warning LAND ROVER DISCOVERY 1999 Workshop Manual

RESTRAINT SYSTEMS
75-22 REPAIRS
Airbag module - drivers
$% 76.74.01
WARNING: It is imperative that before any work
is undertaken on the SRS system the appropriate
information is read thoroughly.
WARNING: Always disconnect both battery leads
before beginning work on the SRS system.
Disconnect the negative battery lead first. Never
reverse connect the battery.
Remove
1.Remove the key from the starter switch.
Disconnect both battery leads, negative lead
first. Wait ten minutes before starting work.
2.Remove 2 Torx bolts securing air bag module
to steering wheel.
3.Release air bag module from steering wheel.
CAUTION: Do not allow the air bag module
to hang by the air bag harness.
4.Disconnect multiplug from air bag module. 5.Remove air bag module.
WARNING: Store the airbag module with the
deployment side uppermost. If it is stored
deployment side down, accidental
deployment will propel the airbag module
with enough force to cause serious injury.
WARNING: Store the airbag module or seat
belt pre-tensioner in a designated storage
area. If there is no designated storage area
available, store in the locked luggage
compartment/loadspace of the vehicle and
inform the workshop supervisor.
Refit
NOTE: If the airbag module is to be replaced,
the bar code of the new module must be
recorded.
1.Position air bag module and connect multiplug.
2.Fit air bag module to steering wheel and tighten
Torx bolts to 9 Nm (7 lbf.ft).
3.Connect battery leads, earth lead last.

RESTRAINT SYSTEMS
REPAIRS 75-23
Airbag module - passenger
$% 76.74.02
WARNING: It is imperative that before any work
is undertaken on the SRS system the appropriate
information is read thoroughly.
WARNING: Always disconnect both battery leads
before beginning work on the SRS system.
Disconnect the negative battery lead first. Never
reverse connect the battery.
Remove
1.Remove the key from the starter switch.
Disconnect both battery leads, negative lead
first. Wait ten minutes before starting work.
2.Release guides supporting glove box.
3.Lower glove box to gain access to air bag
module.4.Disconnect multiplug from air bag module.
5.Remove 4 Torx bolts securing air bag module
to fascia.
6.Remove air bag module from fascia panel.
WARNING: Store the air bag module with
the deployment side uppermost. If it is
stored deployment side down, accidental
deployment will propel the air bag module
with enough force to cause serious injury.
WARNING: Store the air bag module or seat
belt pre-tensioner in a designated storage
area. If there is no designated storage area
available, store in the luggage compartment
of the vehicle and inform the workshop
supervisor.
Refit
NOTE: If the air bag module is to be replaced,
the bar code of the new module must be
recorded.
1.Fit air bag module to fascia and tighten Torx
bolts to 8 Nm (6 lbf.ft).
2.Connect multiplug to air bag module.
3.Position glove box and engage supporting
guides. Close glove box.
4.Connect battery leads, earth lead last.

RESTRAINT SYSTEMS
75-24 REPAIRS
DCU
$% 76.74.06
WARNING: It is imperative that before any work
is undertaken on the SRS system the appropriate
information is read thoroughly.
WARNING: Always disconnect both battery leads
before beginning work on the SRS system.
Disconnect the negative battery lead first. Never
reverse connect the battery.
Remove
1.Remove the key from the starter switch.
Disconnect both battery leads, negative lead
first. Wait ten minutes before starting work.
2.Remove centre console.
lOn manual gearbox models:

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
lOn automatic gearbox models:

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
3.Disconnect multiplug from DCU.
4.Remove 3 Torx bolts securing DCU to body and
remove DCU.
CAUTION: The SRS diagnostic control unit
is a non-serviceable component and no
attempt should be made to repair or modify
the unit.Refit
CAUTION: The SRS diagnostic control unit
is a shock sensitive device and must be
handled with extreme care.
1.Position DCU to body and connect multiplug.
2.Fit and tighten DCU Torx bolts to 10 Nm (7
lbf.ft).
3.Fit centre console.
lOn manual gearbox models:

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
lOn automatic gearbox models:

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
4.Connect battery leads, earth lead last.

RESTRAINT SYSTEMS
REPAIRS 75-25
Air bag - steering wheel - deployment -
off vehicle
$% 76.74.16
These guidelines are written to aid authorised
personnel to carry out the safe disposal of air bag
modules when removed from the vehicle.
Deploy
It is imperative that before any work is
undertaken on the SRS system, the
appropriate information is read thoroughly.
1.Check condition of deployment tool LRT-86-
003 and associated fly leads.
2.Position LRT-86-007/02 in vice, ensuring that
vice jaws grip tool above the bottom flange to
prevent possibility of tool being forced upwards
during detonation. Tighten vice.
3.Fit and secure 2 off LRT-86-007/05 to LRT-86-
007/02.4.Fit and secure air bag to LRT-86-007/05.
5.Connect deployment tool fly lead LRT-86-003/
08 to air bag.
6.Connect deployment tool LRT-86-003 to
deployment tool fly lead LRT-86-003/08.
7.Connect deployment tool LRT-86-003 to
battery.
WARNING: Ensure all personnel are at least
15 metres (50 feet) away from the air bag
module.
8.Press deployment tool operating button to
deploy air bag module.
9.Disconnect deployment tool from battery.
WARNING: During deployment parts of the
air bag module become hot enough to burn
you. Wait 30 minutes after deployment
before touching the air bag module.
10.Disconnect deployment tool fly lead from air
bag.
11.Remove air bag module from holding tools and
place in a sealed bag, ready for disposal.
NOTE: Do not transport deployed SRS
components in the vehicle passenger
compartment.
12.Wipe down holding tools with a damp cloth and
remove from vice.
13.Transport deployed air bag module to
designated area for incineration.
14. Do not re-use or salvage any parts of the
SRS system.

RESTRAINT SYSTEMS
REPAIRS 75-27
6.Connect deployment tool fly lead LRT-86-003/
04 to air bag.
7.Connect deployment tool LRT-86-003 to
deployment tool fly lead LRT-86-003/04.
8.Connect deployment tool LRT-86-003 to
battery.
WARNING: Ensure all personnel are at least
15 metres (50 feet) away from the air bag
module.
9.Press deployment tool operating button to
deploy air bag module.
10.Disconnect deployment tool from battery.
WARNING: During deployment parts of the
air bag module become hot enough to burn
you. Wait 30 minutes after deployment
before touching the air bag module.
11.Disconnect deployment tool fly lead from air
bag.
12. Do not re-use or salvage any parts of the
SRS system.
NOTE: Do not transport deployed SRS
components in the vehicle passenger
compartment.
Air bag - fascia - passenger - deployment
- off vehicle
$% 76.74.18
These guidelines are written to aid authorised
personnel to carry out the safe disposal of air bag
modules when removed from the vehicle.
Deploy
It is imperative that before any work is
undertaken on the SRS system, the
appropriate information is read thoroughly.
1.Check condition of deployment tool LRT-86-
003 and associated fly leads.
2.Position LRT-86-007/03 in vice, ensuring that
vice jaws grip tool above the bottom flange to
prevent possibility of tool being forced upwards
during detonation. Tighten vice.
3.Fit and secure 2 off LRT-86-007/04 to LRT-86-
007/03.

RESTRAINT SYSTEMS
75-28 REPAIRS
4.Fit and secure air bag to LRT-86-007/04.
5.Connect deployment tool fly lead LRT-86-003/
08 to air bag.
6.Connect deployment tool LRT-86-003 to
deployment tool fly lead LRT-86-003/08.
7.Connect deployment tool LRT-86-003 to
battery.
WARNING: Ensure all personnel are at least
15 metres (50 feet) away from the air bag
module.
8.Press deployment tool operating button to
deploy air bag module.
9.Disconnect deployment tool from battery.
WARNING: During deployment parts of the
air bag module become hot enough to burn
you. Wait 30 minutes after deployment
before touching the air bag module.
10.Disconnect deployment tool fly lead from air
bag.
11.Remove air bag module from holding tools and
place in a sealed bag, ready for disposal.
NOTE: Do not transport deployed SRS
components in the vehicle passenger
compartment.
12.Wipe down holding tools with a damp cloth and
remove from vice.
13.Transport deployed air bag module to
designated area for incineration.
14. Do not re-use or salvage any parts of the
SRS system.
M76 4621
LRT-86-007/04
LRT-86-003/08
LRT-86-003

RESTRAINT SYSTEMS
REPAIRS 75-29
Rotary coupler
$% 76.74.20
WARNING: It is imperative that before any work
is undertaken on the SRS system the appropriate
information is read thoroughly.
WARNING: Always disconnect both battery leads
before beginning work on the SRS system.
Disconnect the negative battery lead first. Never
reverse connect the battery.
Remove
1.Remove the key from the starter switch.
Disconnect both battery leads, negative lead
first. Wait ten minutes before starting work.
2.Remove steering wheel.

+ STEERING, REPAIRS, Steering
wheel.
3.Remove steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
steering column.4.Release rotary coupler multiplug from bracket
and disconnect from harness.
5.Disconnect rotary coupler multiplug from
harness.
6.Remove rotary coupler.
Refit
1.Fit rotary coupler to steering column and
connect multiplug to harness.
2.Connect rotary coupler multiplug to harness
and secure to bracket.
3.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
steering column.
4.Fit steering wheel.

+ STEERING, REPAIRS, Steering
wheel.

EXTERIOR FITTINGS
REPAIRS 76-2-7
Panel - underbelly
$% 76.10.50
Remove
1.Raise front of vehicle, support underbody and
lower front axle
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove nut securing drag link to drop arm.
3.Using tool LRT-57-036 break taper joint and
release drag link from drop arm.
4.Remove nut and bolt securing steering damper
to chassis and remove damper.
5.Remove 7 screws securing underbelly panel.
6.Remove underbelly panel.
7.Remove 7 studs securing sound deadening to
underbelly panel.
8.Remove sound deadening.
Refit
1.Position sound deadening to underbelly panel
and secure with studs.
2.Fit underbelly panel and secure with screws.
3.Position steering damper, fit nut and bolt and
tighten to 125 Nm (92 lbf.ft)
4.Fit drag link to drop arm and tighten nut to 80
Nm (59 lbf.ft).
5.Lower front of vehicle.
Mirror - exterior - electric
$% 76.10.57
Remove
1.Release cheater panel from front door.
2.Remove anti-rattle foam pad from front door.
3.Release mirror multiplug from mounting plate.
4.Disconnect multiplug from mirror.
5.Remove 3 bolts securing mirror to door.
6.Remove mirror and collect mounting plate.
Refit
1.Fit mirror and mounting plate to door.
2.Fit bolts securing mirror to door and tighten to
4 Nm (3 lbf.ft).
3.Connect multiplug to mirror.
4.Secure multiplug to mounting plate.
5.Fit anti-rattle foam pad to front door.
6.Secure cheater panel to front door.

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
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.