45 Nm (33 lbf.ft)
Second row seats to floor 45 Nm (33 lbf.ft)
Third row seats to lower rear quarter 22 Nm (16 lbf.ft)
Sunroof tray to frame 2 Nm (1.5 lbf.ft)
Solenoid securing cap 11 Nm (8 lbf.ft)
Support stay to alternator 25 Nm (18 lbf.ft)
Sunroof glass3 Nm (2.2 lbf.ft)
Motor to sunroof tray 2 Nm (1.5 lbf.ft)
Drive cable assembly to frame 2.5 Nm (1.8 lbf.ft)
Front and rear door striker bolts 26 Nm (19 lbf.ft)
Tail door striker bolts 26 Nm (19 lbf.ft)

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-7
Description
General
The R380 all synchromesh gearbox has five forward speeds and reverse and is mounted in line with the engine. The
clutch bell housing is bolted to the front of the gearbox and the transfer box is mounted at the rear.
Gearbox casings
Gearbox casings consist of a front cover, gearcase, centre plate and extension housing. All casings with the exception
of the front cover are located to each other by dowels and sealed. Gearbox filler/level and drain plugs are located in
the gearcase.
Reverse lamp switch
A reverse lamp switch is inserted into the extension housing. Selection of reverse gear will close the switch allowing
current from fuse 25 to flow through the switch to illuminate the reverse lamps. The switch also provides a feed to the
BCU and the automatic interior mirror - if fitted; the mirror moving to the dimming position.
Gearchange assembly
The gearchange assembly is bolted to the top of the gearcase, the upper gear lever being attached to the lower gear
lever by means of a clamp bolt. The lower gear lever ball is housed in a Railko bush inserted in the gear change
housing, the end of the lever locating in the selector yoke which is attached to the end of the selector shaft. Bias
springs provide a positive return of the gear lever to the neutral position with selection of 1st/2nd and 5th/reverse gears
being against bias spring pressure. Spring loaded detent balls fitted in the centre plate locate in grooves in the selector
shaft to provide positive gear and neutral selection.
Lubrication
Lubrication is by an oil pump located in the extension housing and driven by the layshaft with additional lubrication
being provided by splash. The pump directs oil via a filter and internal drillings in the output shaft to lubricate the
components. On non UK and non European models, provision for oil cooling is by means of a thermostat housed in
a cover bolted to the side of the extension housing. The cover incorporates tappings for connections to an oil cooler.
On UK and European models, the thermostat and cover are replaced by an oil by-pass block.
Internal pressures produced within the gearbox are vented to atmosphere via a plastic breather pipe. The pipe is
attached to the extension housing and is routed across the top of the gearcase and secured at the open end by a clip
attached to the engine cylinder block.
Selector shaft and forks
Selector forks for 1st/2nd, 3rd/4th and 5th/reverse gears are located on a single selector shaft; the 1st/2nd and 3rd/
4th selector forks are inside the main gearcase whilst the 5th/reverse selector fork is inside the extension housing.
Each of the selector forks locates inside its corresponding synchromesh hub.
Synchromesh assemblies
Each synchromesh assembly is located on the output shaft adjacent to its corresponding gears and comprises a
synchromesh ring, hub, slippers and sleeve. The hubs and slippers are retained in the sleeves by means of spring
clips. 1st/2nd and 3rd synchromesh assemblies are fitted with double synchromesh rings whilst 4th, 5th and reverse
assemblies are fitted with single rings.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-12 DESCRIPTION AND OPERATION
Reverse gear
Clutches (5), (8) and (11) are engaged. The front planet gear carrier of gear set (9) is locked. Gear set (10) also rotates
as a solid block.
Gear position switch
The gear position switch outputs signals that are related to the position of the selector lever assembly. The switch is
installed on the selector shaft on the left side of the gearbox. Slotted mounting holes allow the switch to be turned
relative to the shaft for adjustment. A fly lead connects the switch to the vehicle wiring.
Movement of the selector lever assembly turns the selector shaft, which operates six pairs of contacts in the switch.
The pairs of contacts are identified as the W, X, Y, Z, Park/Neutral and Reverse contacts. When closed:
lThe W, X, Y and Z contacts output a 12V ignition supply from the BCU.
lThe Park/Neutral contacts output an earth.
lThe Reverse contacts output a 12V ignition supply from the passenger compartment fuse box.
The outputs of the W, X, Y and Z contacts are monitored by the EAT ECU and the BCU to determine the position of
the selector lever assembly.
Gear position switch W, X, Y, Z outputs
The Park/Neutral contacts output to the BCU and, on diesel models, the ECM. The Reverse contacts output to the
BCU, the reversing lamps, the SLABS ECU and, where fitted, the ACE ECU and the electrochromic interior mirror.
Switch
contactsOutput
PRND 3 2 1
W12V - 12V 12V - - -
X- 12V 12V - 12V - -
Y- - 12V 12V 12V - 12V
Z- - - 12V 12V 12V -

FRONT SUSPENSION
DESCRIPTION AND OPERATION 60-19
The right hand end of the torsion bar has a machined spigot which provides for the attachment of the forged steel
short and long arms. The spigot for the short arm is splined and mates with splines in the short arm. The short arm is
located in a specific position on the splines and clamped to the spigot with a Torx bolt and locknut. The short arm is
not a serviceable item other than the actuator attachment bush. The smaller spigot diameter locates the long arm.
The long arm is fitted with a slipper bush which is located on the spigot and secured with a large washer and a special
bolt. The slipper bush comprises two inner and two outer bushes which are installed from each side of the long arm.
The outer bushes have three lugs which locate in the long arm to prevent the bush from rotating. The long arm also
provides the attachment point for the actuator piston rod and the anti-roll bar link.
The actuator has a forked end which locates on the bush in the short arm and is secured with a bolt and nut. The
piston rod of the actuator locates through a hole in a cast boss on the long arm which is fitted with a special bush. A
shoulder on the piston rod seats in a hole in the bush and a locknut on the end of the piston rod secures the rod to
the long arm and bush.
The front torsion bar is attached to the front chassis cross member. Two rubber bushes are fitted to the torsion bar
and are located in clamp plates. The clamp plates are located in slots in the cross member and secured with bolts.
The rear torsion bar is attached to the tubular cross member at the rear section of the chassis. Two rubber bushes
are fitted to the torsion bar and are located in clamp plates. The clamp plates are located in fabricated brackets
attached to the tubular cross-member and secured with bolts.
Two anti-roll bar links are mounted on brackets on the front and rear axles. Each anti-roll bar link is fitted with a
spherical bearing at each end. One bearing is attached to the link at a 90
° angle. The threaded shank of the bearing
is located through a hole in a bracket on the axle and secured with a locknut; a washer is installed on the threaded
shank between the bearing and the bracket. The second spherical bearing is attached in-line with the link and locates
in the torsion bar on the left hand side and the long arm on the right hand side. The front anti-roll bar links are longer
than the rear links and are not interchangeable.
Accelerometers
Two accelerometers are used for the ACE system. The upper accelerometer is mounted on a bracket, behind the
headlining adjacent to the rear view mirror and the sunroof ECU. The lower accelerometer is located on a bracket on
the inner sill panel under the RH front floor.
The lower accelerometer is the primary sensor used to measure lateral acceleration of the vehicle for roll control. The
upper accelerometer is used by the ECU for roll correction and fault detection in conjunction with the lower
accelerometer.
Each accelerometer is a solid state capacitive acceleration sensor and operates on a 5 V supply from the ECU. The
upper and lower sensors can measure acceleration in the range of
± 1.10 g and return an output to the ECU of
between 0.5 and 4.5 V.
Failures of an accelerometer are recorded by the ECU and can be retrieved using TestBook. A special tool is required
to remove and replace a sensor in the bracket.

DOORS
76-1-4 REPAIRS
19.Remove 6 bolts securing tail door hinges to
body and, with assistance, remove tail door.
Refit
1.Support the tail door on a jack, using a block of
wood to protect the door.
2.With assistance position door. Fit securing
bolts but do not tighten at this stage.
3.Fit washer and spring clip securing check strap
to aperture.
4.Adjust position of tail door in relation to
aperture, ensuring gaps around all 4 edges
are consistent, and door closes cleanly onto
dove tail.
5.When tail door is correctly adjusted, tighten tail
door hinge bolts to 34 Nm (25 lbf.ft).
6.Feed harness and washer tube through outer
edge of door and connect harness sleeve to
door.
7.Secure harness to tail door with clips.
8.Connect washer tube to rear of wiper arm.
9.Remove tape from draw string and secure to
CHMSL wires.
10.Draw wires through tail door and connect
Lucars to CHMSL.
11.Fit CHMSL cover and secure with screws.
12.Connect multiplug of number plate lamp.
13.Connect Lucars to HRW.
14.Connect multiplug to rear wiper motor.
15.Connect multiplug to door latch.
16.Fit water shedder to door.
17.Fit tail door trim casing.

+ DOORS, REPAIRS, Trim casing - tail
door.
18.Fit spare wheel to tail door.
Glass - front or rear door
$% 76.31.01
Remove
1.Remove door trim casing.

+ DOORS, REPAIRS, Trim casing -
front door.

+ DOORS, REPAIRS, Trim casing -
rear door.
2.Carefully release water shedder from door.
3. Front door glass only: Remove exterior door
mirror.

+ EXTERIOR FITTINGS, REPAIRS,
Mirror - exterior - electric.
4.Remove inner waist seal.
Front door shown, rear door similar
5.Remove 2 clips securing ends of outer waist
seal.
6.Remove outer waist seal.
7.Remove 2 bolts securing glass to regulator. If
necessary, lower glass to access bolts.
8.Remove bolts securing frame to door.
9.Remove door frame complete with glass.
10.Slide out and remove glass from frame.

DOORS
REPAIRS 76-1-5
Refit
1.Fit glass to frame.
2.Position frame to door and tighten bolts
securing front door frame to 10 Nm (7 lbf.ft) and
bolts securing rear door frame to 22 Nm (16
lbf.ft).
3.Secure regulator to glass with bolts and tighten
to 6 Nm (4.4 lbf.ft).
4.Fit inner and outer waist seal and secure with
clips.
5. Front door glass only: Fit exterior door mirror.

+ EXTERIOR FITTINGS, REPAIRS,
Mirror - exterior - electric.
6.Fit water shedder to door.
7.Fit door trim casing.

+ DOORS, REPAIRS, Trim casing -
front door.

+ DOORS, REPAIRS, Trim casing -
rear door.
Quarter light
$% 76.31.31
Remove
1.Remove rear door glass.

+ DOORS, REPAIRS, Glass - front or
rear door.
2.Remove 2 bolts securing quarter light glass to
frame.
3.Remove quarter light glass from frame.
Refit
1.Fit quarter light glass to frame.
2.Fit bolts securing quarter light glass to frame
and tighten to 10 Nm (7 lbf.ft).
3.Fit rear door glass.

+ DOORS, REPAIRS, Glass - front or
rear door.

EXTERIOR FITTINGS
REPAIRS 76-2-7
Mirror - exterior - electric
$% 76.10.57
Remove
1.Release cheater panel from front door.
2.Remove anti-rattle foam pad from front door.
3.Release mirror multiplug from mounting plate.
4.Disconnect multiplug from mirror.
5.Remove 3 bolts securing mirror to door.
6.Remove mirror and collect mounting plate.
Refit
1.Fit mirror and mounting plate to door.
2.Fit bolts securing mirror to door and tighten to
4 Nm (3 lbf.ft).
3.Connect multiplug to mirror.
4.Secure multiplug to mounting plate.
5.Fit anti-rattle foam pad to front door.
6.Secure cheater panel to front door.
Roof bars
$% 76.11.31
Remove
1.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
2. Models with rear A/C: Drill out 4 rivets
securing rear centre duct to roof.
3. Models with rear A/C: Release and remove
rear centre duct.
4. Models with rear A/C: Drill out 2 rivets
securing each upper side duct to roof.
5. Models with rear A/C: Remove upper side
ducts.