1999 LAND ROVER DISCOVERY Workshop Manual

DOORS
76-1-4 REPAIRS
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.

DOORS
REPAIRS 76-1-5
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. Refit
1.Fit glass to frame.
2.Position frame to door and tighten bolts
securing front door frame to 10 Nm (7 lbf.ft) and
bolts securing rear door frame to 22 Nm (16
lbf.ft).
3.Secure regulator to glass with bolts and tighten
to 6 Nm (4.4 lbf.ft).
4.Fit inner and outer waist seal and secure with
clips.
5. Front door glass only: Fit exterior door mirror.

+ EXTERIOR FITTINGS, REPAIRS,
Mirror - exterior - electric.
6.Fit water shedder to door.
7.Fit door trim casing.

+ DOORS, REPAIRS, Trim casing -
front door.

+ DOORS, REPAIRS, Trim casing -
rear door.

DOORS
76-1-6 REPAIRS
Quarter light
$% 76.31.31
Remove
1.Remove rear door glass.

+ DOORS, REPAIRS, Glass - front or
rear door.
2.Remove 2 bolts securing quarter light glass to
frame.
3.Remove quarter light glass from frame. Refit
1.Fit quarter light glass to frame.
2.Fit bolts securing quarter light glass to frame
and tighten to 10 Nm (7 lbf.ft).
3.Fit rear door glass.

+ DOORS, REPAIRS, Glass - front or
rear door.

DOORS
REPAIRS 76-1-7
Regulator and motor - front and rear
door glass
$% 76.31.45
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.Lower glass and remove 2 bolts securing door
glass to regulator.
4.Raise glass and secure with a suitable wedge.
5.Disconnect multiplug from glass lift motor.
6. Front door: Remove 6 bolts securing glass
regulator assembly to door.
7. Rear door: Remove 4 bolts securing glass
regulator assembly to door.
8.Manoeuvre regulator through access hole at
bottom of the door. 9.Remove 3 Torx screws securing glass lift
motor to regulator and remove motor.
Refit
1.Clean mating faces of regulator and motor.
2.Fit glass lift motor to regulator and tighten 3
Torx screws to 5 Nm (3.7 lbf.ft).
3.Position regulator in door. Fit bolts securing
regulator to door and tighten to 6 Nm (4.4
lbf.ft).
4.Connect multiplug to glass lift motor.
5.Remove wedge holding glass and position
glass to regulator.
6.Secure glass to regulator with bolts and tighten
to 6 Nm (4.4 lbf.ft).
7.Fit water shedder to door.
8.Fit door trim casing.

+ DOORS, REPAIRS, Trim casing -
front door.

+ DOORS, REPAIRS, Trim casing -
rear door.

DOORS
76-1-8 REPAIRS
Trim casing - front door
$% 76.34.01.99
Remove
1.Remove 2 screws securing hand rail to door.
2.Remove screw securing door handle
escutcheon to door.
3.Remove escutcheon.
4.Remove 4 screws securing pocket to door.
5.Carefully release 10 clips securing trim casing
to door.
6.If fitted, disconnect multiplug from upper door
speaker. 7.Disconnect multiplug from lower door speaker.
8.Remove trim casing from door.
Refit
1.Position trim casing to door and connect door
speaker multiplug(s).
2.Secure trim casing to door with clips.
3.Fit escutcheon to door handle and secure with
screw.
4.Fit hand rail to door and secure with screws.
5.Fit pocket to door and secure with screws.

DOORS
REPAIRS 76-1-9
Trim casing - rear door
$% 76.34.04.99
Remove
1.Remove screw securing door handle
escutcheon to door.
2.Disconnect multiplug from window switch.
3.Remove door handle escutcheon.
4.Remove 2 screws securing hand rail to door.
5.Carefully release 11 clips securing trim casing
to door.6.If fitted, disconnect multiplug from upper door
speaker.
7.Disconnect multiplug from lower door speaker.
8.Remove trim casing from door.
Refit
1.Position trim casing to door and connect door
speaker multiplug(s).
2.Secure trim casing to door with clips.
3.Fit hand rail to door and secure with screws.
4.Connect multiplug to window switch.
5.Fit escutcheon to door handle and secure with
screw.

DOORS
76-1-10 REPAIRS
Trim casing - tail door
$% 76.34.09.99
Remove
1.If fitted, remove tail door speaker.

+ IN CAR ENTERTAINMENT,
REPAIRS, Speaker - tail door.
2.Remove 2 bolts securing hand rail to tail door
and remove hand rail.
3.Remove screw securing door handle
escutcheon to door and remove escutcheon.
4.Carefully release 20 clips securing trim casing
to tail door.
5.Remove tail door trim casing. Refit
1.Fit trim casing to tail door and secure with clips.
2.Fit escutcheon to door handle and secure with
screw.
3.Fit hand rail to tail door and secure with bolts
tightened to 10 Nm (7 lbf.ft).
4.If applicable, fit tail door speaker.
+ IN CAR ENTERTAINMENT,
REPAIRS, Speaker - tail door.

DOORS
REPAIRS 76-1-11
Latch and motor - front door
$% 76.37.12
Remove
1.Remove front door frame.

+ DOORS, REPAIRS, Glass - front or
rear door.
2.Release exterior handle control rod from latch.
3.Release and disconnect sill button lock rod
from 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
aperture in the lower section of the door. 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.