lock LAND ROVER DISCOVERY 1995 Workshop Manual

76CHASSIS AND BODY
10
REPAIR ADJUSTMENT-REAR SIDE DOOR LOCK AND
HANDLE
Service repair no - 76.37.47
Outside door release handle to lock
1.Disconnect the short off-set connecting rod at
the rear of the outer release handle, rotate the
rod clockwise or counter clockwise to shorten or
extend the operating length of the rod as
required.
NOTE: Door release should occur before
the total handle movement is achieved to
provide a small overthrow movement.
REAR SIDE DOOR GLASS AND REGULATOR
Service repair no - 76.31.45
Remove
1.Ensure that the window is in the fully closed
position and secure it with adhesive tape over
the top of the door to prevent the glass from
dropping down.
2.Disconnect battery negative lead.
3.Remove the door trim panel.
See rear side
door - trim panel.
4.Remove the plastic vapour barrier.
5.Where applicable remove the door actuator and
window lift motor.
See ELECTRICAL, Repair,
window lift motor - rear. See ELECTRICAL,
Repair, rear side door actuator units.
6.Remove the four window regulator securing
screws and shakeproof washers from the inner
door panel.
7.Carefully disengage the lifting arm stud from the
glass lifting channel and remove the window
regulator from the lower opening in the inner
door panel.
8.Remove the waist rail seal from the top of the
door panel.
9.Remove the single bolt, spring and plain
washers from inside the door, securing the
bottom of the short glass run channel.
10.Remove the two bolts, spring and plain washers
from the hinge face of the door.

76CHASSIS AND BODY
12
REPAIR REAR DOOR TRIM PANEL
Service repair no - 76.34.09
Remove
1.Remove the two screws securing the door pull
and remove it from the door.
2.Remove the finisher from the inner door handle.
3.Using a trim panel removing tool release the
seventeen trim panel fasteners and withdraw the
panel from the door.
4.If necessary remove the sixteen screws securing
the stowage bins to the trim panel and detach
the bins.
Refit
5.Reverse removal procedure.REAR DOOR LOCK AND INNER AND OUTER
RELEASE HANDLES
Service repair no - 76.37.16/74/77/78
Remove
1.Disconnect battery negative lead.
2.Remove the door pull, the trim panel and the
vapour protective sheet, to allow access to the
door handles and lock mechanisms.
3.Disconnect the inner release handle connecting
rod at the lock.
4.Remove the two screws securing the inner
handle and withdraw the handle complete with
connecting rod.
NOTE: Two identical 'Y' shaped levers
(bellcranks) are fitted to the rear door lock
mechanism and are referred to as inner
and outer 'Y' levers; the inner one being the
nearest to the inner door panel.
5.If fitted, remove the central locking actuator
control rod link from the actuator and from the
inner 'Y' lever.
6.Detach the remote button connecting rod at the
inner 'Y' lever and withdraw from inside the door.
7.Detach the lock and barrel connecting rods from
the upper leg of the inner 'Y' lever.

CHASSIS AND BODY
13
REPAIR 8.Remove the screws securing the lock control
mechanism pivot bracket and the door pull
mounting bracket, ease the bracket from the lock
barrel stem and remove from the door.
9.Remove the two screws and withdraw the
childproof lock actuator.
10.Disconnect the adjustable lock rod from the
outer 'Y' lever.
11.Remove the centre pin from the outer 'Y' lever
pivot and release the pivot from the door.
12.Remove the three lock securing screws and
manoeuvre the lock and 'Y' lever out of the door
panels.
13.Disconnect the number plate light leads from the
door harness.
14.Remove the 'E' clip securing the fulcrum to the
barrel stem and withdraw the fulcrum and lock
rod.
15.From inside the door panel remove the nuts and
washers securing the lock barrel and number
plate light housing.
16.Remove the logo from the housing and working
through the logo aperture, remove the single bolt
securing the housing.
17.Partially withdraw the housing and its rubber
seal from the door, displace the rubber grommet
from the door panel, withdraw the number plate
light leads and complete the removal of the
housing and seal from the door.
18.Remove the connecting rod from the outer door
handle lever.
19.Remove the two nuts and washers securing the
outer handle from inside the door panels and
detach the handle and seal.

76CHASSIS AND BODY
14
REPAIR Lock barrel and number plate light housing
Disassemble
NOTE: The lock barrel can only be
removed from its housing when the lock
barrel and number plate light housing is
removed from the door.
20.Remove the bolt securing the lock barrel
mounting bracket to the housing and withdraw
the assembled barrel and bracket.
21.Remove the 'O' ring seal from inside the
housing.
22.Remove the spring clip securing the barrel to the
bracket and withdraw the barrel and stem
assembly from the bracket complete with seal.
23.Remove the 'U' clip securing the stem to the
barrel and detach the seal from the inner face of
the barrel.
24.If the lock barrel and number plate light housing
is being renewed, remove the number plate
lights, harness and the housing mounting
bracket, from the existing housing and fit them to
the new housing.
Reassemble
25.Fit the stem to the barrel and secure with the 'U'
clip.
26.Position a new seal on the inner face of the
barrel, insert the stem and barrel into the
mounting bracket and secure with the spring clip.
27.Place a new 'O' ring seal on the inner face of the
barrel aperture in the housing.
28.Insert the assembled bracket and barrel into its
location in the housing, taking care not to disturb
the seal, and secure with the bolt.Refit
29.Fit the outer handle to the door and secure from
the inside with the two nuts and washers.
30.Fit the lock barrel and number plate light housing
by inserting the number plate light leads through
the aperture in the door panel and locating the
rubber grommet in the aperture. Insert the barrel
stem through the door, locate the housing on the
door panel, ensure that the seal seats correctly,
and secure with the single bolt and washer
through the logo aperture.
31.Connect the number plate light leads to the door
harness.
32.Fit the logo to the aperture in the housing.
33.Fit the fulcrum and connecting rod to the barrel
stem and secure with secure with the 'E' clip.
34.Fit the lock and assembled outer 'Y' lever,
secure the lock with the three screws, locate the
'Y' lever pivot and secure with the pin.
35.Fit the connecting rod from the outer handle
lever to the outer 'Y' lever.
36.Fit the childproof lock actuator and check that it
is functioning.
37.Insert the remote button and rod to the location
in the door.
38.Offer up the assembled inner 'Y' lever and
bracket, attach the barrel connecting rod to the
top clip of the upper leg and the rod from the
lock to the lower clip of the upper leg.
39.Locate the barrel stem in the insert on the
bracket.
40.Secure the bracket with the four screws; fitting
the door pull mounting bracket under the heads
of the top two screws.
41.Attach the remote button and the actuator
connecting rods to the 'Y' lever.
42.Fit the inner release handle and attach the
connecting rod to the lock.
43.Refit the vapour protective sheet, door trim panel
and door pull.

CHASSIS AND BODY
27
REPAIR REAR SEAT CUSHION COVER
Service repair no - 76.70.88/89
Remove
NOTE: The procedure for removing both
left and right hand seat cushions is the
same.
1.Remove the rear seat assembly from the
vehicle.
See rear passenger seat.
2.Remove the seat squab.
3.Remove the seat cushion.
4.Remove the cushion base cover retaining
screws and withdraw the cover.
5.Release the seat cover securing clips at the
frame and at the seat belt aperture.
6.Remove the cover from the cushion.
Refit
7.Reverse removal procedure.SPLIT REAR SEAT LOCKING MECHANISM
Service repair no - 76.70.51
Remove
1.Remove the front body side trim casing.
See
front body side trim casing.
2.Remove the three screws securing the latch to
the tower, noting that access to the single screw
is gained through the hole in the front of the
tower.
3.Retrieve the latch from the opening at the rear of
the tower. If necessary retrieve the single screw.
4.The operating rod can be removed from the latch
by releasing it at the plastic clip.
Refit
5.Reverse removal procedure. Setting the release
button to achieve a gap of 5 - 8 mm (3/16 - 5/16
in).

76CHASSIS AND BODY
36
REPAIR SUNROOF ELECTRIC/MANUAL
Introduction
Twin sunroofs are fitted to the vehicle, the open/close
sequence for both electric and manual versions
sharing the same operation:-
A Closed position,
B Tilt position,
C Fully open position. When fully open the sunroof
slides back in a tilt position over the vehicle roof.
The electric front and rear sunroofs, operated by roof
mounted switches are controlled by an electronic
control unit. A roof mounted isolation switch is also
fitted to cut off power to the rear sunroof.
On manual sunroofs a pull down handle is used,
incorporating a depress button that locks the handle
after each sequence.
Twin sun blinds are installed in the clamping frame of
the sunroof and can be drawn forwards
independently.

76CHASSIS AND BODY
46
REPAIR DASH PANEL CENTRAL LOUVRE PANEL
Service repair no - 76.46.42
Remove
1.Disconnect battery negative lead.
2.Remove radio.
See ELECTRICAL, Repair,
radio.
3.Release tags securing radio cage to louvre
panel and remove cage.
4.Remove clock.
See ELECTRICAL, Repair,
clock.
5.Release 4 coin tray securing tags.
6.Remove coin tray.
7.Remove 3 heater control and blower switch
knob.
8.Remove 2 screws securing heater graphic
display panel and remove panel.
9.Remove 4 screws securing heater control unit to
panel.
10.Working through coin tray aperture, remove
screw securing panel.
11.Working through clock aperture, remove screw
securing panel.
12.Loosen 2 uppermost panel retaining screws.
NOTE: On some models the panel is fitted
with an LED. In this case, manoeuvre LED
from panel and disconnect.
13.Remove panel retaining screw cover.

CHASSIS AND BODY
47
REPAIR
14.Remove 2 screws securing louvre panel.
15.Remove louvre panel from dash panel.
Refit
16.Position louvre panel, feed harness connectors
through their correct apertures,and align to dash
panel.
CAUTION: When refitting avoid trapping of
electrical wiring.
17.Fit and tighten screws securing louvre panel.
18.Fit panel retaining screw cover.
19.Position heater control unit to panel and secure
with screws.
20.Fit heater graphic display panel and secure with
screws.
21.Fit heater control and blower switch knobs.
22.Fit clock.
See ELECTRICAL, Repair, clock.
23.Position coin tray and secure to tags.
24.Position radio cage, feed electrical connectors
and aerial through cage, and position to panel.
25.Bend back radio cage retaining tags.
26.Fit radio.
See ELECTRICAL, Repair, radio.
27.Connect battery negative lead.DASH PANEL ASSEMBLY
Service repair no - 76.46.23
Remove
1.Move front seats to rearmost position.
2.Disconnect battery negative lead.
3.Disconnect air bag multiplugs under dash panel.
CAUTION: When air bags are fitted,
reference must be made to the Airbag
Supplementary Restraint System section.
4.Remove passenger glove box.
5.Remove driver's side access panel.
6.Remove centre console assembly.
See centre
console.
7.Remove airbag from steering wheel.See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair, driver's airbag module.
8.Remove passenger's airbag from dash panel.
See SUPPLEMENTARY RESTRAINT SYSTEM,
Repair, passenger's airbag module.
9.Release clamp and lower steering column.
10.Remove steering wheel.
See STEERING,
Repair, steering wheel.
11.Remove column switch.See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair, column switch assembly.
12.Remove instrument binnacle.See
ELECTRICAL, Repair, instrument binnacle.
13.Remove radio.See ELECTRICAL, Repair,
radio.
14.Remove exterior mirrors switch panel.
15.Remove coin tray.
16.Remove switch panel.
17.Remove clock.
18.Undo screw securing mounting bracket and
position passenger's side relay assembly aside.
19.Set heater controls fully clockwise.

CHASSIS AND BODY
51
REPAIR 16.Cut through sealer between the supports.
If heated front screen: Cut through the 2 wires
each side of the supports. Tape cut wires and
panels to prevent damage to bodywork when
screen is removed.
17.Attach suction cups to glass and lift glass from
body flange, cut sealer free around supports as
necessary.
WARNING: If glass has splintered: Protect
eyes and operate demister blower at
maximum speed to remove any glass from
ducts. Use a vacuum cleaner to remove glass
particles from inside the vehicle.
Refit
18.Check condition of supports, renew if necessary.
Locating studs must be at right angle to flange.
NOTE: The supports were fitted to early
vehicles and now replaced with nylon
sheaths.
19.Carefully cut back old sealant around body
flange to obtain a smooth surface 2mm (1/10in)
thick.DO NOT cut down to flange.
20. If refitting original glass:It must be free from
chips or cracks. Cut back old sealant around
glass to obtain a smooth surface 2mm (1/10 in)
thick.DO NOT cut down to glass surface.
CAUTION: Lay glass on felt covered
supports, do not stand on edge. Any
chipping of glass edge may develop into
cracks.
21.Align header finisher on top edge of glass, push
flange fully onto glass and use a wooden block
and mallet to ensure fit.
22.Carefully align each side finisher on edge of
glass, push flange fully onto glass and use a
wooden block and mallet to ensure fit.
23.Using a cotton bud, apply glass cleaning solvent
(yellow cap) to inside face of glass, 20mm (13/16
in) strip around inside of finishers and 30mm (1
1/8 in) wide along bottom edge. Immediately
wipe off solvent with a clean cloth.
CAUTION: Do not touch cleaned or primed
surfaces with fingers.

CHASSIS AND BODY
53
REPAIR
31. With assistance:Attach suction cups to glass
and lift into position, carefully align the indicators
on the obscuration band with the supports.
Lower screen onto body flange, check alignment
and firmly press to seat glass in the aperture.
NOTE: The finisher on later vehicles will
not have cutouts, or supports fitted, as
shown.
32.Align cut outs with the supports and push
finisher fully onto the glass. Use a wooden block
to ensure fit.
33.Refit 'A' post finishers and interior mirror.
34.Refit wiper arms.FRONT SEAT - ELECTRIC
Service repair no - 76.77.01
Remove
1.Operate controls to adjust seat fully backwards
and remove 2 bolts securing seat slides.
2.Operate controls to adjust seat fully forwards.
3.Remove 3 studs securing seat side valance.
4.Remove side valance.