1995 LAND ROVER DISCOVERY warning

CHASSIS AND BODY
11
REPAIR
11.Remove the two bolts, spring and plain washers
securing the door frame to the edge of the door.
12.Lift out the door frame complete with glass and
remove to a suitable workbench.
13.Remove the tape and slide the glass out of the
door frame channel.
Refit
14.Reverse removal procedure.
NOTE: When refitting the door glass frame
ensure that it is adjusted to suit the door
opening before fully tightening the
securing bolts.REAR DOOR
Service repair no - 76.28.19
Remove
1.Remove the spare wheel from the exterior of the
door.
2.Remove the trim panel from inside the rear door.
See rear door trim panel.
3.Release the convoluted grommet from the door
post, expose the door harness connectors and
multiplugs and disconnect.
4.Remove the circlip and washer from the check
stay pivot on the body.
WARNING: Instruction 5 MUST BE carried
out with assistance.
5.Suitably support the door, remove the four bolts
securing the hinges to the door and with
assistance slide the door off the hinges.
Refit
6.Reverse removal procedure.

76CHASSIS AND BODY
22
REPAIR FRONT FOLDING SEATS 3 DOOR VEHICLES
Service repair no - 76.70.01
WARNING: Care must be taken if the seat
lifting mechanism is operated when the
seat is removed from the base otherwise
personal injury could occur.
Remove
1.Slide the seat to the full extent rearwards and
remove the rear seat to base securing bolts.
2.Slide the seat forward and remove the front seat
to base securing bolts.
3.Lift the seat from the base and withdraw from the
vehicle.
Refit
4.Reverse removal procedure.
5.Tighten all securing bolts to
22 Nm (16 lbf ft).

CHASSIS AND BODY
23
REPAIR SEAT BASE
Service repair no - 76.70.06/25
WARNING: Care must be taken if the seat
lifting mechanism is operated when the
seat is removed from the base otherwise
personal injury could occur.
Remove
1.Remove the seat from the base.
2.Carefully operate the seat mechanism to raise it
to the tilt position.
3.Remove the two bolts securing the rear of the
base to the floor.
4.Return the seat mechanism to the upright
position.
5.Pull the carpet flap forward to expose the front
securing bolts, remove the bolts and lift out the
seat base.
Refit
6.Reverse removal procedure.SEAT BASE RUNNERS
Remove
7.Remove the seat from the base.
8.Spring the release handle off its locations on the
runners.
9.Slide the runners forward sufficient to gain
access to the rear securing bolts and rearward
for the front bolts.
10.Remove the bolts and withdraw the runners.
Refit
11.Fit the runners and release handle.
12.Reverse removal procedure.
13.Refit the seat to the base.

CHASSIS AND BODY
51
REPAIR 16.Cut through sealer between the supports.
If heated front screen: Cut through the 2 wires
each side of the supports. Tape cut wires and
panels to prevent damage to bodywork when
screen is removed.
17.Attach suction cups to glass and lift glass from
body flange, cut sealer free around supports as
necessary.
WARNING: If glass has splintered: Protect
eyes and operate demister blower at
maximum speed to remove any glass from
ducts. Use a vacuum cleaner to remove glass
particles from inside the vehicle.
Refit
18.Check condition of supports, renew if necessary.
Locating studs must be at right angle to flange.
NOTE: The supports were fitted to early
vehicles and now replaced with nylon
sheaths.
19.Carefully cut back old sealant around body
flange to obtain a smooth surface 2mm (1/10in)
thick.DO NOT cut down to flange.
20. If refitting original glass:It must be free from
chips or cracks. Cut back old sealant around
glass to obtain a smooth surface 2mm (1/10 in)
thick.DO NOT cut down to glass surface.
CAUTION: Lay glass on felt covered
supports, do not stand on edge. Any
chipping of glass edge may develop into
cracks.
21.Align header finisher on top edge of glass, push
flange fully onto glass and use a wooden block
and mallet to ensure fit.
22.Carefully align each side finisher on edge of
glass, push flange fully onto glass and use a
wooden block and mallet to ensure fit.
23.Using a cotton bud, apply glass cleaning solvent
(yellow cap) to inside face of glass, 20mm (13/16
in) strip around inside of finishers and 30mm (1
1/8 in) wide along bottom edge. Immediately
wipe off solvent with a clean cloth.
CAUTION: Do not touch cleaned or primed
surfaces with fingers.

AIR CONDITIONING
1
ADJUSTMENT GENERAL PRECAUTIONS
The refrigerant used in the air conditioning system is
HFC (Hydrofluorocarbon) R134a.
WARNING: R134a is a hazardous liquid
and when handled incorrectly can cause
serious injury. Suitable protective clothing
must be worn when carrying out servicing
operations on the air conditioning system.
WARNING: R134a is odourless and
colourless. Do not handle or discharge in
an enclosed area, or in any area where the
vapour or liquid can come in contact with naked
flame or hot metal. R134a is not flammable but
can form a highly toxic gas.
WARNING: Do not smoke or weld in areas
where R134a is in use. Inhalation of
concentrations of the vapour can cause
dizziness, disorientation. uncoordination,
narcosis, nausea or vomiting.
WARNING: Do not allow fluids other than
R134a or compressor lubricant to enter the
air conditioning system. Spontaneous
combustion may occur.
WARNING: R134a splashed on any part of
the body will cause immediate freezing of
that area. Also refrigerant cylinders and
replenishment trolleys when discharging will
freeze skin to them if contact is made.
WARNING: The refrigerant used in an air
conditioning system must be reclaimed in
accordance with the recommendations
given with a Refrigerant Recovery Recycling
Recharging Station.
NOTE: Suitable protective clothing
comprises: Wrap around safety glasses or
helmet, heatproof gloves, rubber apron or
waterproof overalls and rubber boots.REMEDIAL ACTIONS
1.If liquid R134a strikes the eye, do not rub it.
Gently run large quantities of eyewash over the
eye to raise the temperature. If eyewash is not
available cool, clean water may be used. Cover
eye with clean pad and seek immediate medical
attention.
2.If liquid R134a is splashed on the skin run large
quantities of water over the area as soon as
possible to raise the temperature. Carry out the
same actions if skin comes into contact with
discharging cylinders. Wrap affected parts in
blankets or similar material and seek immediate
medical attention.
3.If suspected of being overcome by inhalation of
R134a vapour seek fresh air. If unconscious
remove to fresh air. Apply artificial respiration
and/or oxygen and seek immediate medical
attention.
NOTE: Due to its low evaporating
temperature of -30°C, R134a should be
handled with care.
WARNING: Do not allow a refrigerant
container to be heated by a direct flame or
to be placed near any heating appliance. A
refrigerant container must not be heated above
50°C.
WARNING: Do not leave a container of
refrigerant without its cap fitted. Do not
transport a container of refrigerant that is
unrestrained, especially in the boot of a car.

AIR CONDITIONING
3
ADJUSTMENT SERVICING EQUIPMENT
The following equipment is required for full servicing
of the air conditioning system.
Recovery, recycling and charging station
Leak detector
Thermometer +20°C to -60°C
Safety goggles and gloves
REFRIGERANT RECOVERY RECYCLING
RECHARGING
WARNING: The air conditioning system is
charged with a high pressure, potentially
toxic refrigerant. Repairs or servicing must
only be carried out by an operator familiar with
both the vehicle system and the charging and
testing equipment.
All operations must be carried out in a
well-ventilated area away from open flame and
heat sources.
Always wear safety goggles and gloves when
opening refrigerant connections.
WARNING: Wear eye and hand safety
protection. Open connections slowly in
case liquid or pressure is present. Allow to
bleed off slowly.
CAUTION: Overcharging air conditioning
system will cause excessive head
pressure.
An air conditioning portable Refrigerant Recovery
Recycling Recharging Station for use with R134a
refrigerant incorporates all the features necessary to
recover refrigerant R134a from the air conditioning
system, to filter and remove moisture, to evacuate and
recharge with the reclaimed refrigerant. The unit can
also be used for performance testing and air
conditioning system analysis.
The operator must adhere to the equipment
manufacturer's instructions.Recovery and recycling
1. High pressure servicing connection
2. Low pressure servicing connection
1.Connect a Refrigerant Station to the high and
low pressure servicing connections.
2.Operate the refrigerant recovery system
according to the manufacturer's instructions.
3.Measure the amount of oil discharged from the
system. Add an equal amount of new refrigerant
oil to compressor before evacuation sequence.
WARNING: Refrigerant must always be
recycled before reuse, to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system.
Recycling should always be carried out with
equipment which is design certified by
Underwriter Laboratory Inc. for compliance with
SAE-J1991. Other equipment may not recycle
refrigerant to the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and commercial
sources must not be used in motor vehicle air
conditioning systems.

AIR CONDITIONING
5
ADJUSTMENT AIR CONDITIONING SYSTEM - PERFORMANCE
TEST
WARNING: R134a is hazardous, refer to
the GENERAL PRECAUTIONS given at the
beginning of this section.
Carry out this test with bonnet and doors or windows
open, air conditioning switched on, temperature
control set to cold and blower at maximum speed. Set
the air supply control to supply fresh air.
1.Close low pressure valve on refrigerant station.
2.Close high pressure valve on refrigerant station.
3.Connect a Refrigerant Station to the high and
low pressure servicing connections.4.Insert dry bulb thermometer into cold air outlet
and position dry and wet bulb thermometer close
to outside air inlet.
Do not spill water from the wet thermometer
(psychrometer).
5.Start engine and run it at 1500 rev/min for 10
minutes with air conditioning switched on.
6.Check that sight glass is free of bubbles.
7.Read both pressure gauges and thermometers.
Check readings against table below with
humidity between 60% and 80%. If readings are
incorrect.
See Fault diagnosis, Refrigeration
System Faults.
8.Switch off air conditioning, stop engine,
disconnect test equipment.
Performance range
Intake temperature Outlet temperature Low pressure High pressure
20 - 24°C4-10°C 18 - 28 lbf/in
2213 - 299 lbf/in2
1.2 - 1.9 bar 14.7 - 20.6 bar
25 - 29°C9-19°C 27 - 37 lbf/in2256 - 341 lbf/in2
1.9 - 2.6 bar 17.6 - 23.5 bar
30 - 35°C20-27°C 33 - 47 lbf/in2299 - 384 lbf/in2
2.3 - 3.2 bar 20.6 - 26.5 bar
Table 1
Ambient Compound Gauge High Pressure
Temperature Readings Gauge Readings
ÊC°F bar lbf/in
2bar lbf/in2
16 60 1,03-1,4 15-20 6,9-10,3 100-150
26,7 80 1,4-1,72 20-25 9,6-13,1 140-190
38 100 1,72-2,1 25-30 12,4-15,5 180-225
43,5 110 2,1-2,4 30-35 14,8-17,2 215-250

AIR CONDITIONING
1
REPAIR PRECAUTIONS IN HANDLING REFRIGERANT
LINES
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
1.When disconnecting any hose or pipe
connection the system must be discharged of all
pressure. Proceed cautiously, regardless of
gauge readings. Open connections slowly,
keeping hands and face well clear, so that no
injury occurs if there is liquid in the line. If
pressure is noticed, allow it to bleed off slowly.
2.Lines, flexible end connections and components
must be capped immediately they are opened to
prevent the entrance of moisture and dirt.
3.Any dirt or grease on fittings must be wiped off
with a clean alcohol dampened cloth. Do not use
chlorinated solvents such as trichloroethylene. If
dirt, grease or moisture cannot be removed from
inside the hoses, they must be replaced with
new hoses.
4.All replacement components and flexible end
connections must be sealed, and only opened
immediately prior to making the connection.
5.Ensure the components are at room temperature
before uncapping, to prevent condensation of
moisture from the air that enters.
6.Components must not remain uncapped for
longer than fifteen minutes. In the event of delay,
the caps must be fitted.
7.Receiver/driers must never be left uncapped as
they contain Silica Gel crystals which will absorb
moisture from the atmosphere. A receiver/ drier
left uncapped must not be used, fit a new unit.
8.The compressor shaft must not be rotated until
the system is entirely assembled and contains a
charge of refrigerant.
9.A new compressor contains an initial charge of
of refrigerant oil. The compressor also contains a
holding charge of gas when received which
should be retained by leaving the seals in place
until the pipes are re-connected.10.The receiver/drier should be the last component
connected to the system to ensure optimum
dehydration and maximum moisture protection of
the system.
11.All precautions must be taken to prevent
damage to fittings and connections. Slight
damage could cause a leak with the high
pressures used in the system.
12.Always use two wrenches of the correct size,
one on each fitting when releasing and
tightening refrigeration unions.
13.Joints and 'O' rings should be coated with
refrigeration oil to aid correct seating. Fittings
which are not lubricated with refrigerant oil are
almost certain to leak.
14.All lines must be free of kinks. The efficiency of
the system is reduced by a single kink or
restriction.
15.Flexible hoses should not be bent to a radius
less than 90mm.
16.Flexible hoses should not be within 100mm of
the exhaust manifold.
17.Completed assemblies must be checked for
refrigeration lines touching metal panels. Any
direct contact of lines and panels transmits noise
and must be eliminated.