lock LAND ROVER DISCOVERY 1999 Workshop Manual

DOORS
76-1-4 REPAIRS
Refit
1.Support the tail door on a jack, using a block of
wood to protect the door.
2.With assistance position door. Fit securing
bolts but do not tighten at this stage.
3.Fit washer and spring clip securing check strap
to aperture.
4.Adjust position of tail door in relation to
aperture, ensuring gaps around all 4 edges
are consistent, and door closes cleanly onto
dove tail.
5.When tail door is correctly adjusted, tighten tail
door hinge bolts to 34 Nm (25 lbf.ft).
6.Feed harness and washer tube through outer
edge of door and connect harness sleeve to
door.
7.Secure harness to tail door with clips.
8.Connect washer tube to rear of wiper arm.
9.Remove tape from draw string and secure to
CHMSL wires.
10.Draw wires through tail door and connect
Lucars to CHMSL.
11.Fit CHMSL cover and secure with screws.
12.Connect multiplug of number plate lamp.
13.Connect Lucars to HRW.
14.Connect multiplug to rear wiper motor.
15.Connect multiplug to door latch.
16.Fit water shedder to door.
17.Fit tail door trim casing.

+ DOORS, REPAIRS, Trim casing - tail
door.
18.Fit spare wheel to tail door.

DOORS
REPAIRS 76-1-11
Latch and motor - front door
$% 76.37.12
Remove
1.Remove front door frame.

+ DOORS, REPAIRS, Glass - front or
rear door.
2.Release exterior handle control rod from latch.
3.Release and disconnect sill button lock rod
from latch.
4.Disconnect multiplug from motor.
5.Remove 3 Torx screws securing latch and
motor assembly to door.
6.Remove latch and motor assembly through
aperture in the lower section of the door. 7.Disconnect release cable from latch and
remove latch and motor assembly.
Refit
1.Connect release cable to latch.
2.Position latch and motor assembly to door. Fit
Torx screws securing latch to door and tighten
to 7 Nm (5.2 lbf.ft).
3.Connect multiplug to motor.
4.Connect exterior handle control rod to latch.
5.Connect sill button lock rod to latch.
6.Fit front door frame.

+ DOORS, REPAIRS, Glass - front or
rear door.

DOORS
76-1-12 REPAIRS
Latch and motor - rear door
$% 76.37.13
Remove
1.Remove rear door frame.

+ DOORS, REPAIRS, Glass - front or
rear door.
2.Release exterior handle control rod from latch.
3.Release sill button lock rod from door latch.
4.Disconnect multiplug from motor.
5.Remove 3 Torx screws securing latch and
motor assembly to door.
6.Remove latch and motor assembly through
lower aperture in door. 7.Open security flap on latch.
8.Disconnect release cable from latch.
Refit
1.Connect release cable to latch and close
security flap.
2.Position latch to door, fit Torx screws securing
latch to door and tighten to 7 Nm (5.2 lbf.ft).
3.Connect multiplug to motor.
4.Connect exterior handle control rod to latch.
5.Connect sill button lock rod to latch.
6.Fit rear door frame.

+ DOORS, REPAIRS, Glass - front or
rear door.

DOORS
REPAIRS 76-1-13
Latch and motor - tail door
$% 76.37.16
Remove
1.Remove tail door trim casing.

+ DOORS, REPAIRS, Trim casing - tail
door.
2.Carefully release water shedder from tail door.
3.Release and remove control rod from exterior
handle and latch.
4.Release and remove sill button lock rod.
5.Disconnect multiplug from motor.
6.Remove release cable from clip.
7.Remove 3 Torx screws securing latch and
motor assembly to door.
8.Remove door latch.
9.Disconnect release cable from latch.
Refit
1.Connect release cable to latch.
2.Position door latch and motor assembly, secure
with Torx screws and tighten to 7 Nm (5.2 lbf.ft).
3.Position control rod and connect to exterior
handle and latch.
4.Position sill button lock rod and connect to
latch.
5.Secure release cable in clip.
6.Connect multiplug to motor.
7.Fit water shedder to door.
8.Fit tail door trim casing.

+ DOORS, REPAIRS, Trim casing - tail
door.
Handle - exterior - rear door
$% 76.58.02
Remove
1.Remove rear door trim casing.

+ DOORS, REPAIRS, Trim casing -
rear door.
2.Carefully release water shedder from door.
3.Release control rod from latch.
4.Remove Torx bolt securing exterior handle to
door.
5.Remove exterior handle.
6.Remove control rod from exterior handle.
Refit
1.Fit control rod to exterior handle.
2.Position exterior handle and secure to door with
Torx bolt.
3.Connect control rod to latch.
4.Fit water shedder to door.
5.Fit rear door trim casing.

+ DOORS, REPAIRS, Trim casing -
rear door.

EXTERIOR FITTINGS
76-2-4 REPAIRS
Refit
1.Clean front wing body mounting brackets.
2.Fit and secure the front wheel arch finisher to
the front wing.
3.Position lower support bracket to the front wing,
fit nut and tighten to 8 Nm (6 lbf.ft).
4.Position front wing to body, fit bracket and bolts
but do not tighten at this stage.
5.Check and adjust alignment of the front wing to
the bonnet and door.
6.Tighten the front wing retaining bolts to 8 Nm (6
lbf.ft).
7.Fit bonnet sealing rubber to the front wing
flange.
8.Fit bolt securing lower support bracket to the
body and tighten to 8 Nm (6 lbf.ft).
9.Fit nut securing sill finisher to the front wing
lower support bracket and tighten to 8 Nm (6
lbf.ft).
10.Fit bolt securing front wing to the front support
bracket and tighten to 8 Nm (6 lbf.ft).
11.Fit side repeater lamp to the front wing and
connect the multiplug.
12.Fit front wheel arch liner extension panel to the
front bumper and secure with screws.
13.Fit and tighten screw securing front wheel arch
liner extension panel to the inner wing.
14.Fit the front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - front.
15.Fit the headlamp assembly.

+ LIGHTING, REPAIRS, Headlamp -
from 03MY.
Rear folding step
$% 76.10.41
Remove
1.Remove 2 bolts securing step and damper
assembly to chassis.
2.Remove step and damper assembly.
3.Remove 2 patch lock nuts securing damper to
step and discard nuts.
4.Remove damper from step.
Refit
1.Fit damper to step and secure with new patch
lock nuts. Tighten nuts to 17 Nm (13 lbf.ft).
2.Position step and damper assembly to chassis
and secure with bolts. Tighten bolts to 45 Nm
(33 lbf.ft).

EXTERIOR FITTINGS
REPAIRS 76-2-9
Bonnet
$% 76.16.01.99
Remove
1.Support bonnet in open position.
2.Fit protection covers to wings and mark hinge
outline on bonnet if bonnet is to be refitted.
3.Disconnect windscreen washer tube at elbow
joint.
4.With assistance, remove bolts securing hinges
to bonnet and remove bonnet.
Refit
1.With assistance, position bonnet to hinges. Fit
and lightly tighten bolts.
2.Connect windscreen washer tube.
3.Close bonnet. Check that bonnet is aligned to
both front wings and that gaps are equal. If
necessary, adjust bonnet alignment and/or
gaps.
4.Finally tighten hinge bolts to 25 Nm (18 lbf.ft).
Cable - bonnet release - up to 03MY
$% 76.16.29
Remove
1.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
2.Release LH headlamp from adjuster pin
sockets.
3.Disconnect 2 multiplugs from headlamp and
remove headlamp.
4.Drill out 4 rivets securing bonnet lock shield to
bonnet platform and remove shield.
5.Disconnect bonnet release cable inner and
outer from lock.

EXTERIOR FITTINGS
76-2-10 REPAIRS
6.Remove 4 fasteners securing LH fascia closing
panel to fascia and remove panel.
7.Remove 2 nuts securing bonnet release lever
assembly to body.
8.Remove bonnet release cable from lever
assembly.
9. Diesel models: Pull sound insulation away
from bulkhead for access to bonnet release
cable grommet. 10.Remove grommet from engine bulkhead.
11.Tie a draw string to end of bonnet release
cable in passenger compartment.
12.Pull bonnet release cable, from bonnet lock
end, until whole of cable is released.
13.Untie draw string from bonnet release cable
and remove cable.
14.Remove grommet from cable.
Refit
1.Fit grommet to bonnet release cable.
2.Tie draw string to passenger compartment end
of bonnet release cable.
3.Use draw string to pull bonnet release cable
into position.
4.Fit grommet to engine bulkhead.
5.Untie draw string from bonnet release cable.
6.Position bonnet release lever assembly and
connect bonnet release cable to lever.
7.Fit release lever assembly to body and tighten
nuts to 10 Nm (7 lbf.ft) .
8.Connect bonnet release cable to lock.
9.With assistance, operate bonnet release lever
and check for correct operation of lock.
10.Fit fascia closing panel and secure with
fasteners.
11.Fit bonnet lock shield and secure with rivets.
12.Position headlamp to body, connect multiplugs
and fit headlamp to sockets.
13.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.

EXTERIOR FITTINGS
REPAIRS 76-2-11
Cable - bonnet release - from 03MY
$% 76.16.29
Remove
1.Remove the front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - from 03MY.
2.Drill out 4 rivets securing bonnet lock shield to
the bonnet locking platform and remove the
shield.
3.Disconnect bonnet release cable from the
bonnet lock.
4.Disconnect bonnet release cable from the front
panel retaining clip.5.Remove 2 nuts securing bonnet release lever
to the 'A' post.
6.Disconnect bonnet release cable from the
bonnet release lever.
7.Remove bonnet release cable grommet from
the bulkhead.
8.Remove the bonnet release cable.
9.Remove grommet from the bonnet release
cable.
Refit
1.Fit grommet to the bonnet release cable.
2.Position bonnet release cable to body and
connect to the bonnet release lever.
3.Position bonnet release lever to 'A' post, fit nuts
and tighten to 10 Nm (7 lbf.ft).
4.Fit bonnet release cable grommet to the
bulkhead.
5.Connect bonnet release cable to the bonnet
lock.
6.Align timing mark on bonnet release cable to
retaining clip and secure to the clip.
7.With assistance operate bonnet release lever
and check for the correct operation of the lock.
8.Fit bonnet lock shield and secure with rivets
9.Fit the front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - from 03MY.
M76 4573
M76 3029B
M76 4574

EXTERIOR FITTINGS
REPAIRS 76-2-17
Grille - front - from 03MY
$% 76.55.03
Remove
1.Remove 3 scrivets securing front grille to
bonnet locking platform.
2.Remove front grille.
NOTE: Do not carry out further dismantling if
component is removed for access only.
3.Remove motif from front grille.
Refit
1.Clean front grille to motif mating face.
2.Fit and secure motif to front grille.
3.Fit front grille and secure with scrivets.

INTERIOR TRIM COMPONENTS
76-3-16 REPAIRS
Louvre panel assembly - centre fascia
$% 76.46.42
Remove
1.Remove radio cassette player from fascia.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio.
2.Carefully release and remove radio DIN socket
from louvre panel.
3.Remove screw cover from radio aperture.
4.Remove drink tray assembly.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Drink tray assembly - centre
fascia.
5.Carefully release clock assembly from louvre
panel.
6.Disconnect multiplugs from clock and door
locking switch. Remove clock assembly.7.Carefully release switch pack from louvre
panel.
8.Disconnect multiplugs from switches and
remove switch pack.
9. Models without A/C: Carefully remove blower
speed and heater control knobs.
10. Models without A/C: Remove 2 screws
securing heater control panel graphic plate and
remove graphic plate.