1995 LAND ROVER DISCOVERY Workshop Manual

76CHASSIS AND BODY
14
REPAIR Lock barrel and number plate light housing
Disassemble
NOTE: The lock barrel can only be
removed from its housing when the lock
barrel and number plate light housing is
removed from the door.
20.Remove the bolt securing the lock barrel
mounting bracket to the housing and withdraw
the assembled barrel and bracket.
21.Remove the 'O' ring seal from inside the
housing.
22.Remove the spring clip securing the barrel to the
bracket and withdraw the barrel and stem
assembly from the bracket complete with seal.
23.Remove the 'U' clip securing the stem to the
barrel and detach the seal from the inner face of
the barrel.
24.If the lock barrel and number plate light housing
is being renewed, remove the number plate
lights, harness and the housing mounting
bracket, from the existing housing and fit them to
the new housing.
Reassemble
25.Fit the stem to the barrel and secure with the 'U'
clip.
26.Position a new seal on the inner face of the
barrel, insert the stem and barrel into the
mounting bracket and secure with the spring clip.
27.Place a new 'O' ring seal on the inner face of the
barrel aperture in the housing.
28.Insert the assembled bracket and barrel into its
location in the housing, taking care not to disturb
the seal, and secure with the bolt.Refit
29.Fit the outer handle to the door and secure from
the inside with the two nuts and washers.
30.Fit the lock barrel and number plate light housing
by inserting the number plate light leads through
the aperture in the door panel and locating the
rubber grommet in the aperture. Insert the barrel
stem through the door, locate the housing on the
door panel, ensure that the seal seats correctly,
and secure with the single bolt and washer
through the logo aperture.
31.Connect the number plate light leads to the door
harness.
32.Fit the logo to the aperture in the housing.
33.Fit the fulcrum and connecting rod to the barrel
stem and secure with secure with the 'E' clip.
34.Fit the lock and assembled outer 'Y' lever,
secure the lock with the three screws, locate the
'Y' lever pivot and secure with the pin.
35.Fit the connecting rod from the outer handle
lever to the outer 'Y' lever.
36.Fit the childproof lock actuator and check that it
is functioning.
37.Insert the remote button and rod to the location
in the door.
38.Offer up the assembled inner 'Y' lever and
bracket, attach the barrel connecting rod to the
top clip of the upper leg and the rod from the
lock to the lower clip of the upper leg.
39.Locate the barrel stem in the insert on the
bracket.
40.Secure the bracket with the four screws; fitting
the door pull mounting bracket under the heads
of the top two screws.
41.Attach the remote button and the actuator
connecting rods to the 'Y' lever.
42.Fit the inner release handle and attach the
connecting rod to the lock.
43.Refit the vapour protective sheet, door trim panel
and door pull.

CHASSIS AND BODY
15
REPAIR REAR DOOR CHECK STAY
Service repair no - 76.40.30
Remove
1.Remove the rear door from the vehicle.
See
rear door.
2.Invert the door on a suitable protected area.
3.Remove the two securing bolts and withdraw the
check stay assembly.
Refit
4.Reverse removal procedure.REAR COMPARTMENT LOWER TRIM PANELS
Service repair no - 76.13.03
Remove
1.Remove the fold down seat or pocket side panel,
whichever is applicable.
See rear fold down
seats.
2.Remove speaker by releasing screws and
disconnecting Lucars. Withdraw rear quarter trim
panel.
3.Remove the five trim panel retainers.
4.Ease the trim panel from its location, feed the
seat belts through the apertures and withdraw
the panel.
Refit
5.Reverse removal procedure.

76CHASSIS AND BODY
16
REPAIR ALPINE LIGHT TRIM CASING
Service repair no - 76.13.20
Remove
1.Remove RH 'E' post trim casing.
See 'E' post
trim casing - rh.
2.Remove rear seat belt anchorage retaining bolt
cover.
3.Remove bolt securing rear seat belt anchorage.
4.Remove 2 trim studs securing trim casing.
5.Release trim casing from 2 retaining studs.
6.Remove trim casing.
Refit
7.Fit and align trim casing and secure with studs.
8.Fit 2 trim studs securing trim casing.
9.Position seat belt anchorage, fit bolt and tighten
to
32 Nm (24 lbf ft).
10.Fit cover to seat belt anchorage bolt.
11.Fit 'E' post trim casing.
See 'E' post trim
casing - rh.

CHASSIS AND BODY
17
REPAIR FRONT BODYSIDE TRIM CASING
Service repair no - 76.13.01
Remove
1.Remove the grab handle.
2.Remove the rear compartment lower trim panel.
See rear compartment lower trim panels.
3.Remove the alpine light trim casing.See alpine
light trim casing.
4.Remove the bolts securing the upper and lower
seat belt mountings.
5.Remove the finisher from its location over the
seat belt inertia reel.
6.Remove the front seat belt guide from the upper
aperture in the casing.
7.Open the side window, remove the catch
securing screws and withdraw the catch trim.
8.Remove the side window hinge finishers.
9.Release the casing from the window rubber.
10.Release the rear seat belt from the guide
attached to the casing.
11.Fold down the rear seats and carefully ease the
casing from the fastenings.
12.Pass the front seat belt through the upper
aperture and withdraw the casing from the
vehicle.
Refit
13.Reverse removal procedure.
NOTE: Ensure that the trim material glued
to the door post is not wrinkled when the
door seal is fitted.
14.Tighten upper and lower seat belt fixings to
32
Nm (24 lbf ft)
.

76CHASSIS AND BODY
18
REPAIR HEADLINING
Service repair no - 76.64.01/14
Remove
1.Disconnect battery negative lead.
2.Remove the lower trim panels from the rear
compartment.
See rear compartment lower
trim panels.
3.Remove the alpine light trim casing.See alpine
light trim casing.
4.Remove the front bodyside trim casing.See
front bodyside trim casing.
5.Remove the roof lights from the headlining
pocket and from the headlining.
6.Remove the front grab handles.
7.Remove the sun visors and their retaining clips.
8.Remove the front headlining pocket.9.Remove the finishers from the sun roof
apertures.
10.Release the headlining from the channel above
the rear door and manoeuvre it from the vehicle
through the rear door.
11.If the existing headlining is being replaced, if
fitted, remove the passenger net pockets and fit
them to the new headlining.
Refit
12.Reverse removal procedure.

CHASSIS AND BODY
19
REPAIR 'D' POST TRIM CASING
Service repair no - 76.13.73
Remove
1.Remove the rear compartment lower trim panel.
See rear compartment lower trim panels.
2.Remove the alpine light trim casing.See alpine
light trim casing.
3.Release the rear seat belt from the guide
attached to the casing.
4.Fold down the rear seats.
5.Release the D' post casing from the rear side
window seal and carefully ease the casing from
the fasteners.
Refit
6.Reverse removal procedure.BODY SIDE OPENING WINDOWS
Service repair no - 76.81.18
Remove
1.Remove the screws securing the catch to the
body and detach the catch trim.
2.Remove the hinge finishers from the hinges.
3.Remove the screws securing the glass to the
hinges, withdraw the glass and fixings taking
care not to lose the joint washers.
Refit
4.Reverse removal procedure.

76CHASSIS AND BODY
20
REPAIR BODY SIDE WINDOW HINGES
Service repair no - 76.81.47
Remove
1.Remove the window.
See body side opening
windows.
2.Remove the passenger grab handle.
3.Detach the front seat belt top mounting from the
door post.
4.Ease the trim panel away from the door post to
gain access to the window hinges.
5.Remove the screws securing the window hinges,
taking care not to lose the the packing washers
where fitted. Note the thickness and location of
any packing washers fitted.
Refit
6.Fit the hinges with packing washers fitted to the
locations and thickness noted during removal.
Do not fully tighten the screws at this stage.
7.Refit the glass to the hinges.
8.Locate the window catch trim and secure the
catch to the body.
9.Close the window and secure with the catch.
10.Check the alignment and squareness of the
glass, adjust as necessary by adding or deleting
washers and using the elongated slots in the
hinges for adjustment, finally tighten the screws.
11.Reposition the trim panel and refit the hinge
finishers.
12.Refit the top seat belt bracket and the grab
handle.REAR SIDE FIXED WINDOWS
Service repair no - 76.81.18
Remove
1.If fitted push out the glass and remove the
mounting rubber.
2.Remove the rear seat belt top fixing.
Refit
3.Thoroughly clean the opening to be glazed.
4.Clean the glass and fit the mounting rubber,
ensuring that the glass sits correctly in the
groove.
5.Fit a draw cord around the exterior of the
mounting rubber.
6.To aid assembly, coat the flange in the bodyside
with liquid soap.
7.Position the assembled glass and rubber
mounting to the opening in the body, with the
tails of the draw cord fed into the interior of the
vehicle.
8.With assistance from a second operator, pushing
the glass and mounting rubber into the opening,
pull the draw cord from the mounting rubber
enabling the seal to ride up over the retaining
flange.
9.Ease the inner section of the mounting rubber
over the interior trim panel.

CHASSIS AND BODY
21
REPAIR REAR DOOR GLASS
Service repair no - 76.31.21
Remove
1.Remove the spare wheel from the rear door.
2.Remove the rear door wiper arm.
See WIPERS
AND WASHERS, Repair, wiper arm - rear
window.
3.If the glass is fitted, disconnect the heater leads
from the terminals, push out the glass and
remove the mounting rubber.Refit
4.Thoroughly clean the opening to be glazed.
5.Clean the glass and fit the mounting rubber,
ensuring that the glass sits correctly in the
groove.
6.Fit a draw cord around the exterior of the
mounting rubber with the tails of the cord
situated on the top corner of the bend at the
bottom of the glass.
7.To aid assembly, coat the glass opening in the
door with liquid soap.
8.Position the assembled glass and rubber
mounting to the opening, with the tails of the
draw cord fed into the interior of the vehicle.
9.With assistance from a second operator, pushing
the glass and mounting rubber into the opening,
pull the draw cord from the mounting rubber
enabling the seal to ride up over the retaining
flange.
10.Connect the heater leads to the terminals on the
glass.