LAND ROVER DISCOVERY 2002 Workshop Manual

INTERIOR TRIM COMPONENTS
76-3-18 REPAIRS
Refit
1.With assistance position carpet.
2.Secure main body harness to transmission
tunnel with nuts.
3.Position front carpet retainers and secure to
floor with screws.
4.Fit finishers to front carpet retainers
5.Fit both lower 'A' post trim panels.
6.Fit centre console.
lFor models with manual gearbox:

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

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
7. Models with premium ICE: Fit CD
autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
8. Models with premium ICE: Fit power
amplifier.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
Carpet - rear
$% 76.49.03
Remove
1. Models with premium ICE: Remove power
amplifier.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
2.Remove RH front seat.

+ SEATS, REPAIRS, Seat - front.
3.Remove both 'B' post lower trim panels.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
4.Remove finishers from front and rear carpet
retainers.
5.Remove 12 screws securing front and rear
carpet retainers to floor.
6.Remove front and rear carpet retainers.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-19
7.Remove 4 screws securing trim panel to rear of
centre console.
8.Remove trim panel.
9.Position harnesses clear of rear carpet.
10.Remove rear carpet.
Refit
1.Position new rear carpet.
2.Fit front and rear carpet retainers to floor and
secure with screws.
3.Fit finishers to front and rear carpet retainers
4.Position trim panel to rear of centre console
and secure with screws.
5.Fit lower 'B' post trim panels.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
6.Fit RH front seat to floor.

+ SEATS, REPAIRS, Seat - front.
7. Models with premium ICE: Fit power
amplifier.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
Carpet - loadspace
$% 76.49.04
Remove
1.Remove both rear seat belt lower fixings.
2. Models with third row seats: Remove both
third row seats.

+ SEATS, REPAIRS, Seat - third row.
3.Remove both loadspace side trim casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
4. Models with third row seats: Remove 4
screws and remove both seat lower mounting
escutcheons.
5.Recline rear seats fully forward.
6.Remove finisher from loadspace carpet
retainer.
7.Remove 6 screws securing loadspace carpet
retainer to floor and remove retainer.
8.Remove loadspace carpet.
Refit
1.Position loadspace carpet to floor.
2.Position loadspace carpet retainer to floor and
secure with screws.
3.Fit finisher to loadspace carpet retainer
4.Return rear seats to their normal position.
5. Models with third row seats: Position both
third row seats lower mounting escutcheons to
floor and secure with screws.
6.Fit both loadspace side trim casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
7. Models with third row seats: Fit both third row
seats.

+ SEATS, REPAIRS, Seat - third row.
8.Position both rear seat belt lower mountings
and secure with bolts tightened to 32 Nm (24
lbf.ft).

INTERIOR TRIM COMPONENTS
76-3-20 REPAIRS
Headlining
$% 76.64.15.21
Remove
1.Remove both 'D' post trim casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - 'D' post.
2.Remove both 'B' post upper trim casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - upper - 'B' post.
3.Release clips securing both 'A' post trim
casings.
4. Models with premium ICE: Disconnect
multiplugs from 'A' post speakers.
5.Remove both 'A' post trim casings.
6.Remove 3 screws securing sun visor to
headlining.
7.Release sun visor from clip.
8.Disconnect multiplug from sun visor.
9.Remove sun visor.
10.Repeat process for second sun visor. 11.Remove access panel from front edge of front
stowage pocket.
12.Remove screw securing front stowage pocket
to headlining.
13.Remove lens from front interior lamp.
14.Remove 2 nuts securing front interior lamp to
headlining.
15.Disconnect multiplug from front interior lamp.
16.Remove front interior lamp.
17.Remove 10 screws securing front stowage
pocket to headlining.
18.Disconnect 3 multiplugs from sunroof switches.
19.Remove front stowage pocket.
20.Remove caps from sun visor clips.
21.Remove screws and release both sun visor
clips.
22.Remove tail door aperture upper trim casing.
23.Remove rear sunroof aperture trim.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-21
24.Remove front sunroof aperture trim.
25.Release end caps from all grab handles.
26.Remove 2 bolts securing each grab handle to
roof.
27.Remove all 4 grab handles.
28. Models with volumetric alarm: Release front
volumetric sensor from headlining and
disconnect multiplug.
29. Models with rear A/C:
aRelease rear A/C control panel from
headlining.
bDisconnect 2 multiplugs and 2 Lucar
connectors from rear A/C control panel.
cRemove rear A/C control panel.
30.Release rear interior lamp from headlining and
disconnect multiplug.
31.Remove rear interior lamp. 32.Remove 2 clips securing rear of headlining to
roof.
33.Release rear sunroof switch from headlining.
34.Disconnect multiplug and remove rear sunroof
switch.
35.Remove screw securing headlining to roof.
36.With assistance, remove headlining.
37. Models with rear A/C:
aRemove foam pads from air vents.
bRelease 2 rear air vents from headlining.
cRelease 3 central air vents from headlining.

INTERIOR TRIM COMPONENTS
76-3-22 REPAIRS
38.Remove 7 nuts securing each stowage pocket
to headlining and collect mounting plates.
39.Remove both pockets from headlining.
40.Remove 8 screws securing rear console to
headlining and collect 3 mounting plates.
41.Remove rear console from headlining.
Refit
1.Fit rear console and mounting plates to
headlining.
2.Fit and tighten nuts securing rear console to
headlining.
3.Fit both stowage pockets and mounting plates
to headlining.
4.Fit and tighten nuts securing stowage pockets
to headlining.
5. Models with rear A/C:
aFit 3 central air vents to headlining.
bFit 2 rear air vents to headlining.
cFit foam pads to air vents.
6.With assistance, position headlining in vehicle.
7.Fit and tighten screw securing centre of
headlining to roof.
8.Connect multiplug to rear sunroof switch.
9.Fit rear sunroof switch to rear console.
10.Fit clips securing rear edge of headlining to
sunroof. 11.Position rear interior lamp to headlining and
connect multiplug.
12.Fit rear interior lamp to headlining.
13. Models with rear A/C:
aPosition rear A/C control panel to headlining
and connect multiplugs and Lucar
connectors.
bFit rear A/C control panel to headlining.
14. Models with volumetric alarm: Connect
multiplug to front volumetric sensor and fit
sensor to headlining.
15.Fit grab handles to headlining and secure with
bolts.
16.Fit end caps to grab handles.
17.Fit front sunroof aperture trim.
18.Fit rear sunroof aperture trim.
19.Fit tail door aperture upper trim casing.
20.Fit sun visor clips to headlining and secure with
screws.
21.Fit caps to sun visor clips.
22.Position front stowage pocket to headlining and
connect multiplugs to sunroof switches.
23.Fit and tighten 10 screws securing front
stowage pocket to headlining.
24.Connect multiplug to front interior lamp.
25.Fit front interior lamp to headlining and secure
with nuts.
26.Fit lens to front interior lamp.
27.Fit and tighten screw securing front stowage
pocket to headlining.
28.Fit access panel to front edge of front stowage
pocket.
29.Position sun visor to headlining and secure to
clip.
30.Connect multiplug to sun visor.
31.Fit and tighten screws securing sun visor to
headlining.
32.Repeat process for second sun visor.
33. Models with premium ICE: Position both 'A'
post trim casings and connect multiplugs to
speakers.
34.Fit both trim casings to 'A' posts and secure
with clips.
35.Fit both 'B' post upper trim casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - upper - 'B' post.
36.Fit both 'D' post trim casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - 'D' post.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-23
Stowage pocket - front
$% 76.67.26
Remove
1.Remove access panel from front edge of front
stowage pocket.
2.Remove screw securing front stowage pocket
to headlining.
3.Remove lense from front interior lamp.
4.Remove 2 nuts securing front interior lamp to
headlining.
5.Disconnect multiplug from front interior lamp.
6.Remove front interior lamp.
7.Remove 10 screws securing front stowage
pocket to headlining.
8.Disconnect 3 multiplugs from sunroof
switches.
9.Remove front stowage pocket. 10.Release clips securing sunroof switch pack.
11.Remove switch pack.
Refit
1.Fit sunroof switch pack to front stowage pocket
and secure with clips.
2.Position front stowage pocket to headlining
and connect multiplugs to sunroof switches.
3.Fit and tighten 10 screws securing front
stowage pocket to headlining.
4.Connect multiplug to front interior lamp.
5.Fit front interior lamp to headlining and secure
with nuts.
6.Fit lense to front interior lamp.
7.Fit and tighten screw securing front of front
stowage pocket to headlining.
8.Fit access panel to front stowage pocket.

INTERIOR TRIM COMPONENTS
76-3-24 REPAIRS

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
76-4-2 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
REPAIRS 76-4-3
10.From outside of vehicle, use a Kent knife and
carefully cut through sealant securing sides of
screen to body.
11.Using suitable cutting wire, with assistance if
required, carefully cut through sealant securing
top of screen to body and any remaining
sealant at sides.
CAUTION: Hold the cutting wire as close to
the glass as possible to prevent damage to
the body and surrounding trim.
12.Cut through sealant securing lower edge of
screen to body with glazing knife.
13.Attach suction cups and use assistance to
remove glass from body.
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.
14.Collect screen support block. Refit
1.Carefully remove sealant from body to leave a
smooth surface.
2.Use a vacuum cleaner to clear away any waste.
3. Original glass: Carefully cut back old sealer to
obtain a smooth surface without damaging
obscuration band on glass. Fit new top finisher
to screen.
4.Fit screen support block to body.
5.With assistance, locate screen to body.
6.Apply masking tape to establish reference
marks as an alignment aid.
7.With assistance, remove screen and place
aside.
8.Clean body and sealant face on screen with
solvent.
CAUTION: Do not touch cleaned or primed
surfaces with fingers.
9.Apply etch primer to any bare metal on frame.
10.Apply screen primer to sealant face on screen
and allow to cure.
11.Apply primer over etch primer on body.
12.Apply activator over old sealant on body.
13.Allow activator to cure.
14.Fit pre-cut nozzle to sealer cartridge, remove
lid, shake out crystals and fit cartridge to
applicator gun. If necessary modify the nozzle
to achieve required bead section.