LAND ROVER DISCOVERY 1995 Workshop Manual

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.

CHASSIS AND BODY
45
REPAIR Refit
20.Position centre console assembly, ensuring
harnesses and connectors are not trapped and
are routed to their correct locations.
21.Connect cigar lighter multiplug and illumination
bulb Lucar.
22.Align centre console to body fixings and fascia.
23.Fit and tighten screws securing centre console to
body.
24.Lubricate hand brake lever to cable clevis pin.
25.Align hand brake cable to lever, fit clevis pin and
secure with clip.
26.Secure hand brake lever gaiter to centre
console.
Models fitted with electric front seats
27.Position electric front seat switches,connect
multiplugs and secure to centre console.
All models
28.Position centre console switch pack and connect
multiplugs to switches.
29.Align switch pack to centre console and secure
with screws.
30.Fit centre console switch pack cover.
31.Fit centre console rubber mat.
32.Fit gear selector lever knob and secure gaiter.
33.Fit transfer gear lever knob and secure gaiter.
34.Reconnect battery earth lead.DRINKS TRAY
Service repair no - 76.46.41
Remove
1.Disconnect battery negative lead.
2.Remove ash tray.
See ash tray - dash panel
central louvre panel.
3.Remove switch pack.See switch pack - dash
panel central louvre panel.
4.Remove 6 screws securing drinks tray to dash
panel central louvre panel.
5.Remove drinks tray.
Refit
6.Position drinks tray to dash panel central louvre
panel and secure with screws.
7.Fit switch pack.
See switch pack - dash panel
central louvre panel.
8.Fit ash tray.See ash tray - dash panel central
louvre panel.
9.Connect battery negative lead.

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.

76CHASSIS AND BODY
48
REPAIR 20.Note position of levers, disconnect heater control
cables from levers and outer cable from retaining
clips.
21.Remove 4 bolts securing dash panel to centre
lower mounting brackets.
22.Remove 4 bolts securing dash panel to side
lower mounting brackets.
23.Undo 4 screws and remove 2 driver's knee
bolster pads from below steering column.
24.Remove 4 nuts securing instrument mounting
bracket to dash panel.
25. With assistance:Manoeuvre dash panel
partially rearward.
26.Driver's side: Disconnect 6 multiplugs
connecting dash harness to main harness.
27.Disconnect 3 multiplugs connecting dash
harness to fusebox.
28. With assistance:Lift dash panel rearward to
clear fixings and remove from vehicle.

CHASSIS AND BODY
49
REPAIR Refit
CAUTION: When refitting avoid trapping
electrical wiring.
29.Reverse removal procedure.
30.With assistance: Position dash panel and
connect dash harness multiplugs to fusebox and
main harness.
31.Reverse removal procedure. Ensure dash panel
upper bracket studs are located before the 4
lower brackets.
32.Reverse removal procedure. Disconnect
glovebox switch Lucars to ease fitting of relay
bracket.WINDSCREEN GLASS
Service repair no - 76.81.01
Information
The following equipment is required:
·Cutting wire and handles
·Windscreen repair kit (see Technical
Bulletin).
See Electrical Trouble Shooting
Manual.Windscreen Glass Replacement.
·Sealant applicator gun.
·Suction cup lifters.
The following materials are included in the windscreen
repair kit:
·Glass cleaning solvent - 'Betawipe' Glass
activator (yellow cap).
·Cotton buds.
·Glass primer - 'Betaprime'(green cap).
·Body primer - 'Betaprime' paint/plastic
primer (red cap).
·Betaseal Adhesive sealant.
NOTE: The adhesive sealant cures in 6 to 8
hours
CAUTION: Once existing sealant is cut, the
exposed surfaces oxidises in
approximately 90 minutes. The refit
procedure must be completed within this time
span to prevent the sealant oxidising, to effect a
satisfactory joint.
CAUTION: If the windscreen aperture body
flange shows signs of corrosion it must be
treated with anti corrosion primer and
repainted. Newly painted areas must then be left
for 8 hours or more before applying adhesive
sealant.

76CHASSIS AND BODY
50
REPAIR
NOTE: If heated front screen: 2 electrical
multiplug connectors are located under
the decker [cowl] panel. To access release
decker panel.
Remove
1.Remove windscreen wiper arms.
See WIPERS
AND WASHERS, Repair, wiper arms -
windscreen.
2.Remove rear view mirror and stickers from
glass.
3.Remove'A'post finishers.
4.Fit protective cover over dash panel and apply
masking tape to protect'A'posts.
5.Ease one end of bottom finisher away from
glass, pull to disengage finisher flange and
remove.
6.Lift lip of LH'A'post finisher and release sealing
strip along its length, pull to disengage finisher
flange from glass and remove.7.Remove RH'A'post finisher.
8.Remove header finisher.
9.Apply masking tape to protect paint finish around
glass.
10.Prepare cutting wire in handle'A'.Bend end of
wire to handle and tape over end.
11.Force cutting wire through sealer from inside and
100mm (3 7/8 in) from a top corner. Use a
needle if necessary to make a pilot hole.
12.Attach handle'B'.Allow 200mm (7 7/8 in) of wire
between handles, tape over end of wire.
13. With an assistant on the inside:Wedge the
tube of the handle'A'between glass and body
flange 100mm (3 7/8 in) ahead of hole in sealer.
14. From the outside:Carefully cut sealer from
flange using a straight pull away from the glass.
Continue in 100mm (3 7/8 in) steps around the
glass, use a sawing action at the corners.
CAUTION: Along the bottom edge, great
care must be taken to cut up to the 2
supports, positions indicated on the
obscuration band (See item 18).
15.Remove handle'B', withdraw the cutting wire
and insert it through the sealer between the
supports. Refit handle'B'.

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.

76CHASSIS AND BODY
52
REPAIR
24.Ensure body flanges and surfaces covered by
the finishers are clean.
25.Shake the primer container for at least 30
seconds.
26.Using a cotton bud, apply Glass Primer (green
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. This must be touch
dry before applying adhesive.27.Remove protective coverings and tape.
28.Pierce top and pre-cut nozzle to sealer cartridge,
remove lid and shake out crystals and install
cartridge in applicator gun.
29.Apply a continuous bead of adhesive sealant
around the glass as shown. Vertical edge of
sealer to abut finishers and to be 8mm (5/16 in)
from bottom edge of glass.
30.Remove protective covering (RED) from side
finisher sealing strip.

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.