1999 LAND ROVER DISCOVERY door lock

EXTERIOR FITTINGS
76-2-4 REPAIRS
Refit
1.Clean front wing body mounting brackets.
2.Fit and secure the front wheel arch finisher to
the front wing.
3.Position lower support bracket to the front wing,
fit nut and tighten to 8 Nm (6 lbf.ft).
4.Position front wing to body, fit bracket and bolts
but do not tighten at this stage.
5.Check and adjust alignment of the front wing to
the bonnet and door.
6.Tighten the front wing retaining bolts to 8 Nm (6
lbf.ft).
7.Fit bonnet sealing rubber to the front wing
flange.
8.Fit bolt securing lower support bracket to the
body and tighten to 8 Nm (6 lbf.ft).
9.Fit nut securing sill finisher to the front wing
lower support bracket and tighten to 8 Nm (6
lbf.ft).
10.Fit bolt securing front wing to the front support
bracket and tighten to 8 Nm (6 lbf.ft).
11.Fit side repeater lamp to the front wing and
connect the multiplug.
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).

INTERIOR TRIM COMPONENTS
76-3-16 REPAIRS
Louvre panel assembly - centre fascia
$% 76.46.42
Remove
1.Remove radio cassette player from fascia.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio.
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
REPAIRS 76-3-17
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.
9.Fit drinks tray.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Drink tray assembly - centre
fascia.
10.Fit and secure radio DIN socket.
11.Fit screw cover to radio aperture.
12.Fit radio cassette player.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio.

CHASSIS AND BODY DIMENSIONS
77-1-12 BODY DIMENSIONS
Rear end information
I.D Description Length
A Distance between taildoor setting block, jig location hole
and taildoor bottom hinge, middle fixing hole1364.4 (53.716)
B Distance between taildoor setting block, jig location hole
and taildoor top hinge, middle fixing hole1319.8 (51.960)
C Distance between crossmember outer rear panel, jig
location hole and rear headrest fixing hole 1413 (55.629)
M77 1758A
A
B
C

PANEL REPAIRS
REPAIRS 77-2-41
Refit
1.Fit side drip rail finisher.
2.Fit wiring to 'B/C' post and sill areas.
3.Fit front and rear door door aperture seal.
4.Position carpet and secure with fixings.
5.Fit tread plates to front and rear door apertures.
6.Fit head lining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
7.Fit rear seat.

+ SEATS, REPAIRS, Seat - rear.
8.Fit front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
9. LH side: Fit CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
10. RH side: Fit power amplifier.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
11.Fit RH or LH front seat.

+ SEATS, REPAIRS, Seat - front.
12.Fit sill finisher.
13.Fit front door striker to B/C post, fit Torx bolts
and tighten to 26 Nm (19 lbf.ft).
14.Fit rear door.

+ DOORS, REPAIRS, Door - rear.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
Panel body side assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove loadspace side trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
4.Remove head lining rear trim finisher.
5.Remove rear head rests, if fitted.
6.Remove body side rear glass.

+ SCREENS, REPAIRS, Glass - body
side - rear.
7.Remove rear bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - rear - up to 03MY.
8.Remove rear bumper finisher.
9.Remove rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - rear.
10.Remove mud flap.
11.Remove tread plate from rear door aperture.
12.Remove rear door aperture seal.
13.Remove rear door striker from 'D' post.
14.Remove 'D' post outer trim finisher.
15.Remove wheel arch trim finisher.
16.Remove side drip rail finisher.
17. RH side: Remove tail door.
18. LH side: Remove tail door striker and setting
block from 'E' post.
19.Remove tail door tread plate.
20.Remove loadspace carpet retainer.
21.Remove tail door aperture seal.
22.Remove tail lamp.

+ LIGHTING, REPAIRS, Lamp - tail.
23. RH side: Remove fuel filler flap.
24. RH side: Remove fuel filler tube.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
25.Remove aerial amplifier.
26.Remove relevant wiring from body side area.

PANEL REPAIRS
77-2-42 REPAIRS
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. The panel
body side assembly does not require any
welding, as it is bolted into position.Refit
1.Position and secure wiring.
2.Fit aerial amplifier.
3. RH side: Fit fuel filler tube.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
4. RH side: Fit fuel filler flap.
5.Fit tail lamp.

+ LIGHTING, REPAIRS, Lamp - tail.
6.Fit tail door aperture seal.
7.Fit loadspace carpet retainer.
8.Fit tail door tread plate.
9. LH side: Fit tail door striker and setting block to
'E' post, fit Torx bolts and tighten to 26 Nm (19
lbf.ft).
10. RH side: Fit tail door.
11.Fit side drip rail finisher.
12.Fit wheel arch trim finisher.
13.Fit 'D' post outer trim finisher.
14.Fit rear door striker.
15.Fit rear door aperture seal.
16.Fit tread plate to rear door aperture.
17.Fit mud flap.
18.Fit rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - rear.
19.Fit rear bumper finisher.
20.Fit rear bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - rear - up to 03MY.
21.Fit body side rear glass.

+ SCREENS, REPAIRS, Glass - body
side - rear.
22.Fit rear head rests, if fitted.
23.Fit head lining rear trim finisher.
24.Fit loadspace side trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
25.Connect leads/multiplug to alternator.
26.Connect battery leads, negative lead last.
M77 0000

PANEL REPAIRS
TIMES 77-2-55
TIME S
TIME SCHEDULES
The following information shows the time taken to replace damaged panels and assemblies. This time includes
removal of Mechanical, Electrical and Trim (MET) parts, and also time for painting, based on using Clear Over Base
(COB) Metallic paint.
The times shown were generated by Thatcham (the Motor Insurance Repair and Research Centre) and are to be used
as a guide only.
All times shown are in decimal hours.
Single panel/assembly replacement times
Panel DescriptionTotal times
Petrol Diesel
Bonnet 7.4 7.4
Bonnet locking platform 8.4 8.4
Front cross member 9.3 8.1
Front bulkhead assembly 10.5 9.3
Headlamp mounting panel RH 9.3–
Headlamp mounting panel LH 9.4–
Front wing RH 7.2 7.2
Front wing LH 7.1 7.1
Front door – skin 10.8 10.8
Front door 7.9 7.9
Rear door – skin 10.0 10.0
Rear door 7.6 7.6
'A' post assembly RH 11.4–
'A' post assembly LH 11.3–
'B/C' post assembly 11.3–
Sill outer assembly RH 14.8–
Sill outer assembly LH 13.9–
Panel body side assembly RH 15.5 15.5
Panel body side assembly LH 13.4 13.4
Cross member outer rear panel (centre section) 13.4 13.4
Tail door 9.3 9.3
Roof30.3 30.3

CORROSION PREVENTION AND SEALING
77-4-14 SEALING
Seam sealer - doors. Seams symmetrically opposite to those shown are also treated. Ensure drain holes in doors are
not blocked by sealant.
A heat cured, PVC based sealant is applied to specific joint seams during factory assembly. This material is not
suitable for service use and, during repair, should be substituted by an approved Seam Sealer.

+ BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.
Seams to which seam sealer is applied during factory assembly are detailed in the previous illustrations.
Apply seam sealers after the application of primer and before the application of surfacer and top coat. The seam
sealer must form a continuous bead, with the profile of the bead dependant on the type of seam. If seam sealer is
applied with a brush, take particular care to maintain the required coverage of the seam. Where shaping of the seam
sealer is required, use a cloth soaked with solvent such as white spirit or Shell SBP3 to achieve the required finish.
Ensure that ALL accessible repair seams are sealed following a repair. Damage to a vehicle often flexes areas of the
body remote from the impact. As a result, the seam sealer in these areas may be disturbed by subsequent
straightening and repair operations. Check all seams in the vicinity of the area undergoing repair for evidence of
cracked seam sealer, then clean out as required and apply fresh seam sealer using the following procedure:
lClean the affected seam and re-treat any exposed metal areas with a suitable etch phosphate primer;
lApply appropriate seam sealer as necessary;
lTreat affected area with an acid-etch prime (and underbody sealer as applicable);
lApply appropriate colour coat.
Where seams are inaccessible following the reassembly or fitting of components, ensure that a paste-type seam
sealer is applied to such seams. Certain seams also become inaccessible after the completion of panel repairs. In
such instances apply seam sealer and paint before final assembly.
Provided access is adequate, apply seam sealer to both sides of a repair joint. Where access is limited to one side
only (e.g. box sections), treat the affected box member with cavity wax.
M77 1666A