ECU LAND ROVER DISCOVERY 1995 Workshop Manual

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.

76CHASSIS AND BODY
8
REPAIR REAR SIDE DOOR - TRIM PANEL
Service repair no - 76.34.04
Remove
1.Disconnect battery negative lead.
2.Remove the two securing screws and detach the
door pull from its mounting brackets.
3.Remove the securing screw and detach the
interior door release handle surround.
4.Where applicable remove the window winder or
release electric switch and disconnect.
5.Detach the trim panel by inserting a trim panel
removing tool between the trim panel and the
inner door panel, gently prise out the plastic
securing clips from their respective holes in the
inner panel.
6.Lift the trim panel over the remote button and
clear of the door. Where applicable disconnect
the electrical plug from the window lift switch and
withdraw the panel.
NOTE: With the trim panel removed the
remote button and rod will fall from its
location in the bellcrank. Observe its
correct location and withdraw from the door
panel.
7.If a new trim panel is to be fitted, remove the
window lift switch, door bin and remote button
finisher from the existing trim panel and fit them
to the new panel.Refit
8.Reverse removal procedure. Ensuring correct
fitment of the sill button operating rod.

CHASSIS AND BODY
9
REPAIR REAR SIDE DOOR LOCK, INSIDE AND OUTSIDE
RELEASE HANDLES
Service repair no - 76.37.13/32
Remove
1.Ensure that the window is in the fully closed
position.
2.Disconnect battery negative lead.
3.Remove the interior trim panel from the door.
See rear side door - trim panel.
4.Remove the plastic vapour barrier sheet.
5.Disconnect the inside release handle control rod
by pulling it from its location in the door lock.
6.Disconnect the sill locking control rod from the
lock by releasing the metal clip.
7.Disconnect the outside release handle control
rod by pulling it out of the plastic ferrule.
8.Remove the two countersunk screws from the
door edge and the single screw and shakeproof
washer from the inner door panel. Retrieve any
spacing washers which may be fitted between
the inner door panel and lock.
9.Withdraw the lock through the upper rear
opening in the inner door panel.
NOTE: If necessary the following items
can be removed.10.Remove the two nuts, shakeproof washers and
retaining bracket securing the outer release
handle which are accessible through the upper
rear cut-out on the inner door panel.
11.Carefully detach the handle from the outer door
panel.
12.Remove the two screws and plain washers
securing the inside release handle to the inner
door panel and withdraw the handle complete
with connecting rod.
13.Disconnect the sill button connecting rod from
the bellcrank and withdraw the rod complete with
sill button.
Sill locking bellcrank
14.Using a small screwdriver, or length of 3.175 mm
(1/8 in) diameter rod, press the plastic locking
pins through the respective square inserts in the
inner door panel.
15.Release the bellcranks from the inner door panel
and unhook the respective connecting rods.
16.Withdraw the bellcranks from inside the door
panels.
NOTE: When refitting the bellcranks the
locking pins are entered into the square
insert from outside and pressed in flush.

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.

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
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
15
REPAIR REAR DOOR CHECK STAY
Service repair no - 76.40.30
Remove
1.Remove the rear door from the vehicle.
See
rear door.
2.Invert the door on a suitable protected area.
3.Remove the two securing bolts and withdraw the
check stay assembly.
Refit
4.Reverse removal procedure.REAR COMPARTMENT LOWER TRIM PANELS
Service repair no - 76.13.03
Remove
1.Remove the fold down seat or pocket side panel,
whichever is applicable.
See rear fold down
seats.
2.Remove speaker by releasing screws and
disconnecting Lucars. Withdraw rear quarter trim
panel.
3.Remove the five trim panel retainers.
4.Ease the trim panel from its location, feed the
seat belts through the apertures and withdraw
the panel.
Refit
5.Reverse removal procedure.

76CHASSIS AND BODY
16
REPAIR ALPINE LIGHT TRIM CASING
Service repair no - 76.13.20
Remove
1.Remove RH 'E' post trim casing.
See 'E' post
trim casing - rh.
2.Remove rear seat belt anchorage retaining bolt
cover.
3.Remove bolt securing rear seat belt anchorage.
4.Remove 2 trim studs securing trim casing.
5.Release trim casing from 2 retaining studs.
6.Remove trim casing.
Refit
7.Fit and align trim casing and secure with studs.
8.Fit 2 trim studs securing trim casing.
9.Position seat belt anchorage, fit bolt and tighten
to
32 Nm (24 lbf ft).
10.Fit cover to seat belt anchorage bolt.
11.Fit 'E' post trim casing.
See 'E' post trim
casing - rh.