ECU LAND ROVER DISCOVERY 1999 Workshop Manual

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.

EXTERIOR FITTINGS
76-2-8 REPAIRS
Roof bars
$% 76.11.31
Remove
1.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
2. Models with rear A/C: Drill out 4 rivets
securing rear centre duct to roof.
3. Models with rear A/C: Release and remove
rear centre duct.
4. Models with rear A/C: Drill out 2 rivets
securing each upper side duct to roof.
5. Models with rear A/C: Remove upper side
ducts.6.Remove 2 nuts securing each roof bar to roof.
7.Remove roof bars and collect foam pads from
each end.
Refit
1.Fit roof bars to roof, ensuring foam pads are
correctly located.
2.Fit nuts securing roof bars to roof and tighten
to 32 Nm (24 lbf.ft).
3. Models with rear A/C: Fit upper side ducts and
secure with rivets.
4. Models with rear A/C: Fit rear centre duct and
secure with rivets.
5.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.

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
76-2-12 REPAIRS
Bumper assembly - front
$% 76.22.08
Remove
1.Remove 14 screws securing LH and RH wheel
arch liner extensions to wheel arch liners and
bumper valance and remove extensions.
Note: 18 screws are used on 03 MY onwards.
2.Disconnect multiplugs from fog lamps. 3.Remove 2 nuts securing bumper valance side
mountings to body.
4.Remove 4 nuts securing bumper to crush cans
and remove bumper from body.
5.Remove 3 screws securing bumper to front
cross bar.
6. Models with headlamp wash: Position
container to collect screen washer fluid and
disconnect hose from headlamp washer pump.
Refit
1. Models with headlamp wash: Connect hose
to headlamp washer pump. Refill washer
reservoir with fluid.
2.With assistance position bumper to body.
3.Fit and tighten 3 screws securing bumper to
front cross bar.
4.Tighten nuts securing bumper to crush cans to
13 Nm (10 lbf.ft).
5.Tighten nuts securing bumper to side
mountings to 13 Nm (10 lbf.ft).
6.Connect multiplugs to fog lamps.
7.Fit wheel arch liner extensions and secure with
screws.

EXTERIOR FITTINGS
REPAIRS 76-2-13
Bumper assembly - rear - from 03MY
$% 76.22.15
Remove
1.Remove both rear tail lamps.

+ LIGHTING, REPAIRS, Lamp - tail/
flasher - bumper.
2.Disconnect park distance control harness
multiplug.
3.Release rear lamp harness clips.4.Remove 2 bolts securing bumper.
5.With assistance remove bumper.
NOTE: Do not carry out further dismantling if
component is removed for access only.
6.Remove 7 bolts and 5 screws securing closing
panel and remove panel.
M76 4566

EXTERIOR FITTINGS
76-2-14 REPAIRS
7.Disconnect 4 park distance control sensor
harness multiplugs and remove 6 clips
retaining harness.
8.Release 3 clips retaining harness and remove
harness.
9.Noting their fitted positions, release and
remove 4 park distance control sensors and
sensor housings.
Refit
1.Fit sensor housings to bumper, ensuring lugs
on housings are aligned with cut-outs in
bumper.
2.Fit and secure sensors to housings.
3.Fit harness, secure with clips and connect
multiplugs
4.Fit closing panel and secure with bolts and
screws.
5.With assistance, fit bumper assembly to body.
6.Fit bolts securing bumper and tighten to 45 Nm
(33 lbf.ft).
7.Secure rear lamp harness clips and connect
park distance control sensor harness multiplug.
8.Fit both rear tail lamps.

+ LIGHTING, REPAIRS, Lamp - tail/
flasher - bumper.
Trim finisher - bumper - front - from 03MY
$% 76.22.19
Remove
1.Remove 5 screws securing front bumper
finisher to bumper and position the finisher
aside.
2.Release clip securing washer hose to
headlamp washer jet and disconnect the hose.
3.Remove the bumper finisher.
NOTE: Do not carry out further dismantling if
component is removed for access only.
4.Remove clip securing headlamp washer jet to
bumper finisher and remove the washer jet.
Refit
1.Fit and secure headlamp washer jet to bumper
finisher.
2.Position bumper finisher to bumper, fit washer
hose to washer jet and secure with clip.
3.Fit bumper finisher to bumper and secure with
screws.

EXTERIOR FITTINGS
REPAIRS 76-2-15
Bumper assembly - rear - up to 03MY
$% 76.22.52
Remove
1.Remove both rear tail lamps.

+ LIGHTING, REPAIRS, Lamp - tail/
flasher - bumper.
2.Release 2 clips securing rear lamp harnesses
to rear bumper.
3.Remove 2 bolts securing rear bumper to
chassis and collect 2 plates.
4.With assistance, remove bumper assembly.
NOTE: Do not carry out further dismantling if
component is removed for access only.5.Remove centres of 19 trim clips securing
bumper armature to bumper valance.
6.Remove outers of trim clips.
7.Remove bumper armature from bumper
valance.
8.Release clips and remove rear lamps from
bumper valance.
Refit
1.Fit rear lamps to bumper valance.
2.Fit armature to bumper valance and secure
with trim clip outers.
3.Fit centres to trim clips.
4.With assistance, fit bumper assembly to body.
5.Position plates to rear bumper.
6.Fit and tighten bolts securing rear bumper to
chassis to 45 Nm (33 lbf.ft).
7.Fit 2 clips securing rear lamp harnesses to rear
bumper.
8.Connect multiplugs to rear lamps.

EXTERIOR FITTINGS
76-2-16 REPAIRS
Side finisher - windscreen
$% 76.43.39
Remove
1.Push centres from 3 trim clips securing finisher
to 'A' post.
2.Remove trim clip outers from finisher.
3.Release finisher from 3 spring clips.
4.Remove finisher.
Refit
1.Fit finisher to 'A' post and secure with spring
clips.
2.Fit trim clip outers to finisher.
3.Fit centres to trim clips.
Grille - front - up to 03MY
$% 76.55.03
Remove
1.Remove repeater lamps.

+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
2.Via access hole in wheel arch liners, remove
screws securing headlamp finishers.
3.Remove headlamp finishers from grille.
4.Remove 2 screws securing lower corners of
grille.
5.Remove 3 scrivets and remove grille.
Refit
1.Fit grille and secure with scrivets and screws.
2.Fit headlamp finishers and secure with screws.
3.Fit repeater lamps.

+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.