lock LAND ROVER DISCOVERY 1999 Workshop Manual

BRAKES
70-26 DESCRIPTION AND OPERATION
Description
General
The handbrake consists of a drum brake, installed on the rear of the transfer box, operated by a cable connected to
a handbrake lever between the front seats.
Handbrake lever
The handbrake lever is mounted on a base plate which attaches to the transmission tunnel. A conventional ratchet
and thumb operated release button are incorporated for locking and unlocking the lever. A warning switch on the base
of the lever operates the brake warning lamp in the instrument pack. While the handbrake is applied the warning
switch connects an earth to the instrument pack which, if the ignition is on, illuminates the brake warning lamp. In
some markets, the instrument pack performs a bulb check of the brake warning lamp each time the ignition is switched
on.
Cable
The handbrake cable consists of inner and outer cables installed between the handbrake lever and the drum brake.
A protective sleeve is installed on the cable to protect the cable from heat from the exhaust system. Handbrake
adjustment is provided by a threaded sleeve installed on the outer cable where it locates in the handbrake lever.
Turning an adjuster wheel, which is keyed to the threaded sleeve and secured by a 'C' clip, alters the effective length
of the outer sleeve and consequently changes the handbrake lever movement needed to apply the drum brake.

BRAKES
ADJUSTMENTS 70-29
ADJUST ME NTS
Handbrake
$% 70.45.09
Check
1.Apply the handbrake lever 3 notches on the
ratchet. The handbrake should be fully
operational.
2.If the handbrake is not fully operational, the
brake shoes and/or the handbrake cable need
adjusting.
Adjust
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Ensure handbrake lever is fully released.
3.Tighten brake shoe adjusting bolt until brake
drum is locked, then back off adjusting bolt 1.5
turns. Check that the brake drum is free to
rotate.
4.Recheck handbrake operation.If handbrake is
not fully applied with 3 notches on the
ratchet, the handbrake cable requires
adjustment.
5.Remove switch panel from centre console.

+ WINDOWS, REPAIRS, Switch -
console.
6.Release handbrake lever gaiter from centre
console.7.Rotate adjuster anti-clockwise to increase
cable tension (reduce notches) or clockwise to
decrease cable tension (increase notches).
8.Recheck handbrake operation.
9.Secure handbrake lever gaiter to centre
console.
10.Fit switch panel to centre console.

+ WINDOWS, REPAIRS, Switch -
console.
11.Remove stand(s) and lower vehicle.

BRAKES
REPAIRS 70-47
ECU - Self levelling and anti locking
brakes (SLABS)
$% 70.65.01
Remove
1.Remove BCU.

+ BODY CONTROL UNIT, REPAIRS,
Body control unit (BCU).
2.Remove 5 multiplugs from SLABS ECU.
3.Remove multiplug from ACE ECU.
4.Remove lower nut and loosen upper nut
securing SLABS and ACE ECU bracket to
body.
5.Remove ECU's and bracket assembly. 6.Remove 4 nuts securing SLABS ECU and
remove ECU.
Refit
1.Fit new SLABS ECU to bracket and secure with
nuts.
2.Fit ECU's and bracket assembly to body and
secure with nuts.
3.Connect multiplugs to ACE ECU and SLABS
ECU.
4.Fit BCU.

+ BODY CONTROL UNIT, REPAIRS,
Body control unit (BCU).
5.Programme the new SLABS ECU using
TestBook.

RESTRAINT SYSTEMS
75-2 DESCRIPTION AND OPERATION
SRS block diagram
1DCU
2SRS warning lamp
3Driver airbag module4Driver seat belt pretensioner
5Passenger airbag module
6Passenger seat belt pretensioner

RESTRAINT SYSTEMS
DESCRIPTION AND OPERATION 75-11
DESCRIPTION AND OPERAT ION
Description - seat belts
An inertia reel, three point seat belt is installed at each seat position. The inertia reels incorporate a liftshaft locking
system with webbing sensor and car sensor activating mechanisms. The webbing sensor activates the locking system
if the webbing is subjected to a sharp pull. The car sensor activates the locking system if the vehicle is subjected to
sudden deceleration or a severe tilt angle.
Front seat belts
The inertia reel of each front seat belt is attached to the related B/C post, behind the finishers. The webbing runs from
the inertia reel, through a height adjuster, to an anchor point at the base of the B/C post. The buckle assembly for
each belt is attached to the inboard side of the seat and contains the SRS pretensioner.
Rear seat belts
The inertia reels for the outboard rear seats are attached to the body behind the loadspace side trim casings. The
webbing runs from each inertia reel through an upper mounting, suspended from the cantrail, to an anchor point on
the rear wheel arch.
The inertia reel of the centre rear seat is mounted in the back of the seat. The webbing runs through a guide on the
top of the seat and is anchored to one of the seat hinge points. The buckles for the rear seat belts are also attached
to the seat hinge points.
Third row seat belts
The inertia reel of each third row rear seat belt is attached to the related E post, behind the loadspace side trim
casing.The webbing runs from the inertia reel, through an upper mounting on the E post to an anchor point on the
loadspace floor. The buckle is mounted on the inboard side of the seat.

RESTRAINT SYSTEMS
75-18 REPAIRS
Pre-tensioner - front seat belt
$% 76.73.30
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 front seat.

+ SEATS, REPAIRS, Seat - front.
3.Release cable tie securing pre-tensioner
harness to seat.
4.Remove Torx screw securing pre-tensioner to
seat.
5.Remove pre-tensioner.
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
1.Fit pre-tensioner to seat and tighten Torx bolt to
32 Nm (24 lbf.ft).
2.Secure harness to seat with new cable tie.
3.Fit front seat.

+ SEATS, REPAIRS, Seat - front.
4.Connect battery leads, earth lead last.

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.

DOORS
REPAIRS 76-1-1
DOORS REPAIRS
Door - front
$% 76.28.01.99
Remove
1.Release 'A' post lower trim and position aside.
2.Release and disconnect multiplugs from lower
'A' post.
3.Release harness sleeve and pull harness
through 'A' post.
4.Remove roll pin from door check strap.
5.Release check strap from 'A' post.
6.Discard roll pin.
7.Remove 2 'C' clips from door hinges.
8.With assistance raise and remove door. Refit
1.With assistance position door to hinges.
2.Fit 'C' clips to hinge pins.
3.Position check strap to 'A' post and secure with
new roll pin.
4.Feed door harness through 'A' post.
5.Connect and secure multiplugs at lower 'A'
post.
6.Connect harness sleeve to 'A' post and door.
7.Fit 'A' post finisher.
8.Check door for flush fit to adjacent panels and
door edges for equal gap. If adjustment is
necessary:
aOpen door
bPlace a wooden block on jack and position
jack to support door lower edge.
cLoosen 4 bolts securing hinges to door.
dLoosen 2 Torx bolts securing door latch
striker.
eUse jack to assist with door alignment.
fTighten hinge bolts.
gRemove jack, close door and check for
correct alignment.
hWhen alignment is correct, tighten door
hinge bolts to 30 Nm (22 lbf.ft).
iAdjust door latch striker and tighten Torx
bolts to 26 Nm (19 lbf.ft).

DOORS
76-1-2 REPAIRS
Door - rear
$% 76.28.02.99
Remove
1.Release 'B' post lower trim casing and position
aside.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
2.Release multiplugs from within 'B' post and
disconnect.
3.Release harness sleeve and pull through 'B'
post.
4.Remove roll pin from check strap and discard.
5.Release check strap from 'B' post.
6.Remove 2 'C' clips securing door to each hinge.
7.With assistance raise and remove door. Refit
1.With assistance position door to hinges.
2.Fit 'C' clips to hinge pins.
3.Position check strap to 'B' post and secure with
new roll pin.
4.Feed door harness through 'B' post and
connect multiplugs.
5.Connect harness sleeve to 'B' post and door.
6.Fit 'B' post lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
7.Check door for flush fit to adjacent panels and
door edges for equal gap. If adjustment is
necessary:
aOpen door.
bPlace a wooden block on jack and position
jack to support door lower edge.
cLoosen 4 bolts securing hinges to door.
dLoosen 2 Torx bolts securing door latch
striker.
eUse jack to assist with door alignment.
fTighten hinge bolts.
gRemove jack, close door and check for
correct alignment.
hWhen alignment is correct, tighten door
hinge bolts to 30 Nm (22 lbf.ft).
iAdjust door latch striker and tighten Torx
bolts to 26 Nm (19 lbf.ft).

DOORS
REPAIRS 76-1-3
Door - tail
$% 76.28.19.99
Remove
1.Remove spare wheel from tail door.
2.Remove tail door trim casing.

+ DOORS, REPAIRS, Trim casing - tail
door.
3.Carefully release water shedder from tail door.
4.Disconnect multiplug from door latch.
5.Disconnect multiplug from rear wiper motor.
6.Disconnect 2 Lucars from Heated Rear
Window (HRW).
7.Disconnect multiplug from number plate lamp.
8.Remove 2 screws securing Centre High
Mounted Stop Lamp (CHMSL) cover to tail door
glass.
9.Remove CHMSL cover.
10.Disconnect 2 Lucars from CHMSL.
11.Attach draw string to CHMSL wires and draw
wires through tail door. Disconnect draw string
from wires.
12.Tape draw string in tail door to retain its
position.
13.Release washer tube from rear of wiper arm. 14.Release 3 clips securing harness to tail door.
15.Release harness sleeve from door outer edge
and feed harness and washer tube through
door.
16.Remove spring clip securing check strap to tail
door aperture and collect washer.
17.Mark position of hinges.
18.Support the tail door on a jack, using a block of
wood to protect the door.
19.Remove 6 bolts securing tail door hinges to
body and, with assistance, remove tail door.