light LAND ROVER DISCOVERY 1995 Repair Manual

SUPPLEMENTARY RESTRAINT SYSTEM
15
REPAIR AIRBAG MANUAL DEPLOYMENT
CAUTION: Deployment in the vehicle will
damage the steering wheel; if the vehicle
is not being scrapped deploy the module
away from the vehicle in accordance with the
separate procedure.
If a vehicle is to be scrapped and contains an
undeployed airbag module, the module must be
manually deployed. This operation should only be
carried out using the following recommended manual
deployment procedure.
Before deployment is started the deployment tool self
test procedure should be carried out.
Deployment tool SMD 4082/1 self test procedure
1.Insert BLUE and YELLOW connectors of tool
lead into corresponding sockets on face of tool.
2.Connect crocodile clips of second tool lead to
battery, RED to positive and BLACK to negative.
3.RED "READY" light should illuminate.
4.Press and hold both operating buttons.5.GREEN "DEFECTIVE" light should illuminate.
6.Release both operating buttons.
7.RED "READY" light should illuminate.
8.Disconnect tool from battery.
9.Disconnect blue and yellow connectors from tool
face sockets.
10.Self test now complete.
Deployment with module fitted to vehicle
These guidelines are written to aid authorised
personnel to carry out the safe disposal of the airbag
module when fitted to the vehicle.
WARNING: Only use the LAND ROVER
approved deployment equipment. Deploy
airbag module in a well ventilated
designated area. Ensure airbag module is not
damaged or ruptured before deploying.
1.Carry out deployment tool self test.
2.Release 2 turnbuckles securing lower panel to
dash, remove lower panel.

SUPPLEMENTARY RESTRAINT SYSTEM
19
REPAIR
9.Press both operating buttons to deploy airbag
module.
10. DO NOTreturn to airbag module for 30 minutes.
11.Using gloves and face mask, remove airbag
module from tool, place airbag module in plastic
bag and seal bag.
12.Wipe down tool with damp cloth.
13.Transport deployed airbag module to designated
area for incineration.
NOTE: DO NOT transport airbag module in
the vehicle passenger compartment. DO
NOT re-use or salvage any parts of the
airbag system including steering wheel or
steering column.Passenger's Airbag Module
1.Carry out deployment tool self test.
2.Remove airbag module from fascia.
See
passenger's airbag module.
3.Position toolSMD 4082/6in vice, ensuring that
vice jaws grip tool above bottom flange to
prevent possibility of tool being forced upwards
from vice. Tighten vice.
4.Position bracketsSMD 4082/7to tool; lightly
tighten bolts.

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.

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.

CHASSIS AND BODY
17
REPAIR FRONT BODYSIDE TRIM CASING
Service repair no - 76.13.01
Remove
1.Remove the grab handle.
2.Remove the rear compartment lower trim panel.
See rear compartment lower trim panels.
3.Remove the alpine light trim casing.See alpine
light trim casing.
4.Remove the bolts securing the upper and lower
seat belt mountings.
5.Remove the finisher from its location over the
seat belt inertia reel.
6.Remove the front seat belt guide from the upper
aperture in the casing.
7.Open the side window, remove the catch
securing screws and withdraw the catch trim.
8.Remove the side window hinge finishers.
9.Release the casing from the window rubber.
10.Release the rear seat belt from the guide
attached to the casing.
11.Fold down the rear seats and carefully ease the
casing from the fastenings.
12.Pass the front seat belt through the upper
aperture and withdraw the casing from the
vehicle.
Refit
13.Reverse removal procedure.
NOTE: Ensure that the trim material glued
to the door post is not wrinkled when the
door seal is fitted.
14.Tighten upper and lower seat belt fixings to
32
Nm (24 lbf ft)
.

76CHASSIS AND BODY
18
REPAIR HEADLINING
Service repair no - 76.64.01/14
Remove
1.Disconnect battery negative lead.
2.Remove the lower trim panels from the rear
compartment.
See rear compartment lower
trim panels.
3.Remove the alpine light trim casing.See alpine
light trim casing.
4.Remove the front bodyside trim casing.See
front bodyside trim casing.
5.Remove the roof lights from the headlining
pocket and from the headlining.
6.Remove the front grab handles.
7.Remove the sun visors and their retaining clips.
8.Remove the front headlining pocket.9.Remove the finishers from the sun roof
apertures.
10.Release the headlining from the channel above
the rear door and manoeuvre it from the vehicle
through the rear door.
11.If the existing headlining is being replaced, if
fitted, remove the passenger net pockets and fit
them to the new headlining.
Refit
12.Reverse removal procedure.

CHASSIS AND BODY
19
REPAIR 'D' POST TRIM CASING
Service repair no - 76.13.73
Remove
1.Remove the rear compartment lower trim panel.
See rear compartment lower trim panels.
2.Remove the alpine light trim casing.See alpine
light trim casing.
3.Release the rear seat belt from the guide
attached to the casing.
4.Fold down the rear seats.
5.Release the D' post casing from the rear side
window seal and carefully ease the casing from
the fasteners.
Refit
6.Reverse removal procedure.BODY SIDE OPENING WINDOWS
Service repair no - 76.81.18
Remove
1.Remove the screws securing the catch to the
body and detach the catch trim.
2.Remove the hinge finishers from the hinges.
3.Remove the screws securing the glass to the
hinges, withdraw the glass and fixings taking
care not to lose the joint washers.
Refit
4.Reverse removal procedure.

CHASSIS AND BODY
33
REPAIR WINGS [FENDERS]
Service repair no - 76.10.24
Remove
1.Disconnect battery negative lead.
2.Remove the headlamp surround.
3.Remove the front bumper assembly.
4.Remove the indicator repeater light.
5.Remove the four screws securing the wing
[fender] at the 'A' post.
6.Remove the bolts securing the bottom of the
wing [fender] at the bumper retaining bracket
and at the sill finisher.
7.If removing the RH wing [fender] loosen the
radio aerial securing nut.
8.Remove the seven bolts from the drain channel
in the top of the wing [fender].
9.Break the sealed joints at the valance and 'A'
post; then complete the removal of the wing
[fender]. If removing a RH wing withdraw the
wing [fender] sufficiently to allow removal of the
aerial before completing the removal.Cleaning/painting
10.Thoroughly clean all traces of existing sealant
from the sealing faces of the valance and 'A'
post.
11.Paint the cleaned surfaces with etch primer.
12.If the existing wing [fender] is to be refitted
repeat the cleaning and painting procedure on
the wing [fender] sealing surfaces.
Refit
13.Apply 3M 8572 Bolted Panel Sealer to the joint
faces on the valance and 'A' post and to the
bracket face.
14.Refit the wing [fender], on RH wings [fenders] fit
the radio aerial, and secure with the bolts and
screws ensuring that the wing [fender] correctly
aligns with the bonnet [hood].

76CHASSIS AND BODY
44
REPAIR
7.Remove centre console switch pack cover.
8.Remove 4 screws securing switch pack to
console.
9.Release switch pack from console and
disconnect 7 multiplugs.
NOTE: If the 'Cold Pack' option is not fitted
there will only be 5 switches in pack.
10.Remove switch pack.
Models fitted with electric front seats
11.Release electric front seat switches from centre
console.
12.Disconnect 2 multiplugs from each switch.
13.Remove switches.All models
14.Release hand brake lever gaiter from centre
console.
15.Remove clip and clevis pin securing cable to
hand brake lever.
16.Remove 4 screws securing centre console to
body.
17.Raise hand brake lever, pull centre console
rearwards to gain access to cigar lighter
multiplug and illumination bulb Lucar.
18.Disconnect cigar lighter multiplug and
illumination bulb Lucar.
19.Remove centre console assembly.