Discovery (1995+): Body Repair Manual — part 20
76
CHASSIS 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 this section.
3. Remove the alpine light trim casing.
See this
section.
4. Remove the front bodyside trim casing.
See
this section.
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 this section.
2. Remove the alpine light trim casing.
See this
section.
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.
76
CHASSIS AND BODY
20
REPAIR
BODY SIDE WINDOW HINGES
Service repair no - 76.81.47
Remove
1. Remove the window.
See this section.
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.
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.
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