Land Rover DISCOVERY 1996 BODY Repair Manual

CHASSIS AND BODY 1 REPAIR FRONT DOOR Service repair no - 76.28.01 Remove 1. Disconnect battery negative lead. 2. Detach the door seal at the lower section of the ’A’ post. 3. Carefully remove the two retaining buttons from the trim panel on the side of the footwell and ease out the panel. 4. Disconnect the three multiplugs connecting the door harness and speaker leads. 5. Detach the convoluted grommet from the ’A’ post and withdraw the door harness and speaker leads. 6. Set the door in the open position without engaging the check stay; then remove the roll pin securing the check stay at the ’A’ post. WARNING: Instruction 7 MUST BE carried out with assistance. 7. Remove the door hinge ’C’ clips from the hinge posts and with assistance carefully lift the door from the vehicle. Refit 8. Refit the door and secure the hinge posts with the ’C’ clips. 9. Locate the check stay to the bracket on the ’A’ post and secure with a new roll pin. 10. Feed the door harness and speaker leads through the aperture in the ’A’ post, fully open the door and reconnect the multiplugs in the footwell, take up the slack and refit the convoluted grommet to the ’A’ post. 11. Refit the footwell side panel. 12. Check the location of the door and the operation of the door lock. If necessary, adjust the door and striker. 13. The door can be adjusted up and down or in and out of the opening by loosening the six screws securing the hinges to the door, and by the addition or removal of shims between the hinge and door. 14. The door lock striker can be adjusted by loosening the striker and moving it in the appropriate direction or by adding and removing spacing washers between the striker and ’B’ post. cardiagn.com

76 CHASSIS AND BODY 2 REPAIR FRONT DOOR TRIM PANEL Service repair no - 76.34.01 Remove 1. Remove the two securing screws and detach the door pull from its mounting brackets on the inner door panel. 2. Remove the interior door handle finisher button to reveal the screw retaining the handle surround. 3. Remove the screw and detach the handle surround from the trim panel. 4. Where applicable remove the window winder. 5. Detach the trim panel by inserting a trim panel removing tool between the trim panel and the inner door panel, gently prise out the fourteen plastic securing clips from their respective holes in the inner door panel. 6. Disconnect the two speaker connections from inside the door and remove the trim panel complete with speaker, and door bin. 7. If a new trim panel is to be fitted, remove the speaker, door bin and remote button finisher from the existing trim panel and fit them to the new panel. Refit 8. Reverse removal procedure. FRONT DOOR GLASS AND REGULATOR Service repair no - 76.31.45 Remove 1. Ensure the window is in the fully closed position and secure with adhesive tape to prevent the window from dropping down. 2. Disconnect battery negative lead. 3. Remove the door trim panel. See front door trim panel. 4. Remove the plastic vapour barrier. 5. Where applicable remove the window lift motor. See ELECTRICAL, Repair, window lift motor - front. 6. Remove the four window regulator retaining screws and shakeproof washers from the inner door panel. 7. Remove the two screws and shakeproof washers retaining the lower window lift channel, and slide the channel off the stud. cardiagn.com

CHASSIS AND BODY 3 REPAIR 8. Disengage the lifting arm stud from the upper lifting channel, manoeuvre the window regulator and remove it from the lower centre opening in the inner door panel. 9. Remove the exterior driving mirror. See ELECTRICAL, Repair, exterior driving mirrors. 10. Remove the waist rail seal from the top of the door panel. 11. Remove the ’Torx’ bolt from the hinge face of the door which secures the front of the door frame. 12. Remove the bolt and plain washer from the opening edge of the door which secures the rear of the door frame. 13. Remove the bolt and plain washer from the recessed hole in the front of the inner door panel under the exterior driving mirror mounting plate. 14. Remove the screws and plain washers, from inside the door, securing the bottom of the front and rear glass channels. 15. Lift the door glass frame complete with glass out of the door panel and remove to a suitable bench. 16. Remove the adhesive tape securing the glass to the door frame. 17. Slide the glass out of the door frame channel. Refit NOTE: When refitting the door glass frame, ensure it is repositioned to suit the door opening before fully tightening the door frame securing bolts. 18. Reverse removal procedure. cardiagn.com

76 CHASSIS AND BODY 4 REPAIR FRONT DOOR LOCK, OUTSIDE AND INSIDE DOOR RELEASE HANDLES Service repair no - 76.37.12/31 Remove 1. Disconnect battery negative lead. 2. Remove the door trim panel. See front door trim panel. 3. Remove the door glass and regulator. See front door glass and regulator. 4. Where applicable remove the door actuator unit. See ELECTRICAL, Repair, front door actuator unit. 5. Disconnect the lock barrel control rod from the lock by releasing the metal clip at the bottom of the rod. 6. Disconnect the control rod from the outside door release handle by pulling it out of the plastic ferrule. 7. Disconnect the remote button control rod from the lock by releasing the metal clip at the bottom of the rod and withdraw the rod from the door. 8. Disconnect the control rod connector between the inside door release handle and the door lock by releasing the metal clip and pulling one of the control rods out of the plastic connecting block. This is accessible through the small centre cut-out in the door panel. The control rod also passes through a guide bracket in the inside of the inner door panel. 9. From inside the door panel push out the small pin that secures the quadrant to the inner door panel. Push the quadrant out of the panel. 10. Release the door lock by removing the two counter-sunk screws from the door edge and the single screw and shakeproof washer on the inner door panel. cardiagn.com

CHASSIS AND BODY 5 REPAIR 11. Withdraw the lock through the lower rear cut-out on the inner door panel. 12. Remove the two nuts, shakeproof washers and retaining bracket securing the outer door release handle to the outer door panel, accessible through the upper rear cut-out on the inner door panel. 13. Carefully detach the door release handle from the outer panel. 14. Remove the two screws securing the inside door release handle to the inner panel. 15. Withdraw the handle from its location with the connecting rod half still attached. 16. Unclip the end of the connecting rod from the handle. Refit 17. Reverse removal procedure. cardiagn.com

76 CHASSIS AND BODY 6 REPAIR ADJUSTMENT-FRONT DOOR LOCK AND HANDLE ASSEMBLY Service repair no - 76.37.47 Inside door release handle to lock 1. Refit the inside door release handle surround before any adjustment is made, allowing the handle to be set from the correct operating position. 2. At the lock end of the interior handle connecting rod, rotate the spring tensioned nyloc nut clockwise or counter-clockwise, as necessary to shorten or extend the operating length of the rod. Outside door release handle to lock 3. Disconnect the connecting rod from the plastic ferrule at the rear of the outer door release handle. Rotate the rod clockwise or counter-clockwise to shorten or extend the operating length as necessary. NOTE: Door release should be effective before the total handle movement is exhausted to provide a small overthrow movement. cardiagn.com

CHASSIS AND BODY 7 REPAIR REAR SIDE DOORS Service repair no - 76.28.02 Remove 1. Disconnect battery negative lead. 2. Detach the convoluted grommet from the ’B’ post. 3. Withdraw the door harness multiplugs from the ’B’ post and disconnect them. 4. Remove the bolts and washers securing the check strap to the ’B’ post. WARNING: Instruction 5 MUST BE carried out with assistance. 5. Remove the door hinge ’C’ clips from the hinge posts and with assistance carefully lift the door from the vehicle. Refit 6. Reverse removal procedure. Fitting new ’C’ clips if the existing ones are worn or distorted. 7. Check the operation of the door and lock. If necessary, adjust the door and striker. Adjust 8. Adjust the door by adding or removing shims between the hinge and the door to move the door forward or rearward in the opening. 9. To adjust the door up, down or in and out of the opening, loosen the screws securing the hinges to the door, adjust as necessary and retighten the screws to the correct torque value. 10. Adjustment of the door striker is identical to the procedure for front doors. NOTE: If it is necessary to remove the hinges from the ’B’ post they must be refitted in exactly the same position, using an equal thickness of shims to those removed. cardiagn.com

76 CHASSIS AND BODY 8 REPAIR REAR SIDE DOOR - TRIM PANEL Service repair no - 76.34.04 Remove 1. Disconnect battery negative lead. 2. Remove the two securing screws and detach the door pull from its mounting brackets. 3. Remove the securing screw and detach the interior door release handle surround. 4. Where applicable remove the window winder or release electric switch and disconnect. 5. Detach the trim panel by inserting a trim panel removing tool between the trim panel and the inner door panel, gently prise out the plastic securing clips from their respective holes in the inner panel. 6. Lift the trim panel over the remote button and clear of the door. Where applicable disconnect the electrical plug from the window lift switch and withdraw the panel. NOTE: With the trim panel removed the remote button and rod will fall from its location in the bellcrank. Observe its correct location and withdraw from the door panel. 7. If a new trim panel is to be fitted, remove the window lift switch, door bin and remote button finisher from the existing trim panel and fit them to the new panel. Refit 8. Reverse removal procedure. Ensuring correct fitment of the sill button operating rod. cardiagn.com

CHASSIS AND BODY 9 REPAIR REAR SIDE DOOR LOCK, INSIDE AND OUTSIDE RELEASE HANDLES Service repair no - 76.37.13/32 Remove 1. Ensure that the window is in the fully closed position. 2. Disconnect battery negative lead. 3. Remove the interior trim panel from the door. See rear side door - trim panel. 4. Remove the plastic vapour barrier sheet. 5. Disconnect the inside release handle control rod by pulling it from its location in the door lock. 6. Disconnect the sill locking control rod from the lock by releasing the metal clip. 7. Disconnect the outside release handle control rod by pulling it out of the plastic ferrule. 8. Remove the two countersunk screws from the door edge and the single screw and shakeproof washer from the inner door panel. Retrieve any spacing washers which may be fitted between the inner door panel and lock. 9. Withdraw the lock through the upper rear opening in the inner door panel. NOTE: If necessary the following items can be removed. 10. Remove the two nuts, shakeproof washers and retaining bracket securing the outer release handle which are accessible through the upper rear cut-out on the inner door panel. 11. Carefully detach the handle from the outer door panel. 12. Remove the two screws and plain washers securing the inside release handle to the inner door panel and withdraw the handle complete with connecting rod. 13. Disconnect the sill button connecting rod from the bellcrank and withdraw the rod complete with sill button. Sill locking bellcrank 14. Using a small screwdriver, or length of 3.175 mm (1/8 in) diameter rod, press the plastic locking pins through the respective square inserts in the inner door panel. 15. Release the bellcranks from the inner door panel and unhook the respective connecting rods. 16. Withdraw the bellcranks from inside the door panels. NOTE: When refitting the bellcranks the locking pins are entered into the square insert from outside and pressed in flush. cardiagn.com

76 CHASSIS AND BODY 10 REPAIR ADJUSTMENT-REAR SIDE DOOR LOCK AND HANDLE Service repair no - 76.37.47 Outside door release handle to lock 1. Disconnect the short off-set connecting rod at the rear of the outer release handle, rotate the rod clockwise or counter clockwise to shorten or extend the operating length of the rod as required. NOTE: Door release should occur before the total handle movement is achieved to provide a small overthrow movement. REAR SIDE DOOR GLASS AND REGULATOR Service repair no - 76.31.45 Remove 1. Ensure that the window is in the fully closed position and secure it with adhesive tape over the top of the door to prevent the glass from dropping down. 2. Disconnect battery negative lead. 3. Remove the door trim panel. See rear side door - trim panel. 4. Remove the plastic vapour barrier. 5. Where applicable remove the door actuator and window lift motor. See ELECTRICAL, Repair, window lift motor - rear. See ELECTRICAL, Repair, rear side door actuator units. 6. Remove the four window regulator securing screws and shakeproof washers from the inner door panel. 7. Carefully disengage the lifting arm stud from the glass lifting channel and remove the window regulator from the lower opening in the inner door panel. 8. Remove the waist rail seal from the top of the door panel. 9. Remove the single bolt, spring and plain washers from inside the door, securing the bottom of the short glass run channel. 10. Remove the two bolts, spring and plain washers from the hinge face of the door. cardiagn.com

Land Rover DISCOVERY 1996 BODY Repair Manual

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