light LAND ROVER DISCOVERY 1999 Manual Online

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.

INTERIOR TRIM COMPONENTS
76-3-2 REPAIRS
Trim casing - side - loadspace
$% 76.13.12
Remove
1. Models with third row seats: Remove third
row seat.

+ SEATS, REPAIRS, Seat - third row.
2. For LH trim casing: Remove accessory
socket.

+ LIGHTING, REPAIRS, Socket -
accessory.
3.Remove 'D' post trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - 'D' post.
4.Remove screw securing trim cap to trim casing.
5.Release trim cap from trim casing.
6. Models with ICE headphone control panels:
Disconnect multiplug from headphone control
panel and remove trim cap.
7.Partially remove rear door aperture seal.
8.Remove 2 trim clips securing trim casing to
body.
9.Remove access panel. 10.Remove trim clip securing trim casing to lower
'D' post.
11. Models without third row seats: Remove trim
clip from bottom rear corner of trim casing.
12.Release trim casing to gain access to rear seat
belt reel.
13.Remove bolt securing rear seat belt reel to
body.
14.Remove trim casing.
Refit
1.Position trim casing.
2.Fit rear seat belt reel to body and tighten bolt to
50 Nm (37 lbf.ft).
3. Models without third row seats: Fit trim clip
securing bottom rear corner of trim casing.
4.Fit trim clip securing trim casing to lower 'D'
post.
5.Fit access panel to trim casing.
6.Fit trim clips securing trim casing to body.
7.Fit rear door aperture seal.
8. Models with ICE headphone control panels:
Position trim cap and connect multiplug to
headphone control panel.
9.Fit trim cap to trim casing and secure with
screw.
10.Fit 'D' post trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - 'D' post.
11.Fit accessory socket.

+ LIGHTING, REPAIRS, Socket -
accessory.
12. Models with third row seats: Fit third row
seat.

+ SEATS, REPAIRS, Seat - third row.

INTERIOR TRIM COMPONENTS
76-3-6 REPAIRS
7. Models with veneer trim: Release veneered
console cover and remove cigar lighter
element. Disconnect multiplugs from switch
pack and remove veneered console cover.
8.Remove 2 bolts securing forward edge of
console to transmission tunnel. 9.Release handbrake gaiter from console.
10.Remove clip and clevis pin securing cable to
handbrake lever.
11.Move handbrake to fully upward position.
12.Release electric seat switches from console.
13.Disconnect multiplugs from switches and
remove.
14.Remove 2 bolts securing rear of console to
transmission tunnel.
15.Release centre console from fascia.
16.Disconnect multiplug and bulb from cigar
lighter.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-7
17.Remove console.
NOTE: Do not carry out further dismantling if
component is removed for access only.
18.Remove 4 screws securing storage bin lid to
console and remove lid.
19.Release cigar lighter body from console and
remove.
Refit
1.Fit and secure cigar lighter body to console.
2.Fit lid to console and secure with screws.
3.Fit console.
4.Connect multiplug and bulb to cigar lighter.
5.Fit centre console to fascia.
6.Fit 2 bolts securing rear of console to
transmission tunnel.
7.Connect multiplugs to seat switches.
8.Fit switches to console.
9.Move handbrake to lowered position.
10.Fit cable to handbrake and secure with clevis
pin and clip.
11.Fit handbrake gaiter to console.
12.Fit bolts securing forward edge of console to
transmission tunnel.
13. Models with veneer trim: Position veneered
console cover and connect multiplugs to switch
pack. Fit cigar lighter element and secure
veneered console cover to console.
14. Models with base trim: Connect multiplugs to
switch pack, fit switch pack to console and
secure with screws.
15. Models with base trim: Fit cover plate to
switch pack, and rubber mat to console.
16.Fit transfer box gaiter and knob to lever.
17.Secure transfer box gaiter to console.
18.Connect multiplug to selector panel, fit and
secure panel to centre console.
19.Fit spacer and knob to gear selector lever.
20. Models from 03MY:Fit both centre console
cup holders.
Console - centre - manual models
$% 76.25.01
Remove
1.Release clips securing gear lever gaiter to
centre console and remove knob and gaiter.
2. Models from 03MY:Remove both centre
console cup holders.
3.Release clips securing transfer box lever gaiter
to centre console and remove knob and gaiter.

INTERIOR TRIM COMPONENTS
76-3-8 REPAIRS
4. Models with base trim: Remove rubber mat
from console and remove cover plate from
switch pack.
5. Models with base trim: Remove 4 screws
securing switch pack to centre console,
disconnect multiplugs and remove switch pack.6. Models with veneer trim: Release veneered
console cover from console and remove cigar
lighter element. Disconnect multiplugs from
switch pack and remove veneered console
cover.
7.Remove 2 bolts securing forward edge of
console to transmission tunnel.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-9
8.Release handbrake gaiter from console.
9.Remove clip and clevis pin securing cable to
handbrake.
10.Move handbrake to fully upward position.
11.Release electric seat switches from console.
12.Disconnect multiplugs from switches and
remove.
13.Remove 2 bolts securing rear of console to
transmission tunnel.
14.Release centre console from fascia.
15.Disconnect multiplug and bulb from cigar
lighter. 16.Remove console.
NOTE: Do not carry out further dismantling if
component is removed for access only.
17.Remove 4 screws securing storage bin lid to
console and remove lid.
18.Release cigar lighter body from console and
remove.
Refit
1.Fit and secure cigar lighter body to console.
2.Fit lid to console and secure with screws.
3.Fit console.
4.Connect multiplug and bulb to cigar lighter.
5.Fit centre console to fascia.
6.Fit 2 bolts securing rear of console to
transmission tunnel.
7.Connect multiplugs to seat switches.
8.Fit switches to console.
9.Move handbrake to lowered position.
10.Fit cable to handbrake and secure with clevis
pin and clip.
11.Fit handbrake gaiter to console.
12.Fit bolts securing forward edge of console to
transmission tunnel.
13. Models with veneer trim: Position veneered
console cover and connect multiplugs to switch
pack. Fit cigar lighter element and secure
veneered console cover to console.
14. Models with base trim: Connect multiplugs to
switch pack, fit switch pack to console and
secure with screws.
15. Models with base trim: Fit cover plate to
switch pack, and rubber mat to console.
16.Fit transfer gearbox gaiter and knob to lever.
17.Secure gaiter to console.
18.Fit knob and gaiter to gear lever and secure
gear lever gaiter to console with clips.
19. Models from 03MY:Fit both centre console
cup holders.

SCREENS
REPAIRS 76-4-1
SCREENS REPAIRS
Glass/sealing rubber - tail door
$% 76.31.22
Remove
1.Remove spare wheel from rear door.
2.Remove centre high mounted stop lamp.

+ LIGHTING, REPAIRS, Lamp - stop -
centre high mounted (CHMSL).
3.Pull the rear wiper arm away from the glass.
4.Disconnect leads from rear window heater.
5.Ease glass sealing rubber from tail door flange
and with assistance, from inside push the glass
and sealing rubber out.
6.Remove sealing rubber from glass. Refit
1.Thoroughly clean the tail door glass mounting
flange.
2.Clean glass and fit sealing rubber. Ensure
sealing rubber is fully located onto glass.
3.Fit a draw cord into the outside groove of the
sealing rubber with cord ends situated on top
corner of bend at bottom of glass.
4.To aid assembly, lubricate the tail door glass
mounting flange with liquid soap.
5.Position the assembled glass and rubber to
outside of flange.
6.With assistance from second operator pushing
glass into door, hold one end of cord and pull
the other end carefully around the aperture,
easing the rubber seal over the flange.
7.Connect leads to rear window heater.
8.Fit centre high mounted stop lamp.

+ LIGHTING, REPAIRS, Lamp - stop -
centre high mounted (CHMSL).
9.Fit rear wiper onto glass.
10.Fit spare wheel.

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.

SCREENS
REPAIRS 76-4-5
6.From outside of vehicle, use a Kent knife and
carefully cut through sealant to release glass
from body. Any remaining sealant not
accessible with Kent knife can be severed
using cutting wire or knife.
CAUTION: Hold the cutting wire as close to
the glass as possible to prevent damage to
the body and surrounding trim.
7.Remove glass.
CAUTION: Lay glass on felt covered
supports and be careful not to damage the
obscuration band. Do not stand on edge as
this can cause chips which subsequently
develop into cracks.
Refit
1.Carefully remove sealant from body to leave a
smooth surface.
2.With assistance, fit glass without sealant to
body and apply masking tape to establish
reference marks as an alignment aid.
3.Remove glass and place aside.
4.Clean body and sealant face on glass with
solvent.
CAUTION: Do not touch cleaned or primed
surfaces with fingers.5.Apply etch primer to any bare metal on body.
6.Apply glass primer to sealant face on glass and
allow to cure.
7.Apply primer over etch primer on body.
8.Apply activator over old sealant on body.
9.Allow activator to cure.
10.Fit pre-cut nozzle to sealant cartridge, remove
lid, shake out crystals, and fit cartridge to
applicator gun. If necessary modify the nozzle
to achieve required bead section.
11.Apply a continuous bead of sealant to sealant
face on glass as shown.
12.Position glass to body and align to reference
tape.
13.Lightly press glass to ensure correct profile.
14.Secure glass with tape until sealer has cured.
15.Remove protective covers and tape.
16.If applicable, connect coaxial cable to terminal
on glass
17.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.
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.