lock LAND ROVER DISCOVERY 2002 Workshop Manual

DOORS
76-1-10 REPAIRS
7.Disconnect release cable from latch and
remove latch and motor assembly.
Refit
1.Connect release cable to latch.
2.Position latch and motor assembly to door. Fit
Torx screws securing latch to door and tighten
to 7 Nm (5.2 lbf.ft).
3.Connect multiplug to motor.
4.Connect exterior handle control rod to latch.
5.Connect sill button lock rod to latch.
6.Fit front door frame.

+ DOORS, REPAIRS, Glass - front or
rear door.
Latch and motor - rear door
$% 76.37.13
Remove
1.Remove rear door frame.

+ DOORS, REPAIRS, Glass - front or
rear door.
2.Release exterior handle control rod from latch.
3.Release sill button lock rod from door latch.
4.Disconnect multiplug from motor.
5.Remove 3 Torx screws securing latch and
motor assembly to door.
6.Remove latch and motor assembly through
lower aperture in door.

DOORS
REPAIRS 76-1-11
7.Open security flap on latch.
8.Disconnect release cable from latch.
Refit
1.Connect release cable to latch and close
security flap.
2.Position latch to door, fit Torx screws securing
latch to door and tighten to 7 Nm (5.2 lbf.ft).
3.Connect multiplug to motor.
4.Connect exterior handle control rod to latch.
5.Connect sill button lock rod to latch.
6.Fit rear door frame.

+ DOORS, REPAIRS, Glass - front or
rear door.
Latch and motor - tail door
$% 76.37.16
Remove
1.Remove tail door trim casing.

+ DOORS, REPAIRS, Trim casing - tail
door.
2.Carefully release water shedder from tail door.
3.Release and remove control rod from exterior
handle and latch.
4.Release and remove sill button lock rod.
5.Disconnect multiplug from motor.
6.Remove release cable from clip.
7.Remove 3 Torx screws securing latch and
motor assembly to door.
8.Remove door latch.
9.Disconnect release cable from latch.
Refit
1.Connect release cable to latch.
2.Position door latch and motor assembly, secure
with Torx screws and tighten to 7 Nm (5.2 lbf.ft).
3.Position control rod and connect to exterior
handle and latch.
4.Position sill button lock rod and connect to
latch.
5.Secure release cable in clip.
6.Connect multiplug to motor.
7.Fit water shedder to door.
8.Fit tail door trim casing.

+ DOORS, REPAIRS, Trim casing - tail
door.

EXTERIOR FITTINGS
76-2-4 REPAIRS
12.Fit front wheel arch liner extension panel to the
front bumper and secure with screws.
13.Fit and tighten screw securing front wheel arch
liner extension panel to the inner wing.
14.Fit the front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - front.
15.Fit the headlamp assembly.

+ LIGHTING, REPAIRS, Headlamp -
from 03MY.
Rear folding step
$% 76.10.41
Remove
1.Remove 2 bolts securing step and damper
assembly to chassis.
2.Remove step and damper assembly.
3.Remove 2 patch lock nuts securing damper to
step and discard nuts.
4.Remove damper from step.
Refit
1.Fit damper to step and secure with new patch
lock nuts. Tighten nuts to 17 Nm (13 lbf.ft).
2.Position step and damper assembly to chassis
and secure with bolts. Tighten bolts to 45 Nm
(33 lbf.ft).

EXTERIOR FITTINGS
REPAIRS 76-2-9
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. 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.

EXTERIOR FITTINGS
76-2-10 REPAIRS
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.
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.
M76 4573

EXTERIOR FITTINGS
REPAIRS 76-2-11
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.Secure bonnet release cable to the front panel
retaining 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.
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.
M76 3029B
M76 4574

EXTERIOR FITTINGS
76-2-16 REPAIRS
Grille - front - up to 03MY
$% 76.55.03
Remove
1.Remove repeater lamps.

+ LIGHTING, REPAIRS, Lamp - front
repeater.
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.
Grille - front - from 03MY
$% 76.55.03
Remove
1.Remove 3 scrivets securing front grille to
bonnet locking platform.
2.Remove front grille.
NOTE: Do not carry out further dismantling if
component is removed for access only.
3.Remove motif from front grille.
Refit
1.Clean front grille to motif mating face.
2.Fit and secure motif to front grille.
3.Fit front grille and secure with scrivets.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-15
Louvre panel assembly - centre fascia
$% 76.46.42
Remove
1.Remove radio cassette player from fascia.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio cassette player.
2.Carefully release and remove radio DIN socket
from louvre panel.
3.Remove screw cover from radio aperture.
4.Remove drink tray assembly.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Drink tray assembly - centre
fascia.
5.Carefully release clock assembly from louvre
panel.
6.Disconnect multiplugs from clock and door
locking switch. Remove clock assembly.7.Carefully release switch pack from louvre
panel.
8.Disconnect multiplugs from switches and
remove switch pack.
9. Models without A/C: Carefully remove blower
speed and heater control knobs.
10. Models without A/C: Remove 2 screws
securing heater control panel graphic plate and
remove graphic plate.

INTERIOR TRIM COMPONENTS
76-3-16 REPAIRS
11. Models without A/C: Remove 4 screws
securing heater control panel to louvre panel.
12. Models with A/C: Carefully release ATC ECU
from louvre panel, disconnect multiplugs and
remove ATC ECU.13.Loosen 2 upper screws and remove 4
remaining screws securing louvre panel to
fascia.
14.Remove louvre panel assembly.
15.Remove seals from face level vents.
Refit
1.Fit seals to face level vents on new louvre
panel.
2.Fit louvre panel to fascia and secure with
screws.
3. Models with A/C: Connect multiplugs to ATC
ECU and fit ATC ECU to fascia.
4. Models without A/C: Fit screws securing
heater control panel to louvre panel.
5. Models without A/C: Fit heater control panel
graphic plate and secure with screws.
6. Models without A/C: Fit blower speed and
heater control knobs.
7.Position switch pack, connect multiplugs to
switches and fit switch pack to louvre panel.
8.Position clock assembly, connect multiplug to
clock and door locking switch and fit clock
assembly to louvre panel.

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.