Discovery (1995+): Body Repair Manual — part 3
01
INTRODUCTION
12
INFORMATION
Vehicle identification number (VIN)
An adhesive label containing the Vehicle Identification
Number, date of manufacture and gross axle weight
ratings is fixed to the lock face of the front left hand
door. The information includes wheel and tyre sizes
and tyre pressures at gross axle weight ratings.
Key to vehicle identification label
A.
Month and year of manufacture
B.
Gross vehicle weight rating
C.
Gross axle weight rating for front axle
D.
Gross axle weight rating for rear axle
E.
Vehicle identification number (17 digits)
F.
Vehicle identification number - bar code
LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - 300Tdi Engine
The 300Tdi engine number is stamped on the cylinder
block on the right hand side of the engine above the
camshaft front cover plate.
Engine serial number - Mpi engine
Stamped on the R.H. face of the cylinder block
adjacent to the gearbox.
Engine serial number - V8i engine
Stamped on a cast pad on the cylinder block, between
numbers 3 and 5 cylinders.
NOTE: The appropriate engine
compression ratio is stamped above the
serial number.
INTRODUCTION
13
INFORMATION
Main gearbox R380
Stamped on a cast pad on the bottom right hand side
of the gearbox.
Transfer gearbox LT230
The serial number is stamped on the left hand side of
the gearbox casing below the mainshaft rear bearing
housing adjacent to the bottom cover.
Front and rear axles
Serial number is stamped on top of the left hand axle
tube.
Automatic gearbox
Stamped on a plate riveted to the bottom left hand
side of the gearbox casing.
READING THIS MANUAL
This manual is divided into sections shown on the
contents page, alongside a range of icons, familiar to
service technicians.
Sections are further divided into sub-sections, the
titles of which appear at the foot of each page. Typical
examples are given below:
Information
Fault Diagnosis
Seaking and Corrosion Protection
Body Dimensions
Description and operation
Repair
Panels
Procedures
To avoid repeating information through the sections,
where part of the repair operation impacts on another
section, a cross reference is given to direct the reader
to where the information is sited.
American terminology.
A few words used in this manual differ to words used
in America. Where this occurs the American word is
placed inside brackets. For example: bonnet [hood],
wing [fender], ramp [hoist].
GENERAL SPECIFICATION DATA
1
INFORMATION
STEERING
Power steering box
Make/type
Adwest Varamatic - worm and roller box
. . . . . . . . . . . . . . . . . .
Ratio
Variable: straight ahead 19.3:1 on lock 14.3:1
. . . . . . . . . . . . . . . . . . . . .
Steering wheel turns, lock-to-lock
3.375
. . . . . . . . .
Steering pump
Make/type -V8i
ZF - Unicorn
. . . . . . . . . . . . . . . . .
Make/type - Mpi & Tdi
Hobourn-Eaton series 500
. . . . . . . . . . . . . ..
Steering geometry
Steering wheel diameter
405 mm, 16 in
. . . . . . . . . . . . ..
Steering wheel diameter airbag model
400 mm, 15 3/4 in
. . . . . . . .
Toe-out measurement
0 to 2 mm, 0 to 1/4 in toe out
. . . . . . . . . . . . . ..
Toe-out included angle
0˚ to 0˚ 16’
. . . . . . . . . . . . . .
Camber angle
0˚ *
. . . . . . . . . . . . . . . . ..
Castor angle
3˚ *
. . . . . . . . . . . . . . . . . .
Swivel pin inclination static
7˚ *
. . . . . . . . . . . ...
* Check with vehicle in static unladen condition, that is,
vehicle with water, oil and five gallons of fuel. Rock the
vehicle up and down at the front to allow it to take up a
position.
04
GENERAL SPECIFICATION DATA
2
INFORMATION
VEHICLE WEIGHTS AND PAYLOAD
When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the unladen
vehicle weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted
maximum values.
It is the customer’s responsibility to limit the vehicle’s payload in an appropriate manner such that neither
maximum axle loads nor Gross Vehicle Weight are exceeded.
Maximum EEC kerb weight and distribution - all optional equipment
VEHICLE WEIGHTS - Mpi
3 Door
5 Door
Front axle
930 kg, 2050 lb
. . . . . . . . . . . . . . . . . . .
930 kg, 2050 lb
Rear axle
1010 kg, 2227 lb
. . . . . . . . . . . . . . . . . . ..
1055 kg, 2326 lb
Total
1940 kg, 4278 lb
. . . . . . . . . . . . . . . . . . . . .
1985 kg, 4377 lb
Maximum axle weights
Front axle
1110 kg, 2446 lb
. . . . . . . . . . . . . . . . . . .
Rear axle
1650 kg, 3638 lb
. . . . . . . . . . . . . . . . . . ..
Gross vehicle weight
2720 kg, 5998 lb
. . . . . . . . . . . . . .
VEHICLE WEIGHTS - V8i
Front axle
970 kg, 2139 lb
. . . . . . . . . . . . . . . . . . .
970 kg, 2139 lb
Rear axle
1010 kg, 2227 lb
. . . . . . . . . . . . . . . . . . ..
1055 kg, 2326 lb
Total
1980 kg, 4366 lb
. . . . . . . . . . . . . . . . . . . . .
2025 kg, 4465 lb
Maximum axle weights
Front axle
1100 kg, 2426 lb
. . . . . . . . . . . . . . . . . . .
Rear axle
1650 kg, 3638 lb
. . . . . . . . . . . . . . . . . . ..
Gross vehicle weight
2720 kg, 5998 lb
. . . . . . . . . . . . . .
VEHICLE WEIGHTS - 300 Tdi
Front axle
1040 kg, 2293 lb
. . . . . . . . . . . . . . . . . . .
1040 kg, 2293 lb
Rear axle
1015 kg, 2238 lb
. . . . . . . . . . . . . . . . . . ..
1060 kg, 2337 lb
Total
2055 kg, 4531 lb
. . . . . . . . . . . . . . . . . . . . .
2100 kg, 4630 lb
Maximum axle weights
Front axle
1200 kg, 2646 lb
. . . . . . . . . . . . . . . . . . .
Rear axle
1650 kg, 3638 lb
. . . . . . . . . . . . . . . . . . ..
Gross vehicle weight
2720 kg, 5998 lb
. . . . . . . . . . . . . .
EEC kerb weight = Unladen weight + Full fuel tank + 75 kg (165 kg) driver.
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