Discovery 2. Manual — part 227
DOORS
REPAIRS
76-1-3
Door - tail
$% 76.28.19.99
Remove
1. Remove spare wheel from tail door.
2. Remove tail door trim casing.
DOORS, REPAIRS, Trim casing - tail
3. Carefully release water shedder from tail door.
4. Disconnect multiplug from door latch.
5. Disconnect multiplug from rear wiper motor.
6. Disconnect 2 Lucars from Heated Rear
Window (HRW).
7. Disconnect multiplug from number plate lamp.
8. Remove 2 screws securing Centre High
Mounted Stop Lamp (CHMSL) cover to tail door
glass.
9. Remove CHMSL cover.
10. Disconnect 2 Lucars from CHMSL.
11. Attach draw string to CHMSL wires and draw
wires through tail door. Disconnect draw string
from wires.
12. Tape draw string in tail door to retain its
position.
13. Release washer tube from rear of wiper arm.
14. Release 3 clips securing harness to tail door.
15. Release harness sleeve from door outer edge
and feed harness and washer tube through
door.
16. Remove spring clip securing check strap to tail
door aperture and collect washer.
17. Mark position of hinges.
18. Support the tail door on a jack, using a block of
wood to protect the door.
19. Remove 6 bolts securing tail door hinges to
body and, with assistance, remove tail door.
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
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.
2. Carefully release water shedder from door.
3. Front door glass only: Remove exterior door
mirror.
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.
6. Fit water shedder to door.
7. Fit door trim casing.
DOORS
76-1-6
REPAIRS
Quarter light
$% 76.31.31
Remove
DOORS, REPAIRS, Glass - front or
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.
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