The Discovery, Land Rover’s legendary 4WD adventurer, enters the third phase of its 13-year history with a new look and a number of significant technical enhancements designed to keep it at the head of the fiercely competitive SUV (sports utility vehicle) market.

The unveiling of the latest Discovery marks the second new vehicle launch in a matter of months by Land Rover, the British-based company now part of the Ford-owned Premier Automotive Group.

Like the all-new Range Rover, launched to considerable critical acclaim at the start of 2002, the new Discovery is instantly recognisable by its dynamic new ‘face’, dominated by stylish and highly efficient twin pocket headlamps and a revised front bumper assembly. There have been changes at the rear, too, with enhanced lighting arrangements, as well as a new alloy wheel collection further to emphasise the visual changes.

The changes to the latest Discovery go far deeper than cosmetic alterations. There are also improvements to the vehicle‘s on-road driveability, refinement, quality, reliability and off-road ability.

Like the new Range Rover, the latest Discovery is designed to be equally at home on the motorway as it is on the mountainside. Enhancements to the chassis have improved the on-road ride and handling while new colours have given the interior a new ambience. Greater attention to refinement has produced a vehicle that’s quieter than before, while improvements in build quality will enhance the ownership experience.

Among the 700 major and detail changes are:

• A new face, inspired by the new Range Rover

• Revised rear lights for extra safety

• A new centre Diff-Lock for greater off-road ability

• Prestigious new interior colours

• New thicker-style roof bars

• New front bumper with an increased step height

• Refinement improvements

• Braking and suspension improvements

• A new 4.6-litre V8 version, for the North American market

Add these new features to Discovery’s proven attributes such as high and low ratio permanent four-wheel drive system, rear air suspension and the vehicle’s battery of pioneering electronic control systems including Electronic Traction Control and Hill Descent Control, and the new Discovery is well equipped to defend successfully Land Rover’s reputation as the world’s leading 4x4 manufacturer.

Indeed, the new Discovery builds on the formidable reputation of its tough forebears with extra weapons in its 4x4 armoury. These include the availability of a locking centre differential to improve even further its remarkable ability in extreme off-road conditions, such as over boulders or through shifting desert sand.

The 2003 Discovery is powered either by the proven 4.0-litre 136 kW (185 PS) V8 petrol engine or the 2.5-litre 101 kW (137 PS) Td5 five-cylinder turbo diesel engine. The Td5 engine produces up to 340 Nm (250 lb ft) of torque at under 2,000 rpm for on-road driveability and road prowess. For North America only, the latest Discovery gets a 162 kW (220PS) 4.6-litre V8 power unit in place of the 4.0 V8.  This move is to suit the unique requirements of that market.

 The interior features three new trim colours: ‘Tundra’ green, ‘Alpaca’ beige and ‘Land Rover Black’. These colour themes give the interior a new ambience, enhancing the spacious feel of the Discovery interior that can seat up to seven occupants. Among other improvements, changes to noise insulation and body mountings improve the refinement of the latest 2003 Discovery.

 Bob Dover, Land Rover’s managing director, said: ‘The changes to the 2003 Discovery improve key aspects of the vehicle, from its distinctive styling to its on-and off-road performance. The front-end styling provides an easily identified family resemblance to the new Range Rover while the interior treatments complement its spacious packaging.Land Rover has built on the Discovery’s well-known strengths in road handling and off-road capability to re-assert the model’s class-leading position in the 4x4 marketplace.’

Refinement and enhancements

Discovery’s striking new face might be the new model’s most obvious change, but it is far from the most significant. Much of the £24 million (€ 39.3 million) invested in the new Discovery has gone into subtle but far reaching refinement and quality improvements.

Typical of the attention to detail are the efforts that have been made to reduce the radial force variation (RFV) caused by out of balance wheels and tyres. Conventional wheel balancing, no matter how well done, still results in some out of balance vibrations between the wheel and tyre. And it is also rare for the wheel and tyre assemblies at either end of the same axle to be in perfect harmony with one another. Even perfectly balanced assemblies tend to go out of balance once they have been used on a vehicle.

To overcome RFV problems, has developed a new system of balancing not only the tyre to the rim, but also to bed down each wheel and tyre assembly before they reach the production line – including that destined for use as the spare – so that they are in perfect balance with each other not just from the outset but also after the vehicle has been used in anger.

Changes to the transfer box, including new mesh patterns on the gears, extra ribbing on the case itself and revised mounting points, have been made to lower NVH (noise, vibration and harshness) intrusion while extensive use of new damping panels has been made to prevent body generated boom.

A comprehensive overhaul of all seal fits has been made to reduce wind noise and water ingress while changes in production techniques and tolerances has further improved panel fit. Other NVH issues have been addressed by changes to the air induction system. A second resonator has been added to the system to quieten induction roar.

Improvements in the materials used in the interior has minimised squeaks and rattles while quality improvements on the production line has dramatically lowered the level of faults per vehicle.

Greater emphasis has also been placed on pre-production testing. The new Discovery underwent more exhaustive testing than any previous example of the model, with the vehicle often being ‘real world’ tested alongside the new Range Rover during the latter’s development programme. Special prominence was placed on hot environment testing, reflecting Discovery’s popularity in Gulf and North American markets. Here heat management issues came to the fore, with new heat shields and air deflectors being developed for the vehicle, especially in connection with the availability of the 4.6-litre V8 engine for North America.

Equipment enhancements include the availability of park distance control (PDC) to simplify parking manoeuvres while new in car entertainment systems have also been developed. Later this year a DVD player using a roof-mounted screen visible by rear passengers will become available. A stylish new range of alloy wheels and two new body colours allows a degree of personalisation.

Chassis

The new Discovery continues the Land Rover tradition of a wide breadth of capability, combining confident on-road handling with renowned off-road prowess. The key to this ability is the widespread use of some of the most sophisticated electronic chassis control systems in the world.

Designed to give outstanding car-like handling attributes in a large vehicle, Active Cornering Enhancement (ACE) is unique to the Land Rover Discovery. The system is operated by quick-reacting hydraulic actuators powered by a high pressure pump. The actuators automatically stiffen the suspension guided by an electronic control unit taking information from vehicle-mounted sensors. The result is a reduction in body roll in cornering, giving extra driver confidence and passenger comfort. 

ACE functions off-road too. The control unit can detect off-road driving patterns and adjusts the suspension to allow greater articulation giving extra agility. On side slopes the ACE system will lock the suspension for improved confidence. This innovative and intelligent system is a no-compromise approach giving agile on-road handling without compromising off-road performance.

The Discovery can seat up to seven passengers, carry a large payload and tow up to 3500 kg. With this wide variety of load conditions, it is important that the Discovery maintains a level stance. This is achieved with Self-Levelling Suspension that uses air springs in the rear suspension system fed by an electronically controlled compressor.  Sensors detect vehicle attitude and adjust the suspension to maintain a level position, regardless of load. Self-levelling avoids having to use stiffer springing, preserving smooth ride comfort. 

As with the ACE system, the air suspension has additional functionality reflecting the heritage of the Discovery. Simply by pressing a facia button when off-road, the air suspension raises the body, to provide extra clearance at the rear to increase departure angles. And should the vehicle ground at low speed when off-road, sensors will detect a spinning rear wheel and automatically raise the rear springs to help lift the vehicle out of trouble. A further function allows the rear of the vehicle to be lowered to facilitate hitching of a trailer.

Certain versions of the new Discovery are available with coil spring suspension all-round. As well as improving tolerances, the latest changes include a wider variety of spring rates so that reaction to vehicle mass can be optimised across a wider range of specifications. 

Standard on all models is a four-channel anti-lock braking system (ABS). The system incorporates Electronic Brakeforce Distribution (EBD) that adjusts the braking to suit the vehicle load condition optimising the braking effect. For 2003, the all-round disc brakes have been fitted with new pads and the hydraulic system features a revised master cylinder with revised stroke. Coupled with changes to the brake calliper piston and modifications to the ABS control programme, the new brake system has improved sensitivity, pedal travel and feel.

Allied to the ABS system, the latest Discovery is fitted with four-wheel Electronic Traction Control (ETC) as standard. The system has dual mode functionality for on-and off-road environments increasing driver confidence in all conditions.

The new 2003 Discovery is fitted with Hill Descent Control (HDC) as standard. HDC was granted the Queen’s Award for Enterprise for Innovation in 2001 and is a further example of Land Rover’s innovative approach to off-road driving conditions. First seen on the Land Rover Freelander and also featured on the new Range Rover, HDC supplements normal engine braking while descending steep slopes off-road. Operating only in low range, HDC applies the brakes to slow the vehicle, maintaining maximum control.

The ETC system is designed to give outstanding results when driving off-road without the need for control over the centre differential. ETC operates by applying braking to a spinning wheel preventing it from expending all available power and thereby providing traction to wheels that have grip.

Having a wheel spinning can, under certain extreme circumstances, be undesirable as it means that traction has been broken. For users likely to encounter such conditions, the new 2003 Discovery will be offered with a mechanically locking centre differential operated by a centre-mounted lever. This feature locks the relative movement between the front and rear axles preventing wheel slip and maintaining traction.

Perfected by Land Rover over more than 50 years of development, Discovery’s separate chassis offers the strength and rigidity needed for a serious 4x4, but uses the electronic enhancements to provide confident car-like on-road behaviour and ride refinement.

Featuring six cross members and no fewer than 14 body mounting points, its stiff construction is the anchor for the dynamic control systems that endow the Discovery with its on-road control and refinement and its off-road ability.  For the new 2003 Discovery, the body mounting points use revised materials to improve refinement.

Wide track beam axles have lateral location at the rear by a Watts linkage and by a Panhard rod at the front. Vertical location is by radius arms pivoting on low friction bushes. Revised front suspension geometry includes an optimised ride height to improve cornering composure and steering precision.

The front axle uses open yoke universal joints giving accurate steering response and a tight turning circle.  The power assisted worm and roller steering has also been revised to enhance feedback and on-road accuracy still further.

Drivetrain

The new 2003 Discovery uses a well proven drivetrain with a choice of either petrol or diesel engines and manual or automatic gearboxes. A central diff lock is new for the 2003 model. All models have permanent four-wheel drive and a two-stage transfer gearbox.

The diesel power unit for the new 2003 Discovery is the 2.5 litre, five cylinder Td5, developed and manufactured by Land Rover. This engine features Electronic Unit Injector (EUI) technology where each injector is separately controlled by an electronic control unit. The system injects the fuel at extremely high pressures for maximum control, the result being responsive, clean and economical performance across a wide range of power and torque.

The Td5 engine produces 101 kW (137PS) at 4,200 rpm and recent tuning has taken maximum torque up to 340 Nm (250 lb ft) when coupled to an automatic gearbox. Maximum torque is delivered at only 1,950 rpm for impressive drivability on-road and rugged off-road ability.

Among the special features of the Td5 is its two-stage throttle response, made possible by the unit’s electronically controlled, ‘drive-by-wire’ system. This system has two throttle maps – the on-road version providing the driver with a fast response for maximum driveability while the off-road profile more linear.

A key factor in the development of the Td5 engine was to reduce cost of ownership.  For example, the lubrication system features a centrifugal oil filter in addition to the normal filter. This traps particles that might otherwise contaminate engine oil and pushes oil change points to 20,000 km (12,000 miles). This reduced use of oil reduces servicing costs and has significant environmental benefits.  

The all-alloy 4.0-litre V8 petrol unit is the latest development of a classic engine, providing effortless performance and smooth power delivery. The latest generation of the V8 engine gained a new crankshaft and pistons, revised cylinder block, a new engine management system and a new inlet manifold when the Discovery Series II was introduced. These changes improve the engine’s torque output and response – improving drivability and off-road control. The latest 3,950cc V8 develops 136 kW (185PS) and 340 Nm (250 lb ft) of torque.

To suit unique market requirements Discovery will be fitted exclusively with the 4.6 litre V8 engine in North America. Developing 17 per cent more power and 20 per cent more torque at 162 kW (220PS) and 407 Nm (300 lb ft) respectively, this engine improves the performance of the Discovery giving a top speed of 116 mph and 0 – 60 mph acceleration of 9.5 seconds.

The Td5 diesel engine is available with either a five speed manual or four speed automatic gearboxes.

The well-proven five-speed manual transmission combines a fast and positive action with proven durability. Recent improvements have included increased bush sizes, revised material specifications and changes to production techniques.

Standard with the V8 engine and optional with the Td5 is a four speed automatic transmission with dual mode operation. This electronically controlled unit features a high speed digital link with the engine management system to ensure gear changes are swift and precise. The dual mode function provides for a Sport mode in high range that alters throttle response for a more reactive feel. In low range a Manual mode is available, allowing a selected gear to be held without shifting, allowing the driver greater control to negotiate a wide range of off-road conditions.

The Discovery has permanent four-wheel drive with a two stage transfer gearbox. The high/low shift is operated by a remote, cable operated control that isolates the vehicle interior from the transmission to improve refinement.

For 2003 a locking centre differential is available. Used in conjunction with the dynamic control systems such as Electronic Traction Control (ETC) the differential lock locks the relative movement of the front and rear wheels and help prevent wheel slip in extreme off-road conditions.

Design and body

When the original Discovery was launched in 1989, it represented a bold departure for Land Rover. The company’s first all-new shape since the launch of the original Range Rover in 1970, Discovery included many distinctive elements such as the stepped roof and the alpine roof lights.

But it was clearly a Land Rover, displaying many of the design cues that have made the marque famous world-wide – the upright stance, command driving position, low shoulder line, simple horizontal three bar grille and short overhangs front and rear for good approach and departure angles off road.

When the larger Discovery Series II appeared in 1998, although every panel except the tail door was new, it still retained the iconic silhouette of a Discovery. This distinctive profile is kept for the new 2003 Discovery but its front end styling is radically different.

Taking the latest Range Rover as inspiration, the Land Rover design team has adapted the striking face of the world’s most luxurious 4x4 and created a dramatically different Discovery. Central to the new look are the 'pocketed' headlamps with twin interlocking dip and main beam projectors clearly visible behind a clear lens. The headlamp assembly is completed by smaller indicator and parking lights on the outside edge of the unit.

Although they provide a strong Land Rover 'family' link between Discovery and Range Rover, their adoption is practical as well as cosmetic with the new lamps providing far better performance in terms of the spread and range of the beam and in the evenness of the illumination.

The new headlamps are among a series of changes to the front of the vehicle and are complemented by a new elongated grille and revised bumpers with new integrated fog lamps. The new black three bar grille retains the simplicity of the previous version but has been extended to the edge of the headlamps to reinforce the strong vertical and horizontal elements integral to Land Rover’s design philosophy.

Beneath the grille lies an all-new, three piece bumper assembly, which has a revised profile to improve the Discovery's off-road agility.

The central section of the bumper is black, matching the grille, and is flanked by end caps which are either painted black or finished in body colour depending on the model. The end caps are easily replaceable in the event of minor damage and also house the new Range Rover-style fog lamps: by mounting the fog lamps higher than before, they are less prone to off-road damage.

Visual changes to the rear are restricted to the revised tail-lights. The direction indicators have been enlarged and have been moved from their previous position within the rear bumper assembly to the main light cluster housing in the rear pillars flanking the tailgate. This move enhances visibility of the turn signal for following drivers. The reversing lights are now housed in the rear bumper display alongside the high intensity rear fog lamps.

Other external changes include a new alloy wheel collection, including new five and six spoke 16 inch wheels and a pair of 18 inch wheels styles. New roof bars with a thicker profile can be specified, which as well as being a practical load carrying feature, help define the new look of the latest Discovery.

A wide range of accessories have been developed in conjunction with the main design team and these complement the new look of the latest Discovery.

Interior

The spacious and practical interior of the Discovery has been admired since the introduction of the original Discovery. The new Discovery extends this appeal with the introduction of three new interior colours: ‘Land Rover Black’, ‘Tundra’ green and ‘Alpaca’ beige. ‘Land Rover Black’ is used as a complete interior for a prestige look while ‘Tundra’ and ‘Alpaca’ provide high contrast duo tone themes. To achieve this contemporary ambience ‘Tundra’ trim provides light and dark variations of the same tone while ‘Alpaca’ is paired with ‘Land Rover Black’ for the facia top and carpet.

Trim materials include cloth or leather for seat facings or an alcantara/leather combination. ‘Duragrain’ PVC is used for the third row seats and is also available on the other seats for the North American market. Burr walnut trim is available for the facia and centre console.

Inspired by the levels of customer choice available on the new Range Rover, the new 2003 Discovery buyer may also choose a variety of colour combinations – including ‘Designer Choice’ themes.  

The new 2003 Discovery retains the versatile seating arrangement of previous models. Up to seven passengers can be accommodated in three rows of forward facing seating in a ‘stadium’ arrangement so that each row is higher than the one in front. This, together with the provision of high mounted ‘alpine’ lights, adds to the feeling of spaciousness that is particularly appreciated by children travelling in the rear seats. 

All seats are equipped with three point seat belts, the front seat belts having pretensioners. The front seats also have ‘anti-submarine’ panels in the cushion and further protection is provided by driver and front passenger air bags. Electric seat adjustment is available for the front seats as are adjustable arm rests.

As before, the second row of seats are split 60/40 and jack knife forward under spring assistance to create extra luggage space. The second row seats also feature a centre armrest with a retractable head restraint that deploys when the centre position is occupied. The armrest also incorporates a pop-out cup holder.

The third row seats are securely latched to the sides of the luggage area when not in use. When needed to carry passengers, one or both seats can be swung down and locked into place. Safety latches prevent use when not properly deployed.

Both third row seats have full three point seat belts and head restraints. Child head restraints are integrated into the seat while those for adults are stowed in the roof and fold down when required. This arrangement means the restraints do not block the driver’s rearward visibility when stowed yet, by encroaching on headroom, compel their use when the seats are occupied by adults. Access to the rear seats is through the rear door. Seven seat models have a folding rear step fitted as standard to ease access.

Reflecting its practical nature, the 2003 Discovery has plenty of space for oddments with a large centre console box, glove box, door bins and roof mounted stowage nets. The rear load space area has retaining rings to assist in anchoring luggage and loose items. The new Discovery retains the famous ‘curry hook’ – a handy catch on the passenger side of the centre console where a typical take-away can be carried without fear of the contents being spilled over the interior.

The level of equipment on the new 2003 Discovery reflects its practicality and ability. An intelligent, bi-level air conditioning system with Automatic Temperature Control (ATC) maintains a constant interior temperature, compensating for outside conditions and solar radiation. Front seat occupants may select their own temperature setting which is automatically maintained on that side. Rear air conditioning is also available with air vents located in the roof lining above the middle row of seats.

Several levels of in-car entertainment are available. The most advanced system, developed by harman/kardon incorporates a CD multi-changer and has 11 speakers fed by a 320 watt amplifier. Separate twin audio controls are available for rear seat passengers. This feature enables occupants of the Discovery to listen to two separate audio sources. While the front passengers listen via the car’s extensive internal loudspeaker system, those in the rear can listen to a separate audio source on headphones. An in-dash satellite navigation system is also available while the instrument pack has been revised with clearer graphics. The fuel flap release switch has also been relocated.

The latest Discovery is protected by a variety of security systems including superlocking and perimetric and volumetric sensors. The remote control for the locking system is programmed to open the driver's door only at the first press to prevent unauthorised entry through the other doors. This feature is useful if the vehicle has to be parked in insecure areas.

Also available is Park Distance Control (PDC) which gives an audible warning of obstacles when reversing.

Information reproduced from Land Rover Press release