seat adjustment LAND ROVER DISCOVERY 2002 Workshop Manual

CONTENTS
16 CONTENTS
Brake system control component layout ......................................................................................... 70-1
Brake system control diagram ........................................................................................................ 70-2
Brake system hydraulic component layout ..................................................................................... 70-4
Description ...................................................................................................................................... 70-5
Operation ........................................................................................................................................ 70-20
DESCRIPTION AND OPERATION
Handbrake component layout ......................................................................................................... 70-25
Description ...................................................................................................................................... 70-26
ADJUSTMENTS
Handbrake .................................................................................................................................... 70-29
Brake system bleeding .................................................................................................................. 70-30
REPAIRS
Brake disc - front .......................................................................................................................... 70-33
Brake disc - rear ........................................................................................................................... 70-34
Master cylinder - brake ................................................................................................................. 70-35
Cable - handbrake ........................................................................................................................ 70-36
Switch - brake light ....................................................................................................................... 70-37
Brake pads - front ......................................................................................................................... 70-37
Brake pads - rear .......................................................................................................................... 70-38
Brake shoes - handbrake................................................................................................................ 70-39
Servo - brake .................................................................................................................................. 70-41
Vacuum pump - servo..................................................................................................................... 70-42
Housing - caliper - front ................................................................................................................ 70-43
Housing - caliper - rear ................................................................................................................. 70-44
ECU - Self levelling and anti locking brakes (SLABS) ................................................................. 70-45
Sensor – ABS – front ..................................................................................................................... 70-46
Sensor – ABS – rear ....................................................................................................................... 70-47
Modulator unit - ABS ...................................................................................................................... 70-47
Switch - Hill descent control............................................................................................................ 70-48
Switch - handbrake ....................................................................................................................... 70-49
RESTRAINT SYSTEMS ............................................................................ 75-1
DESCRIPTION AND OPERATION
SRS component layout ................................................................................................................... 75-1
SRS block diagram ......................................................................................................................... 75-2
Description - SRS ........................................................................................................................... 75-3
Operation - SRS ............................................................................................................................. 75-9
DESCRIPTION AND OPERATION
Description - seat belts ................................................................................................................... 75-11
REPAIRS
Seat belt - front .............................................................................................................................. 75-13
Seat belt - rear - centre ................................................................................................................. 75-13
Seat belt - rear - side .................................................................................................................... 75-15
Mounting - seat belt - 'B' post ...................................................................................................... 75-16
Seat belts - third row ....................................................................................................................... 75-17
Pre-tensioner - front seat belt ....................................................................................................... 75-18
Airbag module - drivers .................................................................................................................. 75-18
Airbag module - passenger ........................................................................................................... 75-19
DCU ................................................................................................................................................ 75-20
Rotary coupler ................................................................................................................................ 75-21
Airbag deployment tool - self test ................................................................................................... 75-22
Airbag module - drivers - deployment ............................................................................................. 75-23

GENERAL INFORMATION
03-23
Airbag and pretensioner deployment
Deployment procedures and precautions as detailed
in this manual should be strictly adhered to. Only
personnel who have undergone the appropriate
training should undertake deployment of airbag and
pretensioner modules. The following precautions
must be complied with:
lOnly use deployment equipment approved for
the intended purpose.
lBefore beginning deployment procedure,
ensure deployment tool functions properly by
performing the self test procedure detailed in
SRS section of this manual.
lDeployment of airbag/ pretensioner modules
should be performed in a well ventilated area
which has been designated for the purpose.
lEnsure airbag/pretensioner modules are not
damaged or ruptured before attempting to
deploy.
lNotify the relevant authorities of intention to
deploy airbag and pretensioner units.
lWhen deploying airbag pretensioner units,
ensure that all personnel are at least 15 metres
(45 feet) away from the deployment zone.
lEnsure deployment tool is connected correctly,
in compliance with the instructions detailed in
the SRS section of this manual. In particular,
ensure deployment tool is NOT connected to
battery supply before connecting to airbag
module connector.
lWhen deploying seat belt pretensioners, ensure
pretensioner unit is secured correctly to the
seat.
lWhen removing deployed airbag modules and
pretensioner units, wear protective clothing.
Use gloves and seal deployed units in a plastic
bag.
lFollowing deployment of any component of the
SRS system within the vehicle, all SRS
components must be replaced. DO NOT re-use
or salvage any parts of the SRS system.
lDo not lean over airbag module when
connecting deployment equipment.
If a vehicle is to be scrapped, undeployed airbag
modules and pretensioner units must be manually
deployed. In this case airbags can be deployed in the
vehicle; before deployment, ensure the airbag
module is secure within its correct mounting position.
Deployment of the driver's airbag in the vehicle may
damage the steering wheel; if the vehicle is not being
scrapped, deploy the module outside of the vehicle.
WARNING: During deployment parts of the
airbag module become hot enough to burn you.
Wait 30 minutes after deployment before
touching the airbag module.
SRS Component Replacement Policy
The following information details the policy for
replacement of SRS components; either as a result
of a vehicle accident or as a result of vehicle age.
Impacts which do not deploy the airbags or pre-
tensioners
Check for structural damage in the area of the
impact, paying particular attention to bumper
armatures, longitudinals, crash cans and bracketry.
Impacts which deploy the airbags or pre-
tensioners
The replacement and inspection policy is dependent
on the type and severity of of the crash condition.
The following guidelines are the minimum that
should be exercised as a result of the deployment of
specific SRS components.
If the front airbags or seat belt pre-tensioners are
deployed, the following parts must be replaced:
lSRS DCU.
lDriver airbag module
lPassenger airbag module
lFront seat belt buckle pre-tensioners
lRotary coupler
lDriver's seat belt retractor
lFlyleads (where applicable) connecting airbags
and seat belt pre-tensioners to SRS harness
In addition, the following should be inspected for
damage and replaced as necessary:
lFront passenger's seat belt retractor (webbing,
tongue latching, 'D' loop, body anchorage point)
lRear seat belt buckles (webbing, buckle covers,
body anchorage and tongue latching function)
lFascia moulding adjacent to passenger airbag
module
lSteering wheel (if damage is evident)
lFront seat frames and head restraints (if there is
evidence of damage to the seat frame or
cushion pan)
lSteering column (if adjustment is lost or there
are signs of collapse)
lThird row seats, seat belts and head restraints
(where fitted). Check third row seat latching
mechanism operates correctly.
Periodic replacement of SRS components
The performance of the propellants within airbags
and pre-tensioners will deteriorate over a period of
time. As a result, it is essential that the airbags are
replaced after 10 years and seat belt pre-tensioners
are replaced after 15 years in order to maintain
occupant safety.

CLUTCH - TD5
33-1-6 DESCRIPTION AND OPERATION
Description
General
The clutch system is a diaphragm type clutch operated by a hydraulic cylinder. The drive plate is of the rigid centre
type with no integral damping springs. The flywheel is of the dual mass type with damping springs integral with the
flywheel. The clutch requires no adjustment to compensate for wear.
Hydraulic clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir. The master and slave
cylinders are connected to each other hydraulically by plastic and metal pipes. The plastic section of the pipe allows
ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the fluid reservoir. The bore is also connected to a damper which prevents engine
pulses being transferred hydraulically to the clutch pedal. A piston is fitted in the bore and has an external rod which
is attached to the clutch pedal with a pin. Two coil springs on the clutch pedal reduce the effort required to depress
the pedal.
The master cylinder is mounted on the bulkhead and secured with two bolts. The cylinder is connected to the shared
brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat shield
is fitted to protect the underside of the slave cylinder from heat generated from the exhaust system. The slave cylinder
comprises a cylinder with a piston and a rod. A port in the cylinder body provides the attachment for the hydraulic feed
pipe from the master cylinder. A second port is fitted witha bleed nipple used for removing air from the hydraulic
system after servicing. The piston rod locates on a clutch release lever located in the gearbox housing. The rod is
positively retained on the release lever with a clip.
Clutch mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A spigot
with a ball end is formed on the release bearing sleeve and provides amounting and pivot point for the clutch release
lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located on the ball, the pivot
washer seats against the rear face of the release lever. A spring clip is located on the lever and the pivot washer and
secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned centrally
on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever to pivot freely
around the ball.
The clutch release bearing locates on the clutch release lever and release bearing sleeve. The bearing is retained on
a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever on the
carrier. The bearing and carrier are not serviceable individually.

CLUTCH - V8
33-2-6 DESCRIPTION AND OPERATION
Description
General
The clutch system is a conventional diaphragm type clutch operated by a hydraulic cylinder. The clutch requires no
adjustment to compensate for wear.
Hydraulic clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir, which is also shared with
the braking system. The master and slave cylinders are connected to each other hydraulically by plastic and metal
pipes. The plastic section of the pipe allows ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the brake/clutch fluid reservoir. A piston is fitted in the bore and has an external
rod which is attached to the clutch pedal with a pin. Two coiled springs on the clutch pedal reduce the effort required
to depress the pedal.
The master cylinder is mounted on the bulkhead in the engine compartment and secured with two bolts. The cylinder
is connected to the shared brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat shield
protects the underside of the cylinder from heat generated from the exhaust system. The slave cylinder comprises a
cylinder with a piston and a rod. A port in the cylinder body provides the attachment for the hydraulic feed pipe from
the master cylinder. A second port is fitted with a bleed nipple for removing air from the hydraulic system after
servicing. The piston rod locates on a clutch release lever located in the gearbox housing. The rod is positively
retained on the release lever with a clip.
Clutch mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A spigot
with a ball end is formed on the release bearing sleeve and provides a mounting and pivot point for the clutch release
lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located on the ball, the pivot
washer seats against the rear face of the release lever. A spring clip is located on the lever and the pivot washer and
secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned centrally
on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever to pivot freely
around the ball.
The clutch release bearing locates on the clutch release lever and the release bearing sleeve. The bearing is retained
on a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever on
the carrier. The bearing and carrier are not serviceable individually.

STEERING
57-48 REPAIRS
Ball joint - track rod
$% 57.55.07
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove LH front road wheel.
3.Loosen adjuster clamp bolts.
4.Remove nut securing track rod ball joint to
steering knuckle.
5.Using tool LRT-57-036 break taper joint and
release track rod.
CAUTION: Before disconnecting any part of
the steering linkage, ensure the road wheels
are positioned straight ahead and the
steering wheel is prevented from turning.
Unrestricted turning of the steering wheel
will damage the SRS rotary coupler.
6.Unscrew ball joint and adjuster.
7.Remove clamps from adjuster and track rod. Refit
1.Clean adjuster, clamps and track rod.
2.Fit clamps to track rod and adjuster. Screw in
adjuster and ball joint.
3.Clean ball joint taper and taper seat.
4.Adjust length of track rod so that ball joint taper
is centralised in steering knuckle.
5.Fit track rod to steering knuckle and tighten nut
to 80 Nm (59 lbf.in).
6.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
7.Remove stand(s) and lower vehicle.
8.Check and, if necessary, adjust wheel
alignment.

+ STEERING, ADJUSTMENTS, Wheel
alignment - front.
9.After check/adjustment of wheel alignment,
ensure track rod adjuster clamp bolts are
tightened. Tighten M8 bolts to 22 Nm (16 lbf.ft)
and M10 bolts to 33 Nm (24 lbf.ft).

STEERING
REPAIRS 57-49
Ball joint - drag link
$% 57.55.15
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2. RHD models: Remove LH front road wheel.
3. LHD models: Remove RH front road wheel.
4.Remove nut securing drag link to steering
knuckle.
5.Using LRT-57-036, break taper joint and
release drag link.
CAUTION: Before disconnecting any part of
the steering linkage, ensure the road wheels
are positioned straight ahead and the
steering wheel is prevented from turning.
Unrestricted turning of the steering wheel
will damage the SRS rotary coupler.
6.Loosen adjuster clamp bolts and unscrew ball
joint and adjuster. 7.Remove clamps from adjuster and drag link.
Refit
1.Clean adjuster, clamps and drag link.
2.Fit clamps to drag link and adjuster. Screw in
adjuster and ball joint.
3.Clean ball joint taper and taper seat.
4.Adjust length of drag link so that ball joint taper
is centralised in steering knuckle.
5.Fit drag link to steering knuckle and tighten nut
to 80 Nm (59 lbf.ft).
6.Tighten drag link adjuster clamp bolts. Tighten
M8 bolts to 22 Nm (16 lbf.ft) and M10 bolts to
33 Nm (24 lbf.ft).
7.Check steering linkage is centralised.

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.
8.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
9.Remove stand(s) and lower vehicle.

STEERING
57-50 REPAIRS
Drag link
$% 57.55.17
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2. RHD vehicles: Remove the LH front road
wheel.
3. LHD vehicles: Remove the RH front road
wheel.
4.Remove nut and bolt securing damper to drag
link and release damper.
5.Remove 2 nuts securing drag link to drop arm
and steering knuckle.
6.Using LRT-57-036 break taper joints and
remove drag link.
CAUTION: Before disconnecting any part of
the steering linkage, ensure the road wheels
are positioned straight ahead and the
steering wheel is prevented from turning.
Unrestricted turning of the steering wheel
will damage the SRS rotary coupler.7.Loosen adjuster clamp bolts and remove ball
joint and adjuster.
8.Remove clamps from adjuster and drag link.
Refit
1.Clean adjuster, clamps and ball joint.
2.Fit clamps to drag link and adjuster. Screw in
adjuster and ball joint.
3.Clean ball joint tapers and taper seats.
4.Fit drag link to drop arm and tighten nut to 80
Nm (59 lbf.ft).
5.Adjust length of drag link so that ball joint taper
is centralised in steering knuckle.
6.Fit drag link to steering knuckle and tighten nut
to 80 Nm (59 lbf.ft).
7.Tighten drag link adjuster clamp bolts. Tighten
M8 bolts to 22 Nm (16 lbf.ft) and M10 bolts to
33 Nm (24 lbf.ft)
8.Align damper to drag link, fit nut and bolt and
tighten to 125 Nm (92 lbf.ft).
9.Check steering linkage is centralised.

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.
10.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
11.Remove stand(s) and lower vehicle.

BRAKES
70-26 DESCRIPTION AND OPERATION
Description
General
The handbrake consists of a drum brake, installed on the rear of the transfer box, operated by a cable connected to
a handbrake lever between the front seats.
Handbrake lever
The handbrake lever is mounted on a base plate which attaches to the transmission tunnel. A conventional ratchet
and thumb operated release button are incorporated for locking and unlocking the lever. A warning switch on the base
of the lever operates the brake warning lamp in the instrument pack. While the handbrake is applied the warning
switch connects an earth to the instrument pack which, if the ignition is on, illuminates the brake warning lamp. In
some markets, the instrument pack performs a bulb check of the brake warning lamp each time the ignition is switched
on.
Cable
The handbrake cable consists of inner and outer cables installed between the handbrake lever and the drum brake.
A protective sleeve is installed on the cable to protect the cable from heat from the exhaust system. Handbrake
adjustment is provided by a threaded sleeve installed on the outer cable where it locates in the handbrake lever.
Turning an adjuster wheel, which is keyed to the threaded sleeve and secured by a 'C' clip, alters the effective length
of the outer sleeve and consequently changes the handbrake lever movement needed to apply the drum brake.

SEATS
DESCRIPTION AND OPERATION 76-5-5
Seat switch pack
Each seat switch pack contains two switches representing the seat cushion and the seat squab. The switches provide
the following adjustments:
lSeat fore/ aft.
lCushion front up/ down.
lCushion rear up/ down.
lSquab fore/ aft.
lLumbar inflate.
lLumbar deflate.
The voltage supply to the seat switch pack is from the 40A fuse in the satellite fuse box. A pair of switches controls
the operation of each seat motor, the lumbar pump and the lumbar deflate relay.
Seat fore/ aft motor
The seat fore/ aft motor is a permanent magnet motor coupled to a rack and pinion assembly. Should the motor seize
or stick for 6 seconds or more, an internal thermal cut out switch will trip to remove voltage from the motor. Reset
time for the switch is 35 seconds.

BODY CONTROL UNIT
DESCRIPTION AND OPERATION 86-3-11
Programmable options
The BCU can be programmed with a number of options to satisfy specific market requirements and customer
preferences. The options can be set using TestBook.
Function Option Details
Transmission Manual The vehicle is fitted with manual transmission.
Automatic The vehicle is fitted with automatic transmission.
Front fog lamps None The vehicle is not fitted with front fog lamps.
Main The front fog lamps will operate if the headlamps are on main
beam.
No main The front fog lamps will not operate if the headlamps are on main
beam.
Interlocks None The vehicle is not fitted with key, shift or transfer box interlocks.
Shift The vehicle is fitted with key, shift and transfer box interlocks.
No transfer The vehicle is fitted with key and shift interlocks, but not a transfer
box interlock.
Daylight running lamps None The vehicle is not fitted with daylight running lamps.
No main The daylight running lamps are on if the headlamp main beams
are off.
No heads The daylight running lights are on with headlamp main and dipped
beams off and the gearbox not in Park.
Programmed wash/ wipe Normal The front wipers operate if the front wash is operated.
No wipe The front wipers do not operate if the front wash is operated.
Key-in warning Disabled The ignition key in audible warning is disabled.
Enabled The ignition key in audible warning is generated if the ignition key
is in and the driver's door is open.
Electric front seats None The vehicle is not fitted with electric front seats.
Normal Electric seat adjustment is available for 45 seconds after the
driver's door opens or if the ignition is on.
Ignition II Electric seat adjustment is available if the ignition is on.
Electric front windows Driver cancel The front windows will be disabled 44 seconds after the driver's
door is opened.
All cancel The front windows will be disabled 44 seconds after any door is
opened.
No cancel The front windows will be disabled when the ignition is turned off.
Heated front screen Fitted The vehicle is fitted with heated front screens.
None The vehicle is not fitted with heated front screens.
Rear windows and
sunroofDriver cancel The rear windows and sunroof will be disabled 44 seconds after
the driver's door is opened.
All cancel The rear windows and sunroof will be disabled 44 seconds after
any door is opened.
No cancel The rear windows and sunroof will be disabled when the ignition
switch is turned off.
Gear position indicator
illuminationAlways The automatic gearbox selector illumination is on when the
ignition is on.
Sidelights The automatic gearbox selector illumination is on when the
ignition is on and the sidelights are off.
Hill descent control None The vehicle is not fitted with hill descent control.
Fitted The vehicle is fitted with hill descent control.
Courtesy headlamps Disabled The vehicle is not fitted with courtesy headlamps.
Enabled The vehicle is fitted with courtesy headlamps.
Odometer error warning Disabled The odometer will not flash if there is an odometer error.
Enabled The odometer will flash if there is an odometer error.