sunroof LAND ROVER DISCOVERY 2002 Owner's Manual

SUNROOF
76-6-12 DESCRIPTION AND OPERATION
Operation
Ignition switched-off timeout
There are three timeout modes for operating the sunroof assemblies after the ignition is switched off. The BCU
determines the vehicle's timeout mode. The three modes are:
lWhen the ignition is switched off, no sunroof operation is permitted.
lWhen the ignition is switched off, sunroof remains functional for 45 seconds or until the driver door is opened.
lWhen the ignition is switched off, sunroof remains functional for 45 seconds or until any door is opened.
Sunroof open and close
Both sunroof assemblies operate in the same manner. The front sunroof assembly has one switch while there are
two switches to control rear sunroof assembly, a rear sunroof front switch and a rear sunroof rear switch.
The sunroof ECU monitors the position of the sunroof microswitch to determine if the sunroof is to be tilted or opened.
In order for the sunroof to operate, either of the following conditions must exist:
lIgnition switch in position II.
lIgnition switched from on to off, doors closed (this may enable the system to operate for 45 seconds after the
ignition is switched off, or until a door is opened).
When the sunroof is closed, pressing the rear of the sunroof switch causes the sunroof ECU to operate the sunroof
motor and open the sunroof. When the sunroof opens, the sunroof microswitch opens. The sunroof continues to
open until the switch is released or the sunroof reaches the fully open position.
When the sunroof is open, pressing the front of the sunroof switch causes the sunroof ECU to operate the sunroof
motor and close the sunroof. The sunroof ECU continues to operate the motor until the sunroof microswitch closes.
This indicates to the sunroof ECU that the sunroof is fully closed.
Sunroof tilt
Both sunroof assemblies operate in the same manner. The front sunroof assembly has one switch while there are
two switches to control rear sunroof assembly, a rear sunroof front switch and a rear sunroof rear switch.
The sunroof ECU monitors the position of the sunroof microswitch to determine if the sunroof is to be tilted or opened.
In order for the sunroof to operate, either of the following conditions must exist.
lIgnition in position II.
lIgnition switched from on to off, doors closed (this may enable the system to operate for 45 seconds after the
ignition is switched off, or until a door is opened).
When the sunroof is closed and the front of the sunroof switch is pressed, the sunroof ECU detects the combination
of closed microswitch and front of sunroof switch being pressed and tilts the rear of the sunroof. This causes the
microswitch to open. The sunroof continues to open until the switch is released or the sunroof reaches the fully open
position.
When the sunroof is tilted and the rear of the sunroof switch is pressed, the sunroof ECU detects the combination of
open microswitch and rear of sunroof switch and closes the sunroof until the microswitch closes. This indicates to the
sunroof ECU that the sunroof is fully closed.
Rear sunroof isolation
The rear sunroof isolation switch prevents the rear sunroof rear switch from operating the rear sunroof. This can be
used to prevent small children sitting in the rear seat from playing with the rear sunroof.
Pressing the rear sunroof isolation switch opens the circuit between the rear sunroof rear switch and the sunroof ECU.
The sunroof ECU ignores the rear sunroof switch until the rear sunroof isolation switch is pressed and the circuit
closes.

SUNROOF
REPAIRS 76-6-13
REPAIRS
Sunroof - front
$% 76.84.01
Remove
1.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
2.Remove front sunroof motor.

+ SUNROOF, REPAIRS, Motor -
sunroof.
3.Disconnect drain tubes from sunroof tray.
4.Remove 14 screws securing sunroof tray to
sunroof frame.
5.Carefully remove sunroof tray.
6.With assistance, remove sunroof frame and
glass assembly. Refit
1.With assistance, fit sunroof frame and glass
assembly.
2.Position sunroof tray to roof and locate on front
edge and on rear location pin, arrowed in
illustration.
3.Fit Torx screws securing sunroof tray to frame
and tighten to 2 Nm (1.5 lbf.ft) in the order
shown.
4.Connect drain tubes to sunroof.
5.Fit sunroof motor. Do not fit headlining at this
stage.

+ SUNROOF, REPAIRS, Motor -
sunroof.
6.Check operation of sunroof.
7.Pour water over sunroof and check for water
leaks.
8.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.

SUNROOF
76-6-14 REPAIRS
Sunroof - rear
$% 76.84.02
Remove
1.Remove sunroof motor.

+ SUNROOF, REPAIRS, Motor -
sunroof.
2. Models with rear A/C:
aDrill out 4 rivets securing rear centre duct to
roof.
bRelease and remove rear centre duct.
cDrill out 2 rivets securing each upper side
duct to roof.
dRemove upper side ducts.
3.Disconnect drain tubes from sunroof tray.
4.Remove 14 screws securing sunroof tray to
sunroof frame.
5.Carefully remove sunroof tray.
6.With assistance, remove sunroof frame and
glass assembly. Refit
1.With assistance, fit sunroof frame and glass
assembly.
2.Position sunroof tray to roof and locate on front
edge and on rear location pin, arrowed in
illustration.
3.Fit Torx screws securing sunroof tray to frame
and tighten to 2 Nm (1.5 lbf.ft) in the order
shown.
4.Fit sunroof motor. Do not fit headlining at this
stage.

+ SUNROOF, REPAIRS, Motor -
sunroof.
5. Models with rear A/C:
aFit upper side ducts and secure with rivets.
bFit rear centre duct and secure with rivets.
6.Connect drain tubes to sunroof.
7.Check operation of sunroof.
8.Pour water over sunroof and check for water
leaks.
9.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.

SUNROOF
REPAIRS 76-6-15
Glass panel - sunroof
$% 76.84.03
The procedure for replacing the rear sunroof glass
panel is exactly the same as for the front
Remove
1.Partially open sunroof.
2.Remove 4 Torx screws securing glass to
sunroof frame.
3.Remove sunroof glass.
Refit
1.Position glass to frame.
2.Fit Torx screws securing glass to sunroof
frame. Do not fully tighten screws at this stage.
3.Adjust position of sunroof glass in relation to
roof panel until a 6.5 mm (0.25 in) gap is
produced between the front edge of the glass
and the sunroof frame.
4.Tighten sunroof glass retaining screws to 3 Nm
(2.2 lbf.ft).
Motor - sunroof
$% 76.84.07
This procedure is applicable to the motor of both
sunroofs.
Remove
1.Gain access to the sunroof motor:
lFor front sunroof motor, remove front
stowage pocket.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage pocket - front.
lFor rear sunroof motor, remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
CAUTION: The sunroof must be fully closed
before removing the sunroof motor.
2.Disconnect sunroof motor multiplug.
3.Remove 3 Torx screws securing motor to
sunroof tray.
4.Remove sunroof motor.

SUNROOF
76-6-16 REPAIRS
Refit
1.Check sunroof motor timing notch (A) aligns
with edge of microswitch (B). If motor is out of
alignment, rotate counting wheel (C) to correct
position using an Allen key.
2.Ensure sunroof drive cables are in fully closed
position.
3.Fit motor to sunroof frame.
4.Fit Torx screws securing motor to sunroof tray
and tighten to 2 Nm (1.5 lbf.ft).
5.Connect sunroof motor multiplug.
6.Fit interior trim:
lFor front sunroof motor, fit front stowage
pocket.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage pocket - front.
lFor rear sunroof motor, fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
Drive cable assembly
$% 76.84.09
This procedure is applicable to the drive cable
assembly of both sunroofs.
Remove
1.Remove sunroof:
lFor front drive cable assembly:

+ SUNROOF, REPAIRS, Sunroof -
front.
lFor rear drive cable assembly:

+ SUNROOF, REPAIRS, Sunroof -
rear.
2.Position sunroof assembly on suitable work
bench.
3.Remove 4 Torx screws securing glass to
sunroof frame.
4.Remove sunroof glass.
5.Release both glass carriers from cables and
remove.

SUNROOF
REPAIRS 76-6-17
6.Remove 10 Torx screws securing frame to
drive cable assembly.
7.Remove drive cable assembly from frame.
Refit
1.Fit drive cable assembly to frame.
2.Fit Torx screws securing frame to drive cable
assembly and tighten to 2.5 Nm (1.8 lbf.ft).
3.Fit glass carriers to cables.
4.Fit glass to sunroof frame and secure with Torx
screws. Do not fully tighten screws at this
stage.
5.Fit sunroof.
lFor front drive cable assembly:

+ SUNROOF, REPAIRS, Sunroof -
front.
lFor rear drive cable assembly:

+ SUNROOF, REPAIRS, Sunroof -
rear.
6.Remove timing pegs supplied with drive cables.
7.Adjust position of sunroof glass in relation to
sunroof panel until a 6.5 mm (0.25 in) gap is
produced between the front edge of the glass
and the sunroof frame.
8.Tighten sunroof glass retaining screws to 3 Nm
(2.2 lbf.ft).
Switch pack - sunroof
$% 76.84.44
Remove
1.Release switch pack from front stowage
pocket.
2.Disconnect multiplugs from 3 sunroof
switches.
3.Remove switches from switch pack.
Refit
1.Fit switches to switch pack.
2.Connect multiplugs to switches.
3.Fit switch pack to front stowage pocket.

SUNROOF
76-6-18 REPAIRS
ECU - sunroof
$% 76.84.46
Remove
1.Remove front stowage pocket.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage pocket - front.
2.Remove 2 screws securing ECU to roof.
3.Disconnect 2 multiplugs from ECU.
4.Remove sunroof ECU.
Refit
1.Position sunroof ECU and connect multiplugs.
2.Fit and tighten screws securing ECU to roof.
3.Fit front stowage pocket.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage pocket - front.

PANEL REPAIRS
REPLACEMENT PANELS 77-2-11
Roof panels
1Roof panel with sunroofs and roof bar holes
2Roof panel with roof bar holes only
3Roof panel with sunroofs only
4Roof panel
M77 1674A
1
2
3
4

PANEL REPAIRS
77-2-34 REPAIRS
Refit
1.Fit windscreen side finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
2.Fit insulation pad to engine bulkhead.
3.Fit front mud flap.
4.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
5.Fit wiring harness to valance assembly.
6. Models with A/C: Fit A/C pipes to valance
assembly.
7.Fit PAS/ACE reservoir.
8.Fit brake pipes to valance assembly.
9. LHD models: Fit brake servo.

+ BRAKES, REPAIRS, Servo - brake.
10.Fit ABS modulator unit.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
11.Fit front bulkhead assembly.

+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
12.Connect leads/multiplug to alternator.
13.Connect battery leads, negative lead last.
'A' post assembly
In this procedure, the front wing and the valance
outer reinforcement (rear section) are replaced in
conjunction with the 'A' post assembly. The dash side
assembly can also be replaced in this procedure if
required.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove bonnet.
4.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
5.Remove RH or LH front door.

+ DOORS, REPAIRS, Door - front.
6.Remove RH or LH sill finisher.
7.Remove windscreen.

+ SCREENS, REPAIRS, Windscreen.
8. Diesel models: Remove ECM.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Engine control module
(ECM).
9.Remove RH or LH 'A' post inner finishers and
disconnect speaker multiplug (if fitted).
10.Release sunroof drain tube and position aside.
11.Remove RH or LH front seat.

+ SEATS, REPAIRS, Seat - front.
12. RH side: Remove CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
13.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
14. Driver's side: Remove steering column
support bracket.
15.Remove relevant wiring from 'A' post.
16.Remove tread plate from front door aperture.
17.Release front carpet and position aside.
18.Remove front door aperture seal.
19.Remove engine bulkhead insulation.

PANEL REPAIRS
REPAIRS 77-2-35
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.Refit
1.Fit insulation pad to engine bulkhead.
2.Fit front door aperture seal.
3.Position front carpet and fit tread plate to front
door aperture.
4.Fit wiring to 'A' post.
5. Driver's side: Fit steering column support
bracket.
6.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
7. RH side: Fit CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
8.Fit RH or LH front seat.

+ SEATS, REPAIRS, Seat - front.
9.Fit sunroof drain tube.
10.Connect multiplug to speaker (if fitted) and fit
finisher to 'A' post.
11. Diesel models: Fit ECM.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Engine control module
(ECM).
12.Fit windscreen.

+ SCREENS, REPAIRS, Windscreen.
13.Fit sill finisher.
14.Fit front door.

+ DOORS, REPAIRS, Door - front.
15.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
16.Fit bonnet.
17.Connect leads/multiplug to alternator.
18.Connect battery leads, negative lead last.
M77 1751