wheel LAND ROVER DISCOVERY 2002 Workshop Manual

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.
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 airbag module to
steering wheel.
3.Release airbag module from steering wheel.
CAUTION: Do not allow the airbag module
to hang by the airbag harness.
4.Disconnect multiplug from airbag module.

RESTRAINT SYSTEMS
REPAIRS 75-19
5.Remove airbag 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 airbag module and connect multiplug.
2.Fit airbag module to steering wheel and tighten
Torx bolts to 9 Nm (7 lbf.ft).
3.Connect battery leads, earth lead last.
Airbag module - passenger
$% 76.74.02
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.Release guides supporting glove box.
3.Lower glove box to gain access to airbag
module.

RESTRAINT SYSTEMS
REPAIRS 75-21
Refit
CAUTION: The SRS diagnostic control unit
is a shock sensitive device and must be
handled with extreme care.
1.Position DCU to body and connect multiplug.
2.Fit and tighten DCU Torx bolts to 10 Nm (7
lbf.ft).
3.Fit centre console.
lOn manual gearbox models:

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

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
4.Connect battery leads, earth lead last.
Rotary coupler
$% 76.74.20
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 steering wheel.

+ STEERING, REPAIRS, Steering
wheel.
3.Remove steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
steering column.

RESTRAINT SYSTEMS
75-22 REPAIRS
4.Release rotary coupler multiplug from bracket
and disconnect from harness.
5.Disconnect rotary coupler multiplug from
harness.
6.Remove rotary coupler.
Refit
1.Fit rotary coupler to steering column and
connect multiplug to harness.
2.Connect rotary coupler multiplug to harness
and secure to bracket.
3.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
steering column.
4.Fit steering wheel.

+ STEERING, REPAIRS, Steering
wheel.
Airbag deployment tool - self test
$% 76.74.99
Test
1.Insert BLUE and YELLOW connectors of tool
lead into corresponding sockets on face of tool.
2.Connect crocodile clips of second tool lead to
battery, RED to positive and BLACK to
negative.
3.RED "READY" light should illuminate.
4.Press and hold both operating buttons.
5.GREEN "DEFECTIVE" light should illuminate.
6.Release both operating buttons.
7.RED "READY" light should illuminate.
8.Disconnect tool from battery.
9.Disconnect blue and yellow connectors from
tool face sockets.
10.Self test now complete.

RESTRAINT SYSTEMS
REPAIRS 75-23
Airbag module - drivers - deployment
$% 76.74.99
These guidelines are written to aid authorised
personnel to carry out the safe disposal of airbag
modules when removed from the vehicle.
If a vehicle is to be scrapped and contains an
undeployed airbag module, the module must be
manually deployed. This operation should only
be carried out using the following recommended
manual deployment procedure. Before
deployment is started the deployment tool self
test procedure should be carried out.
WARNING: Only use approved deployment
equipment, and only deploy SRS components in
a well ventilated designated area. Ensure SRS
components are not damaged or ruptured before
deployment. Notify the relevant authorities.
CAUTION: Deployment in the vehicle will damage
the steering wheel. If the vehicle is not being
scrapped, deploy the module away from the
vehicle in accordance with the correct
procedure.
Deploy
1.Carry out deployment tool self test.

+ RESTRAINT SYSTEMS, REPAIRS,
Airbag deployment tool - self test.
2.Remove airbag module from steering wheel.

+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.3.Position tool SMD 4082/2 in vice, ensuring that
vice jaws grip tool above bottom flange to
prevent possibility of tool being forced upwards
from vice. Tighten vice.
4.Secure airbag module to tool SMD 4082/2.
Ensure module is correctly secured using both
fixings.
WARNING: When removing, testing or
installing an airbag module, do not lean
directly over it.

RESTRAINT SYSTEMS
75-24 REPAIRS
5.Ensure airbag module mounting brackets are
secure.
6.Connect flylead SMD 4082/4 to airbag module.
WARNING: Ensure the deployment tool is
not connected to the battery.
7.Connect flylead SMD 4082/4 to tool SMD 4082/
1.
WARNING: Do not lean over module whilst
connecting.
8.Connect tool SMD 4082/1 to battery.
WARNING: Ensure all personnel are at least
15 metres (50 ft) away from the airbag
module.9.Press both operating buttons to deploy airbag
module.
10.DO NOT return to airbag module for 30
minutes.
11.Using gloves and face mask, remove airbag
module from tool, place airbag module in
plastic bag and seal bag.
12.Wipe down tool with damp cloth.
13.Transport deployed airbag module to
designated area for incineration.
NOTE: DO NOT re-use or salvage any parts of
the airbag system including steering wheel or
steering column. Do not transport deployed
SRS components in the vehicle passenger
compartment.

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.

DOORS
76-1-4 REPAIRS
19.Remove 6 bolts securing tail door hinges to
body and, with assistance, remove tail door.
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.
Glass - front or rear door
$% 76.31.01
Remove
1.Remove door trim casing.

+ DOORS, REPAIRS, Trim casing -
front door.

+ DOORS, REPAIRS, Trim casing -
rear door.
2.Carefully release water shedder from door.
3. Front door glass only: Remove exterior door
mirror.

+ EXTERIOR FITTINGS, REPAIRS,
Mirror - exterior - electric.
4.Remove inner waist seal.
Front door shown, rear door similar
5.Remove 2 clips securing ends of outer waist
seal.
6.Remove outer waist seal.
7.Remove 2 bolts securing glass to regulator. If
necessary, lower glass to access bolts.
8.Remove bolts securing frame to door.
9.Remove door frame complete with glass.
10.Slide out and remove glass from frame.

EXTERIOR FITTINGS
REPAIRS 76-2-1
EXTERIOR FITTINGS REPAIRS
Wing - front - up to 03MY
$% 76.10.24
Remove
1.Remove front repeater lamp.

+ LIGHTING, REPAIRS, Lamp - front
repeater.
2.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - front.
3.Remove 5 screws securing wheel arch liner
extension to bumper valance and remove liner.
4.Remove side repeater lamp from wing,
disconnect multiplug and remove lamp.5.Remove bolt securing front of wing to bracket
on body.
6.Remove screw securing headlamp surround
panel to wing.
7.Remove nut securing wing to bracket on sill
finisher.

EXTERIOR FITTINGS
76-2-2 REPAIRS
8.Remove 8 bolts securing wing to body and
remove wing.
Refit
1.Position wing to body.
2.Connect side repeater lamp to multiplug and fit
to wing.
3.Position wing to body, align wing to bonnet and
front door so that the correct gaps are achieved
and tighten bolts to 17 Nm (13 lbf.ft).
4.Check alignment of wing to bonnet and front
door. If necessary, adjust wing to achieve
correct gaps.
5.Fit and tighten nut securing wing to bracket on
sill finisher to 17 Nm (13 lbf.ft).
6.Fit and tighten screw securing wing to
headlamp surround panel.
7.Fit and tighten bolt securing front of wing to
bracket on body to 17 Nm (13 lbf.ft).
8.Fit wheel arch liner extension to bumper and
secure with screws.
9.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - front.
10.Fit front repeater lamp.

+ LIGHTING, REPAIRS, Lamp - front
repeater.
Wing - front - from 03MY
$% 76.10.24
Remove
1.Remove the headlamp assembly.

+ LIGHTING, REPAIRS, Headlamp -
from 03MY.
2.Remove the front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - front.
3.Remove screw securing wheel arch liner
extension panel to the inner wing.
4.Remove 6 screws securing wheel arch liner
extension panel to the front bumper and
remove the extension panel.
5.Release side repeater lamp from front wing,
disconnect the multiplug and remove the lamp.