warning LAND ROVER DISCOVERY 1995 Workshop Manual

75SUPPLEMENTARY RESTRAINT SYSTEM
18
REPAIR
WARNING: Ensure tool SMD 4082/1 is not
connected to battery.
4.Secure airbag module to toolSMD 4082/2.
Ensure module is correctly secured using both
fixings.
5.Ensure airbag module mounting brackets are
secure.
6.Connect flyleadSMD 4082/4to airbag module.
7.Connect flyleadSMD 4082/4to toolSMD
4082/1.
WARNING: Do not lean over module whilst
connecting.
8.Connect toolSMD 4082/1to battery.
WARNING: Ensure all personnel are
standing at least 15 metres (50 ft) away
from module.

75SUPPLEMENTARY RESTRAINT SYSTEM
20
REPAIR
5.Position airbag module to toolSMD 4082/6.
Ensure module is correctly secured using all
fixings.
6.Ensure airbag module mounting brackets are
secure.
WARNING: Ensure tool SMD 4082/1 is not
connected to battery.
7.Connect flyleadSMD 4082/5to airbag module.
8.Connect flyleadSmd 4082/5to toolSMD 4082/1
WARNING: Do not lean over module whilst
connecting.
9.Connect toolSMD 4082/1to battery.
WARNING: Ensure all personnel are
standing at least 15 metres (50 ft) away
from module.

CHASSIS AND BODY
1
REPAIR FRONT DOOR
Service repair no - 76.28.01
Remove
1.Disconnect battery negative lead.
2.Detach the door seal at the lower section of the
'A' post.
3.Carefully remove the two retaining buttons from
the trim panel on the side of the footwell and
ease out the panel.
4.Disconnect the three multiplugs connecting the
door harness and speaker leads.
5.Detach the convoluted grommet from the 'A' post
and withdraw the door harness and speaker
leads.
6.Set the door in the open position without
engaging the check stay; then remove the roll
pin securing the check stay at the 'A' post.
WARNING: Instruction 7 MUST BE carried
out with assistance.
7.Remove the door hinge 'C' clips from the hinge
posts and with assistance carefully lift the door
from the vehicle.
Refit
8.Refit the door and secure the hinge posts with
the 'C' clips.
9.Locate the check stay to the bracket on the 'A'
post and secure with a new roll pin.
10.Feed the door harness and speaker leads
through the aperture in the 'A' post, fully open
the door and reconnect the multiplugs in the
footwell, take up the slack and refit the
convoluted grommet to the 'A' post.
11.Refit the footwell side panel.
12.Check the location of the door and the operation
of the door lock. If necessary, adjust the door
and striker.
13.The door can be adjusted up and down or in and
out of the opening by loosening the six screws
securing the hinges to the door, and by the
addition or removal of shims between the hinge
and door.
14.The door lock striker can be adjusted by
loosening the striker and moving it in the
appropriate direction or by adding and removing
spacing washers between the striker and 'B'
post.

CHASSIS AND BODY
7
REPAIR REAR SIDE DOORS
Service repair no - 76.28.02
Remove
1.Disconnect battery negative lead.
2.Detach the convoluted grommet from the 'B'
post.
3.Withdraw the door harness multiplugs from the
'B' post and disconnect them.
4.Remove the bolts and washers securing the
check strap to the 'B' post.
WARNING: Instruction 5 MUST BE carried
out with assistance.
5.Remove the door hinge 'C' clips from the hinge
posts and with assistance carefully lift the door
from the vehicle.
Refit
6.Reverse removal procedure. Fitting new 'C' clips
if the existing ones are worn or distorted.
7.Check the operation of the door and lock. If
necessary, adjust the door and striker.
Adjust
8.Adjust the door by adding or removing shims
between the hinge and the door to move the
door forward or rearward in the opening.
9.To adjust the door up, down or in and out of the
opening, loosen the screws securing the hinges
to the door, adjust as necessary and retighten
the screws to the correct torque value.
10.Adjustment of the door striker is identical to the
procedure for front doors.
NOTE: If it is necessary to remove the
hinges from the 'B' post they must be
refitted in exactly the same position, using
an equal thickness of shims to those removed.

CHASSIS AND BODY
11
REPAIR
11.Remove the two bolts, spring and plain washers
securing the door frame to the edge of the door.
12.Lift out the door frame complete with glass and
remove to a suitable workbench.
13.Remove the tape and slide the glass out of the
door frame channel.
Refit
14.Reverse removal procedure.
NOTE: When refitting the door glass frame
ensure that it is adjusted to suit the door
opening before fully tightening the
securing bolts.REAR DOOR
Service repair no - 76.28.19
Remove
1.Remove the spare wheel from the exterior of the
door.
2.Remove the trim panel from inside the rear door.
See rear door trim panel.
3.Release the convoluted grommet from the door
post, expose the door harness connectors and
multiplugs and disconnect.
4.Remove the circlip and washer from the check
stay pivot on the body.
WARNING: Instruction 5 MUST BE carried
out with assistance.
5.Suitably support the door, remove the four bolts
securing the hinges to the door and with
assistance slide the door off the hinges.
Refit
6.Reverse removal procedure.

76CHASSIS AND BODY
22
REPAIR FRONT FOLDING SEATS 3 DOOR VEHICLES
Service repair no - 76.70.01
WARNING: Care must be taken if the seat
lifting mechanism is operated when the
seat is removed from the base otherwise
personal injury could occur.
Remove
1.Slide the seat to the full extent rearwards and
remove the rear seat to base securing bolts.
2.Slide the seat forward and remove the front seat
to base securing bolts.
3.Lift the seat from the base and withdraw from the
vehicle.
Refit
4.Reverse removal procedure.
5.Tighten all securing bolts to
22 Nm (16 lbf ft).

CHASSIS AND BODY
23
REPAIR SEAT BASE
Service repair no - 76.70.06/25
WARNING: Care must be taken if the seat
lifting mechanism is operated when the
seat is removed from the base otherwise
personal injury could occur.
Remove
1.Remove the seat from the base.
2.Carefully operate the seat mechanism to raise it
to the tilt position.
3.Remove the two bolts securing the rear of the
base to the floor.
4.Return the seat mechanism to the upright
position.
5.Pull the carpet flap forward to expose the front
securing bolts, remove the bolts and lift out the
seat base.
Refit
6.Reverse removal procedure.SEAT BASE RUNNERS
Remove
7.Remove the seat from the base.
8.Spring the release handle off its locations on the
runners.
9.Slide the runners forward sufficient to gain
access to the rear securing bolts and rearward
for the front bolts.
10.Remove the bolts and withdraw the runners.
Refit
11.Fit the runners and release handle.
12.Reverse removal procedure.
13.Refit the seat to the base.

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.

AIR CONDITIONING
1
ADJUSTMENT GENERAL PRECAUTIONS
The refrigerant used in the air conditioning system is
HFC (Hydrofluorocarbon) R134a.
WARNING: R134a is a hazardous liquid
and when handled incorrectly can cause
serious injury. Suitable protective clothing
must be worn when carrying out servicing
operations on the air conditioning system.
WARNING: R134a is odourless and
colourless. Do not handle or discharge in
an enclosed area, or in any area where the
vapour or liquid can come in contact with naked
flame or hot metal. R134a is not flammable but
can form a highly toxic gas.
WARNING: Do not smoke or weld in areas
where R134a is in use. Inhalation of
concentrations of the vapour can cause
dizziness, disorientation. uncoordination,
narcosis, nausea or vomiting.
WARNING: Do not allow fluids other than
R134a or compressor lubricant to enter the
air conditioning system. Spontaneous
combustion may occur.
WARNING: R134a splashed on any part of
the body will cause immediate freezing of
that area. Also refrigerant cylinders and
replenishment trolleys when discharging will
freeze skin to them if contact is made.
WARNING: The refrigerant used in an air
conditioning system must be reclaimed in
accordance with the recommendations
given with a Refrigerant Recovery Recycling
Recharging Station.
NOTE: Suitable protective clothing
comprises: Wrap around safety glasses or
helmet, heatproof gloves, rubber apron or
waterproof overalls and rubber boots.REMEDIAL ACTIONS
1.If liquid R134a strikes the eye, do not rub it.
Gently run large quantities of eyewash over the
eye to raise the temperature. If eyewash is not
available cool, clean water may be used. Cover
eye with clean pad and seek immediate medical
attention.
2.If liquid R134a is splashed on the skin run large
quantities of water over the area as soon as
possible to raise the temperature. Carry out the
same actions if skin comes into contact with
discharging cylinders. Wrap affected parts in
blankets or similar material and seek immediate
medical attention.
3.If suspected of being overcome by inhalation of
R134a vapour seek fresh air. If unconscious
remove to fresh air. Apply artificial respiration
and/or oxygen and seek immediate medical
attention.
NOTE: Due to its low evaporating
temperature of -30°C, R134a should be
handled with care.
WARNING: Do not allow a refrigerant
container to be heated by a direct flame or
to be placed near any heating appliance. A
refrigerant container must not be heated above
50°C.
WARNING: Do not leave a container of
refrigerant without its cap fitted. Do not
transport a container of refrigerant that is
unrestrained, especially in the boot of a car.

AIR CONDITIONING
3
ADJUSTMENT SERVICING EQUIPMENT
The following equipment is required for full servicing
of the air conditioning system.
Recovery, recycling and charging station
Leak detector
Thermometer +20°C to -60°C
Safety goggles and gloves
REFRIGERANT RECOVERY RECYCLING
RECHARGING
WARNING: The air conditioning system is
charged with a high pressure, potentially
toxic refrigerant. Repairs or servicing must
only be carried out by an operator familiar with
both the vehicle system and the charging and
testing equipment.
All operations must be carried out in a
well-ventilated area away from open flame and
heat sources.
Always wear safety goggles and gloves when
opening refrigerant connections.
WARNING: Wear eye and hand safety
protection. Open connections slowly in
case liquid or pressure is present. Allow to
bleed off slowly.
CAUTION: Overcharging air conditioning
system will cause excessive head
pressure.
An air conditioning portable Refrigerant Recovery
Recycling Recharging Station for use with R134a
refrigerant incorporates all the features necessary to
recover refrigerant R134a from the air conditioning
system, to filter and remove moisture, to evacuate and
recharge with the reclaimed refrigerant. The unit can
also be used for performance testing and air
conditioning system analysis.
The operator must adhere to the equipment
manufacturer's instructions.Recovery and recycling
1. High pressure servicing connection
2. Low pressure servicing connection
1.Connect a Refrigerant Station to the high and
low pressure servicing connections.
2.Operate the refrigerant recovery system
according to the manufacturer's instructions.
3.Measure the amount of oil discharged from the
system. Add an equal amount of new refrigerant
oil to compressor before evacuation sequence.
WARNING: Refrigerant must always be
recycled before reuse, to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system.
Recycling should always be carried out with
equipment which is design certified by
Underwriter Laboratory Inc. for compliance with
SAE-J1991. Other equipment may not recycle
refrigerant to the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and commercial
sources must not be used in motor vehicle air
conditioning systems.