light LAND ROVER DISCOVERY 1999 Workshop Manual

PANEL REPAIRS
REPAIRS 77-2-53
Rear floor (RH/LH section)
In this procedure, the cross member rear assembly,
cross member outer rear panel (RH/LH section),
cross member closing rear panel, 'E' post assembly,
'E' post closing assembly and the panel body side
assembly are replaced in conjunction with the rear
floor (RH/LH section).
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove cross member rear assembly.

+ PANEL REPAIRS, REPAIRS, Cross
member rear assembly.
4.Remove mud flap mounting brackets.
5. LH side: Remove exhaust heatshield from rear
floor.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1. LH side: Fit exhaust heatshield to rear floor.
2.Fit mud flap mounting brackets.
3.Fit cross member rear assembly.

+ PANEL REPAIRS, REPAIRS, Cross
member rear assembly.
4.Connect leads/multiplug to alternator.
5.Connect battery leads, negative lead last.
Roof assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3. Models with sunroof: Remove front sunroof.

+ SUNROOF, REPAIRS, Sunroof -
front.
4. Models with sunroof: Remove rear sunroof.

+ SUNROOF, REPAIRS, Sunroof -
rear.
5. Models with sunroof: Release sunroof drain
tubes and position aside.
6. Models with fixed roof: Remove head lining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
7.Remove front seats.

+ SEATS, REPAIRS, Seat - front.
8.Remove rear seats.

+ SEATS, REPAIRS, Seat - rear.
9.Remove rear headrests, if fitted.
10.Remove roof bars, if fitted.

+ EXTERIOR FITTINGS, REPAIRS,
Roof bars.
11.Remove tread plates from front door apertures.
12.Remove 'A' post lower trim panels.
13.Remove front door aperture seals.
14.Remove tread plates from rear door apertures.
15.Remove rear door aperture seals.
16.Remove 'D' post outer trim finisher.
17.Remove windscreen.

+ SCREENS, REPAIRS, Windscreen.
18.Remove alpine light glass.

+ SCREENS, REPAIRS, Glass - alpine
light.
19.Remove side and rear drip rail finishers.
20.Release relevant wiring and position aside.

PANEL REPAIRS
77-2-54 REPAIRS
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
2. During welding operations, apply 'Heat
shrink paste' to roof and body side panel to
avoid heat damage to paintwork.Refit
1.Fit and secure wiring.
2.Fit side and rear drip rail finishers.
3.Fit alpine light glass.

+ SCREENS, REPAIRS, Glass - alpine
light.
4.Fit windscreen.

+ SCREENS, REPAIRS, Windscreen.
5.Fit 'D' post outer trim finishers.
6.Fit rear door aperture seals.
7.Fit tread plates to rear door apertures.
8.Fit front door aperture seals.
9.Fit 'A' post lower trim panels.
10.Fit tread plates to front door apertures.
11.Fit roof bars.

+ EXTERIOR FITTINGS, REPAIRS,
Roof bars.
12.Fit rear headrests.
13.Fit rear seats.

+ SEATS, REPAIRS, Seat - rear.
14.Fit front seats.

+ SEATS, REPAIRS, Seat - front.
15. Models with fixed roof: Fit head lining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
16. Models with sunroof: Fit sunroof drain tubes.
17. Models with sunroof: Fit rear sunroof.

+ SUNROOF, REPAIRS, Sunroof -
rear.
18. Models with sunroof: Fit front sunroof.

+ SUNROOF, REPAIRS, Sunroof -
front.
19.Connect leads/multiplug to alternator.
20.Connect battery leads, negative lead last.
M77 1715A

BODY SEALING MATERIALS
77-3-2 MATERIALS AND APPLICATIONS
Approved materials
The following is a table of materials approved by Land Rover for use during body repairs.
Description - Usage Supplier Part Number
Cavity waxes
Inner Cavity Wax (Amber) 3M 08901/11/21
Inner Cavity Wax (Transparent) 3M 08909/19/29
Cavity Wax Croda PW57
Engine bay waxes/lacquers
Astrolan Engine Bay Wax and Cosmetic Wax Astors DA3243/1
Engine Bay Cosmetic Wax/Lacquer Croda PW197
Engine Bay Cosmetic Wax/Lacquer Dinol 4010
Miscellaneous materials
Aerosol Auto Adhesive (Trim) - impact adhesive for trim parts 3M 08080
Flexible Parts Repair Material - rubber modified polypropylene parts 3M 05900
Waterproof Cloth Tape - sealing panel apertures 3M Y387/Y3998
Sound Dampening Foam Gurit-Essex Betacore 7999
Water Shedder Repair (Aerosol) Teroson
Seam sealers
Body Caulking - type (b) gaps between panels 3M 08568
Bolted Panel Sealer - between bolted panels 3M 08572
Drip Chek Clear - bolted, spot welded and bonded panel edges; type (a) and (b)
gaps between panels; type (c) clinch joints 3M 08401
Drip Chek Heavy - type (b) gaps between panels; type (c) clinch joints 3M 08531
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges; type
(a) and (b) gaps between panels; type (b) clinch joints3M 08684/89/94
Polyurethane Sealer (Sachet) - bolted panel edges; type (b) clinch joints 3M 08703/83/88
Sprayable Sealer - lap joints 3M 08800/23
Super Seam Sealer - lap joints; type (b) clinch joints 3M 08537
Weld Thru' Sealer - between spot welded panels 3M 08626
Betafill Clinch and Brushable Sealer - type (b) clinch joints Gurit-Essex 10211/15/20
Clinch, Joint and Underbody Coating - lap joints Gurit-Essex 10101/10707
Leak Chek Clear - between bolted panels; spot welded and bonded panel edges;
type (c) clinch joints; type (a) gaps between panels Kent Industries 10075
Putty - type (b) gaps between panels Kent Industries
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges;
between bonded panels; type (a) and (b) gaps between panels PPG 6500
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges;
between bonded panels; type (b) gaps between panels Teroson 92
Terolan Light Seam Sealer - bolted, spot welded and bonded panel edges; type
(a) and (b) gaps between panels; between bonded panels; type (c) clinch jointsTeroson
Terolan Special Brushable Seam Sealer - lap joints Teroson

BODY SEALING MATERIALS
77-3-4 MATERIALS AND APPLICATIONS
Application equipment
Manufacturers and suppliers
Suitable application equipment is available from the following manufacturers and suppliers:
3M
Automotive Trades Group
3M UK Plc
3M House
PO Box 1
Market Place
Bracknell
Berks
RG 12 1JU
( (01344) 858611
Cooper Pegler
Burgess Hill
Sussex
RH15 9LA
( (014 446) 42526
SATA Spray Equipment
Minden Industrial Ltd
16 Greyfriars Road
Moreton Hall
Bury St. Edmunds
Suffolk
IP32 7DX
( (01284) 760791
3M Body Schutz Pistol Spraygun 08996
A pistol type spraygun constructed from case and machined light alloy and designed for use with 3M screw fit Body
Schutz containers.
3M Caulking Gun MKIII 8002
A lightweight, robust metal skeleton gun designed to accept 325 mm (13 in) cartridge for dispensing sealants etc. This
gun provides rapid cartridge insertion and loading, with a quick-release lever for accurate control of material ejection
and shut-off.
3M Pneumatic Cartridge Gun 08012
Air line-fed gun for applying 3M cartridge products. Excellent for ease of application to obtain a smooth bead.
Regulator valve for additional control.
3M Pneumatic Applicator Guns
Air line-fed gun for application of 3M sachet sealers (Part Number 08006 for 200 ml and 310 ml sachet applications,
and Part Number 08007 for all size sachets including 600 ml).
Also available: Heavy Duty Manual Gun 08013.
3M Applicator Gun 08190.
For the application of 3M Structural Adhesive 08120.
3M Inner Cavity Wax Applicator Gun 08997
This equipment accepts 1-litre canisters and has a 750 mm (29.572 in) flexible tube.
The approved system is available from all 3M refinishing factors.

AIR CONDITIONING
82-2DESCRIPTION AND OPERATION
A/C control system component layout
RH drive shown, LH drive similar
1Air temperature control ECU
2Heater coolant temperature sensor
3Evaporator temperature sensor
4Dual pressure switch5Ambient temperature sensor
6Sunlight sensor
7In-car temperature sensor

AIR CONDITIONING
82-10DESCRIPTION AND OPERATION
Temperature and distribution control
Figure shows flaps set for medium heat to face level and footwell outlets
1Windscreen/Side windows outlet
2Heater assembly casing
3Air inlet
4Evaporator5Heater matrix
6Front footwells outlet
7Rear footwells outlet
8Face level outlet
Control system
The control system operates the refrigerant system and the control flaps in the heater assembly to control the
temperature and distribution of air in the vehicle interior. It also outputs signals to the fresh/recirculated air servo motor
and the blower to control the volume and source of inlet air. The control system consists of:
lAn Air Temperature Control (ATC) ECU.
lA dual pressure switch.
lAn evaporator temperature sensor.
lAn in-car temperature sensor.
lA sunlight sensor.
lA heater coolant temperature sensor.
lAn ambient temperature sensor.

AIR CONDITIONING
DESCRIPTION AND OPERATION 82-11
ATC ECU
The ATC ECU is installed in the centre of the fascia, below the radio. An integral control panel on the ATC ECU
contains switches for system control inputs and a LCD to provide system status information.
Inputs from sensors and the control panel switches are processed by the ATC ECU, which then outputs the
appropriate control signals.
ATC ECU connectors
ATC ECU connector pin details
Connector/Pin
No.Description Input/Output
C0791
1 Battery power supply Input
2 Ignition power supply Input
3 Sensor power supply Output
4Earth -
5 Display illumination Input
6 Not used -
7 Not used -
8 Sensor earth -
C0792
1 Night lighting/dimming Input
2 Vehicle speed Input
3 Hand of drive Input
4 Distribution flaps position Input
5 Heater coolant temperature Input
6 External air temperature Input
7 In-car air temperature Input
8 Blower power transistor collector voltage Input
9 Not used -
10 Not used -
11 Windscreen heater status Input
12 Rear screen heater status Input
13 Rear air conditioning ON Input

AIR CONDITIONING
82-14DESCRIPTION AND OPERATION
Display outputs
1LH temperature
2Economy mode
3Recirculated air
4Automatic mode5Manual distribution
6RH temperature
7Blower speed
8External air temperature
Outputs on the display are shown at full brightness when the exterior lights are off, and dimmed when the exterior
lights are on.
LH temperature. Illuminates to show the LH temperature selection, the temperature scale or that the ATC ECU is in
diagnostic mode.
Economy mode. Illuminates when the compressor is manually selected off with the ECON switch.
Recirculated air. Illuminates when the inlet air is manually selected to recirculated mode.
Automatic mode. Illuminates the AUTO legend and related symbol(s) when the blower speed, air distribution or
temperature control are in the automatic mode.
Manual distribution. Illuminates the appropriate symbol(s) to show the manually selected air distribution. Also
illuminates in the automatic modes when one of the temperatures is set to LO or HI.
RH temperature. Illuminates to show the RH temperature selection, external air temperature or diagnostic fault code.
Blower speed. Illuminates when the blower speed is manually selected. Also illuminates in the automatic modes when
one of the temperatures is set to LO or HI.
External air temperature. EXT illuminates to show that external air temperature is selected on.
All temperature indications on the display are in either °C or °F. For 1 second after the system is first switched on, the
display shows only °C or °F, in the LH temperature window, to indicate which temperature scale is in use. After 1
second, the °C or °F indication goes off and the display shows all relevant outputs.
Temperature conversion: While the system is on, the temperature indications on the display can be switched between
the two scales by pressing and holding the fresh/recirculated air switch, then pressing and holding the A/C on/off
switch until the audible warning sounds (approximately 3 seconds).

AIR CONDITIONING
DESCRIPTION AND OPERATION 82-15
Dual pressure switch
The dual pressure switch protects the refrigerant system from extremes of pressure. The normally closed switch is
installed in the top of the receiver drier. If minimum or maximum pressure limits are exceeded the switch contacts
open, causing the compressor clutch to be disengaged. The minimum pressure limit protects the compressor, by
preventing operation of the system unless there is a minimum refrigerant pressure (and thus refrigerant and
lubricating oil) in the system. The maximum pressure limit keeps the refrigerant system within a safe operating
pressure.
Dual pressure switch nominal operating pressures
Evaporator temperature sensor
The evaporator temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input of the
evaporator air outlet temperature. The evaporator temperature sensor is installed in a clip which locates in the
evaporator matrix in the heater assembly. The ATC ECU uses the input to prevent the formation of ice on the
evaporator.
In-car temperature sensor
The in-car temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input of cabin air
temperature. The sensor is integrated into the inlet of an electric fan, which is installed behind a grille in the fascia
outboard of the steering column. The fan runs continuously, while the ignition is on, to draw air through the grille and
across the sensor.
Sunlight sensor
The sunlight sensor consists of two diodes that provide the ATC ECU with inputs of light intensity, one as sensed
coming from the left of the vehicle and one as sensed coming from the right. The inputs are used as a measure of the
solar heating effect on vehicle occupants. The sensor is installed in the centre of the fascia upper surface.
Heater coolant temperature sensor
The heater coolant temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input related
to heater matrix coolant temperature. The sensor is installed in the casing of the heater assembly and presses against
the end tank of the heater matrix.
Ambient temperature sensor
The ambient temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input of external
air temperature. The sensor is attached to the cooling fan mounting bracket in front of the condenser.
Limit Opening pressure, bar (lbf.in2) Closing pressure, bar (lbf.in2)
Minimum 2.0 (29.0), pressure decreasing 2.3 (33.4), pressure increasing
Maximum 32 (464), pressure increasing 26 (377), pressure decreasing

AIR CONDITIONING
DESCRIPTION AND OPERATION 82-19
Diagnostics
The ATC ECU performs a diagnostic check each time the ignition is switched on. To avoid nuisance fault indications
at low light levels, the sunlight sensor is omitted from the diagnostic check. If a fault is detected, the audible warning
sounds three times and the AUTO window on the control panel display flashes for 20 seconds. The ATC ECU then
reverts to normal control but uses a default value or strategy for the detected fault. Faults are identified by performing
a manual diagnostic check of the system.
A manual diagnostic check includes a check of the sunlight sensor, and is initiated by pressing and holding the AUTO
switch and the air distribution switch, then turning the ignition switch from off to on. The audible warning sounds once
and the indications on the control panel display illuminate. FC is shown in the LH temperature window and the results
of the check are shown as a two digit fault code in the RH temperature window. If a fault is detected, the audible
warning sounds three times and the AUTO window on the display flashes on and off for 20 seconds. If more than one
fault is detected, the fault codes cycle in numerical order, at 1 Hz. The audible warning sounds as each fault code is
shown. In low light conditions, to avoid false sunlight sensor fault indications, the sunlight sensor should be illuminated
with a strong light source.
Diagnostic fault codes and fault descriptions
Code Component Fault Default value/strategy
00 - No fault found -
11 In-car temperature sensor Open or short circuit 25°C (77°F)
12 Ambient temperature sensor Open or short circuit 10°C (50°F)
Cooling fan permanently on
Display shows "- -" if external air
temperature selected
13 Thermistor Open or short circuit 0°C (32°F)
14 Heater coolant temperature sensor Open or short circuit 70°C (158°F)
21 Sunlight sensor, left output Open or short circuit No solar heating correction
22 Sunlight sensor, right output Open or short circuit No solar heating correction
31 LH temperature servo motor Open or short circuit
Motor or flap mechanism seizedServo motor locked in position
32 RH temperature servo motor Open or short circuit
Motor or flap mechanism seizedServo motor locked in position
33 Distribution servo motor Open or short circuit
Motor or flap mechanism seizedServo motor locked in position