LAND ROVER DISCOVERY 1995 Workshop Manual

76CHASSIS AND BODY
34
REPAIR SILL FINISHER
Service repair no - 76.76.05
Remove
1.Remove the nut, bolt and washer securing the
front of the sill finisher to the wing [fender]
support bracket.
2.Remove the screw securing the bracket at the
rear end of the finisher to the sill.
3.Using a suitable punch, remove the inserts from
the seven plastic retainers and withdraw the
finisher from the sill.
Refit
4.Reverse removal procedure. Using new plastic
retainers.BONNET [HOOD]
Service repair no - 76.16.01
Remove
1.Open the bonnet [hood] and support with the
stay.
2.Mark the position of the hinges to the bonnet
[hood].
3.With the assistance of a second operator,
remove the hinge to bonnet [hood] securing
screws, remove the support stay and lift bonnet
[hood] from the vehicle. Note the quantity of
shims fitted between the hinge and bonnet
[hood].
Refit
4.Reverse removal procedure. Ensuring that it
aligns with the wings [fenders], cowl panel and
front grille before fully tightening the securing
bolts.

CHASSIS AND BODY
35
REPAIR AIR INTAKE PLENUM COWL
Service repair no - 76.11.08
Remove
1.Remove the windscreen wiper arms.
2.Remove the securing nuts and the steel and
rubber washers from the wiper spindles.
3.Open the vehicle bonnet [hood].
4.Remove the rubber seal from the cowl flange.
5.Release the screen washer tubes from the
washer jets on the cowl.
6.Remove the centre bolt securing the cowl centre
section.
7.Remove the retainers securing the centre
section to the outer section.
8.Detach the centre section from the bulkhead.
9.Remove the nuts and bolts and detach the outer
sections of the cowl.Refit
10.Reverse removal procedure.

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.

CHASSIS AND BODY
37
REPAIR SUNROOF GLASS FRONT AND REAR
Service repair no - 76.82.64
Remove
1.Open sunroof to tilt position.
2.Using a right angled screwdriver remove four
retaining screws and detach sunroof glass from
upper frame. Retain capnuts and washers.Refit
3.Locate sunroof glass in upper frame complete
with capnuts and loosely fit retaining screws.
4.Close sunroof and move glass centrally in upper
frame.
5.Open to tilt position and tighten retaining screws.
CAUTION: Ensure washers under capnuts
do not twist or spread out when tightening
retaining screws.
Sunroof components
1. Glass panel
2. Capnut and washer
3. Screw
4. Upper frame assembly5. Clamping frame assembly
6. Screw
7. Edging trim
8. Drain tube

76CHASSIS AND BODY
38
REPAIR SUNROOF ASSEMBLY - ELECTRICAL, FRONT
AND REAR
Service repair no - 76.82.59
Remove
Refer to sunroof components illustration J5483
1.Ensure sunroof is in normally closed position.
2.Disconnect battery negative lead.
3.Remove headlining.
See headlining.
4.Disconnect electric motor wiring plug.See
sunroof electric motors.
5.Remove screws and detach electric motor from
clamping frame.
6.Disconnect drain tubes from each side of
clamping frame.
7.Remove 13 fixings and remove clamping frame
from upper frame.
8.Remove upper frame assembly.
Refit
9.Position upper frame assembly into roof
aperture.
10.Locate clamping frame and reconnect drain
tubes.
11.Loosely fit screws, centralise upper frame and
clamping frame assemblies and then tighten
screws.
12.Reverse removal procedure.

CHASSIS AND BODY
39
REPAIR SUNROOF ELECTRIC MOTORS
Service repair no - 76.82.84/85
FRONT MOTOR
Remove
1.Disconnect battery negative lead.
2.Ensure sunroof is in normally closed position
NOTE: If the electric motor has failed the
sunroof can be closed manually using an
allen key to turn motor spindle A.
3.Remove switch panel from stowage pocket
panel
4.Remove interior lamp from stowage pocket
panel
5.Remove alarm ultrasonic unit.
6.Unscrew ten fixings and remove stowage pocket
from headlining.
7.Disconnect motor wiring multiplug.
8.Remove three screws and motor.
Refit
9.Reverse removal procedure.
CAUTION: Ensure the motor is aligned
with fixing holes and the sunroof is in the
normally closed position. DO NOT rotate
the motor drive spindle in the rack - this may
result in incorrect operation of the sunroof.REAR MOTOR
Remove
1.Disconnect battery negative lead.
2.Ensure sunroof is in normally closed position
NOTE: If the electric motor has failed the
sunroof can be closed manually using an
allen key to turn motor spindle.
3.Remove headlining.
See headlining.
4.Disconnect motor wiring multiplug.
5.Remove three screws and motor.
Refit
6.Reverse removal procedure.
CAUTION: Ensure the motor is aligned
with fixing holes and the sunroof is in the
normally closed position. DO NOT rotate
the motor drive spindle in the rack - this may
result in incorrect operation of the sunroof.

76CHASSIS AND BODY
40
REPAIR SUNROOF ELECTRIC CONTROL UNIT
Service repair no - 76.82.73
The control unit serves both front and rear sunroofs
and is sited above the front switches behind
headlining.
Remove
1.Disconnect battery negative lead.
2.Ensure sunroof is in normally closed position.
NOTE: If the electric motor has failed the
sunroof can be closed manually using an
allen key to turn motor spindle.
3.Remove switch panel from stowage pocket
panel
4.Remove interior lamp from stowage pocket
panel
5.Remove alarm ultrasonic unit.
6.Unscrew ten fixings and remove stowage pocket
from headlining.
7.Disconnect electric plugs from control unit.
8.Remove two retaining screws and control unit.
Refit
9.Reverse removal procedure.

CHASSIS AND BODY
41
REPAIR SUNROOF ASSEMBLY - MANUAL, FRONT AND
REAR
Service repair no - 76.83.01
Remove
1.Close sunroof.
2.Remove headlining.
See headlining.
3.Remove screws and manual regulator from
clamping frame.
See sunroof regulator
manual.
4.Disconnect drain tubes from each side of
clamping frame.
5.Remove 13 screws and clamping frame from
upper frame.
6.Remove upper frame assembly from roof
aperture.Refit
7.Position upper frame assembly into roof
aperture.
8.Locate clamping frame and reconnect drain
tubes.
9.Loosely fit screws, centralise upper frame and
clamping frame assemblies and then tighten
screws.
10.Reverse removal procedure.
Sunroof components
1. Glass panel
2. Capnut and washer
3. Screw
4. Upper frame assembly5. Clamping frame assembly
6. Screw
7. Edging trim
8. Drain tube

76CHASSIS AND BODY
42
REPAIR SUNROOF REGULATOR MANUAL
Service repair no - 76.83.03/04
FRONT
Remove
1.Ensure sunroof is in normally closed position.
2.Remove retaining screw and regulator handle.
3.Remove switch panel from stowage pocket
panel
4.Remove interior lamp from stowage pocket
panel
5.Remove alarm ultra sonic unit.
6.Unscrew ten fixings and remove stowage pocket
from headlining.
7.Remove two retaining screws and regulator from
clamping frame.
Refit
8.Reverse removal procedure.
CAUTION: Ensure the regulator is aligned
with fixing holes and the sunroof is in the
normally closed position. DO NOT rotate
the regulator spindle in the rack - this may result
in incorrect operation of the sunroof.REAR
Remove
1.Ensure sunroof is in normally closed position.
2.Remove retaining screw and regulator handle.
3.Remove headlining.
See headlining.
4.Remove two retaining screws and regulator from
clamping frame.
Refit
5.Reverse removal procedure.
CAUTION: Ensure the regulator is aligned
with fixing holes and the sunroof is in the
normally closed position. DO NOT rotate
the regulator spindle in the rack - this may result
in incorrect operation of the sunroof.

CHASSIS AND BODY
43
REPAIR SUN BLIND ASSEMBLY
Service repair no - 76.82.78
Remove
1.Open sunroof to the tilt position.
2.Remove the trim finisher from the sunroof
surround.
3.Release the headlining locally to access under
clamping frame of the sunroof.
4.Lever forward and upward the rear leg of 3
retaining clips to release sun blind roll assembly.
Refit
5.Ensure front leg of retaining clips are located.
6.Push in rear leg of retaining clip.
7.Reverse removal procedure.CENTRE CONSOLE
Service repair no - 76.52.02
Remove
1.Disconnect battery earth lead.
2.Release tranfer gear lever gaiter from console.
3.Remove transfer gear lever gaiter and knob
assembly.
4.Release gear selector lever gaiter from centre
console.
5.Remove gear selector lever gaiter and knob
assembly.
6.Remove centre console rubber mat.