LAND ROVER DISCOVERY 1999 Workshop Manual

SCREENS
76-4-2 REPAIRS
Windscreen
$% 76.81.01
Introduction
The following equipment is required:
lCutting wire and handles.
lKent cutting knife.
lGlazing knife.
lWindscreen repair kit.
lSealant applicator gun.
lSuction cups.
lA felt covered table or stand to support glass.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
WARNING: Wear suitable eye protection when
removing and refitting glass.
WARNING: If glass has splintered, protect eyes
and operate demister blower to remove glass
from heater ducts. Use a vacuum cleaner to
remove glass from fascia, carpet and seats.Remove
1.Remove air intake plenum.

+ HEATING AND VENTILATION,
REPAIRS, Plenum Air Intake.
2.If fitted, disconnect screen heater multiplugs.
3.Remove top corner trim finishers from body.
4.Remove windscreen top finisher and discard.
5.Release interior mirror from slug and tie aside.
6.Fit protection to exterior body work adjacent to
screen.
7.Cover body panels adjacent to glass.
8.Cover heater ducts with masking tape.
9.Cover interior of vehicle with protective sheet.

SCREENS
REPAIRS 76-4-3
10.From outside of vehicle, use a Kent knife and
carefully cut through sealant securing sides of
screen to body.
11.Using suitable cutting wire, with assistance if
required, carefully cut through sealant securing
top of screen to body and any remaining
sealant at sides.
CAUTION: Hold the cutting wire as close to
the glass as possible to prevent damage to
the body and surrounding trim.
12.Cut through sealant securing lower edge of
screen to body with glazing knife.
13.Attach suction cups and use assistance to
remove glass from body.
CAUTION: Lay glass on felt covered
supports and be careful not to damage the
obscuration band. Do not stand on edge as
this can cause chips which subsequently
develop into cracks.
14.Collect screen support block. Refit
1.Carefully remove sealant from body to leave a
smooth surface.
2.Use a vacuum cleaner to clear away any waste.
3. Original glass: Carefully cut back old sealer to
obtain a smooth surface without damaging
obscuration band on glass. Fit new top finisher
to screen.
4.Fit screen support block to body.
5.With assistance, locate screen to body.
6.Apply masking tape to establish reference
marks as an alignment aid.
7.With assistance, remove screen and place
aside.
8.Clean body and sealant face on screen with
solvent.
CAUTION: Do not touch cleaned or primed
surfaces with fingers.
9.Apply etch primer to any bare metal on frame.
10.Apply screen primer to sealant face on screen
and allow to cure.
11.Apply primer over etch primer on body.
12.Apply activator over old sealant on body.
13.Allow activator to cure.
14.Fit pre-cut nozzle to sealer cartridge, remove
lid, shake out crystals and fit cartridge to
applicator gun. If necessary modify the nozzle
to achieve required bead section.

SCREENS
76-4-4 REPAIRS
15.Apply a continuous bead of sealant to sealant
face on screen as shown.
16.With assistance, lift screen into place and align
to screen supports and tape. Ensure top
finisher is located into correct position. Lightly
press glass to fully seat sealer.
CAUTION: Do not apply heavy pressure to
the sides of the windscreen. Lightly press
windscreen from centre outwards until
edges are to required gap. Pushing sides
into position can bend windscreen and lead
to cracking in service.
17.Remove protective covers and tape.
18.Test sealer for leaks, apply additional sealer if
necessary. If water is used, allow sealer to dry
before testing. Spray water around glass and
check for leaks. Mark any area that leaks. Dry
glass and sealer then apply additional sealer.
19.Fit interior mirror to slug.
20.If applicable, connect screen heater multiplugs.
21.Fit air intake plenum.

+ HEATING AND VENTILATION,
REPAIRS, Plenum Air Intake.
CAUTION: A curing time of 6 hours is
desirable. During this time leave a window
open to ventilate the vehicle interior. If the
vehicle must be used before the curing time
has elapsed, do not drive at speed or slam
the doors with the windows closed.
CAUTION: Vehicles fitted with a passenger
airbag should not be driven for 24 hours.
Glass - body side - rear
$% 76.81.18
Introduction
The following equipment is required:
lCutting wire and handles.
lKent cutting knife.
lGlazing knife.
lWindscreen repair kit.
lSealant applicator gun.
lSuction cups.
lA felt covered table or stand to support glass.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
WARNING: Wear suitable eye protection when
removing and refitting glass.
Remove
1.If fitted, disconnect coaxial cable from terminal
on glass.
2.Fit protection to exterior body work adjacent to
glass.
3.Cover body panels adjacent to glass.
4.Fit protection to internal trim adjacent to glass.
5.Cover interior of vehicle with protective sheet.

SCREENS
REPAIRS 76-4-5
6.From outside of vehicle, use a Kent knife and
carefully cut through sealant to release glass
from body. Any remaining sealant not
accessible with Kent knife can be severed
using cutting wire or knife.
CAUTION: Hold the cutting wire as close to
the glass as possible to prevent damage to
the body and surrounding trim.
7.Remove glass.
CAUTION: Lay glass on felt covered
supports and be careful not to damage the
obscuration band. Do not stand on edge as
this can cause chips which subsequently
develop into cracks.
Refit
1.Carefully remove sealant from body to leave a
smooth surface.
2.With assistance, fit glass without sealant to
body and apply masking tape to establish
reference marks as an alignment aid.
3.Remove glass and place aside.
4.Clean body and sealant face on glass with
solvent.
CAUTION: Do not touch cleaned or primed
surfaces with fingers.5.Apply etch primer to any bare metal on body.
6.Apply glass primer to sealant face on glass and
allow to cure.
7.Apply primer over etch primer on body.
8.Apply activator over old sealant on body.
9.Allow activator to cure.
10.Fit pre-cut nozzle to sealant cartridge, remove
lid, shake out crystals, and fit cartridge to
applicator gun. If necessary modify the nozzle
to achieve required bead section.
11.Apply a continuous bead of sealant to sealant
face on glass as shown.
12.Position glass to body and align to reference
tape.
13.Lightly press glass to ensure correct profile.
14.Secure glass with tape until sealer has cured.
15.Remove protective covers and tape.
16.If applicable, connect coaxial cable to terminal
on glass
17.Test sealer for leaks, apply additional sealer if
necessary. If water is used, allow sealer to dry
before testing. Spray water around glass and
check for leaks. Mark any area that leaks. Dry
glass and sealer then apply additional sealer.
CAUTION: A curing time of 6 hours is
desirable. During this time leave a window
open to ventilate the vehicle interior. If the
vehicle must be used before the curing time
has elapsed, do not drive at speed or slam
the doors with the windows closed.

SCREENS
76-4-6 REPAIRS
Glass - alpine light
$% 76.81.52
Introduction
The following equipment is required:
lCutting wire and handles.
lKent cutting knife.
lGlazing knife.
lWindscreen repair kit.
lSealant applicator gun.
lSuction cups.
lA felt covered table or stand to support glass.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
WARNING: Wear suitable eye protection when
removing and refitting glass.
Remove
1.Fit protection to exterior body work adjacent to
glass.
2.Fit cover over adjacent body work.
3.Fit protection to internal trim adjacent to glass.
4.Cover interior of vehicle with protective sheet.
5.From outside of vehicle, use a Kent knife and
carefully cut through sealant to release glass
from body. Any remaining sealant not
accessible with Kent knife can be severed
using cutting wire or knife.
CAUTION: Hold the cutting wire as close to
the glass as possible to prevent damage to
the body and surrounding trim.
6.Remove glass.
CAUTION: Lay glass on felt covered
supports and be careful not to damage the
obscuration band. Do not stand on edge as
this can cause chips which subsequently
develop into cracks.Refit
1.Carefully remove sealant from body to leave a
smooth surface.
2.With assistance, fit glass without sealant to
body and apply masking tape to establish
reference marks as an alignment aid.
3.Remove glass and place aside.
4.Clean body and sealant face on glass with
solvent.
CAUTION: Do not touch cleaned or primed
surfaces with fingers.
5.Apply etch primer to any bare metal on body.
6.Apply glass primer to sealant face on glass and
allow to cure.
7.Apply primer over etch primer on body.
8.Apply activator over old sealant on body.
9.Allow activator to cure.
10.Fit pre-cut nozzle to sealant cartridge, remove
lid, shake out crystals, and fit cartridge to
applicator gun. If necessary modify the nozzle
to achieve required bead section.
11.Apply a continuous bead of sealant to sealant
face on glass as shown.

SCREENS
REPAIRS 76-4-7
12.Position glass to body and align to reference
tape.
13.Lightly press glass to ensure correct profile.
14.Secure glass with tape until sealer has cured.
15.Remove protective covers and tape.
16.Test sealer for leaks, apply additional sealer if
necessary. If water is used, allow sealer to dry
before testing. Spray water around glass and
check for leaks. Mark any area that leaks. Dry
glass and sealer then apply additional sealer.
CAUTION: A curing time of 6 hours is
desirable. During this time leave a window
open to ventilate the vehicle interior. If the
vehicle must be used before the curing time
has elapsed, do not drive at speed or slam
the doors with the windows closed.

SEATS
DESCRIPTION AND OPERATION 76-5-1
SEATS DESCRIPTION AND OPERAT ION
Electric seat component location
RHD shown, LHD similar
1BCU
2Drivers door switch
3Power relay
4Satellite fuse box
5Switch pack
6Fore/aft motor7Cushion front up/down motor
8Cushion rear up/down motor
9Squab fore/aft motor
10Lumbar support bladder
11Lumbar pump

SEATS
76-5-2 DESCRIPTION AND OPERATION
Electric seat block diagram

SEATS
DESCRIPTION AND OPERATION 76-5-3
1Ignition switch
2BCU
3Driver door switch
4Left seat power relay
5Left seat satellite fuse box
6Left seat switch pack
7Left seat fore/ aft motor
8Left seat cushion front up/ down motor
9Left seat cushion rear up/ down motor
10Left seat squab fore/ aft motor
11Left seat lumbar pump12Left seat lumbar deflate solenoid
13Right seat power relay
14Right seat satellite fuse box
15Right seat switch pack
16Right seat fore/ aft motor
17Right seat cushion front up/ down motor
18Right seat cushion rear up/ down motor
19Right seat squab fore/ aft motor
20Right seat lumbar pump
21Right seat lumbar deflate solenoid
22Passenger front door switch