Discovery 2. Manual — part 255

SUNROOF

REPAIRS 76-6-17

Glass panel - sunroof

$% 76.84.03

The procedure for replacing the rear sunroof glass
panel is exactly the same as for the front

Remove

1. Partially open sunroof.

2. Remove 4 Torx screws securing glass to

sunroof frame.

3. Remove sunroof glass.

Refit

1. Position glass to frame.
2. Fit Torx screws securing glass to sunroof

frame. Do not fully tighten screws at this stage.

3. Adjust position of sunroof glass in relation to

roof panel until a 6.5 mm (0.25 in) gap is
produced between the front edge of the glass
and the sunroof frame.

4. Tighten sunroof glass retaining screws to 3 Nm

(2.2 lbf.ft).

SUNROOF

76-6-18 REPAIRS

Motor - sunroof

$% 76.84.07

This procedure is applicable to the motor of both
sunroofs.

Remove

1. Gain access to the sunroof motor:

l

For front sunroof motor, remove front
stowage pocket.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Stowage pocket - front.

l

For rear sunroof motor, remove headlining.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Headlining.

CAUTION: The sunroof must be fully closed
before removing the sunroof motor.

2. Disconnect sunroof motor multiplug.
3. Remove 3 Torx screws securing motor to

sunroof tray.

4. Remove sunroof motor.

Refit

1. Check sunroof motor timing notch (A) aligns

with edge of microswitch (B). If motor is out of
alignment, rotate counting wheel (C) to correct
position using an Allen key.

2. Ensure sunroof drive cables are in fully closed

position.

3. Fit motor to sunroof frame.
4. Fit Torx screws securing motor to sunroof tray

and tighten to 2 Nm (1.5 lbf.ft).

5. Connect sunroof motor multiplug.
6. Fit interior trim:

l

For front sunroof motor, fit front stowage
pocket.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Stowage pocket - front.

l

For rear sunroof motor, fit headlining.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Headlining.

SUNROOF

REPAIRS 76-6-19

Drive cable assembly

$% 76.84.09

This procedure is applicable to the drive cable
assembly of both sunroofs.

Remove

1. Remove sunroof:

l

For front drive cable assembly:

+

SUNROOF, REPAIRS, Sunroof -

front.

l

For rear drive cable assembly:

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SUNROOF, REPAIRS, Sunroof -

rear.

2. Position sunroof assembly on suitable work

bench.

3. Remove 4 Torx screws securing glass to

sunroof frame.

4. Remove sunroof glass.

5. Release both glass carriers from cables and

remove.

6. Remove 10 Torx screws securing frame to

drive cable assembly.

7. Remove drive cable assembly from frame.

Refit

1. Fit drive cable assembly to frame.
2. Fit Torx screws securing frame to drive cable

assembly and tighten to 2.5 Nm (1.8 lbf.ft).

3. Fit glass carriers to cables.
4. Fit glass to sunroof frame and secure with Torx

screws. Do not fully tighten screws at this
stage.

5. Fit sunroof.

l

For front drive cable assembly:

+

SUNROOF, REPAIRS, Sunroof -

front.

l

For rear drive cable assembly:

+

SUNROOF, REPAIRS, Sunroof -

rear.

6. Remove timing pegs supplied with drive cables.
7. Adjust position of sunroof glass in relation to

sunroof panel until a 6.5 mm (0.25 in) gap is
produced between the front edge of the glass
and the sunroof frame.

8. Tighten sunroof glass retaining screws to 3 Nm

(2.2 lbf.ft).

SUNROOF

76-6-20 REPAIRS

Switch pack - sunroof

$% 76.84.44

Remove

1. Release switch pack from front stowage

pocket.

2. Disconnect multiplugs from 3 sunroof

switches.

3. Remove switches from switch pack.

Refit

1. Fit switches to switch pack.
2. Connect multiplugs to switches.
3. Fit switch pack to front stowage pocket.

ECU - sunroof

$% 76.84.46

Remove

1. Remove front stowage pocket.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Stowage pocket - front.

2. Remove 2 screws securing ECU to roof.
3. Disconnect 2 multiplugs from ECU.
4. Remove sunroof ECU.

Refit

1. Position sunroof ECU and connect multiplugs.
2. Fit and tighten screws securing ECU to roof.
3. Fit front stowage pocket.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Stowage pocket - front.