Discovery 2. Manual — part 647

DOORS

REPAIRS

76-1-1

DOORS

REPAIRS

Door - front

$% 76.28.01.99

Remove

1. Release 'A' post lower trim and position aside.

2. Release and disconnect multiplugs from lower

'A' post.

3. Release harness sleeve and pull harness

through 'A' post.

4. Remove roll pin from door check strap.
5. Release check strap from 'A' post.
6. Discard roll pin.
7. Remove 2 'C' clips from door hinges.
8. With assistance raise and remove door.

Refit

1. With assistance position door to hinges.
2. Fit 'C' clips to hinge pins.
3. Position check strap to 'A' post and secure with

new roll pin.

4. Feed door harness through 'A' post.
5. Connect and secure multiplugs at lower 'A'

post.

6. Connect harness sleeve to 'A' post and door.
7. Fit 'A' post finisher.
8. Check door for flush fit to adjacent panels and

door edges for equal gap. If adjustment is
necessary:

a Open door

b Place a wooden block on jack and position

jack to support door lower edge.

c Loosen 4 bolts securing hinges to door.

d Loosen 2 Torx bolts securing door latch

striker.

e Use jack to assist with door alignment.

f Tighten hinge bolts.

g Remove jack, close door and check for

correct alignment.

h When alignment is correct, tighten door

hinge bolts to 30 Nm (22 lbf.ft).

i Adjust door latch striker and tighten Torx

bolts to 26 Nm (19 lbf.ft).

DOORS

76-1-2

REPAIRS

Door - rear

$% 76.28.02.99

Remove

1. Release 'B' post lower trim casing and position

aside.

INTERIOR TRIM COMPONENTS,

REPAIRS, Trim casing - lower - 'B' post.

2. Release multiplugs from within 'B' post and

disconnect.

3. Release harness sleeve and pull through 'B'

post.

4. Remove roll pin from check strap and discard.
5. Release check strap from 'B' post.
6. Remove 2 'C' clips securing door to each hinge.
7. With assistance raise and remove door.

Refit

1. With assistance position door to hinges.
2. Fit 'C' clips to hinge pins.
3. Position check strap to 'B' post and secure with

new roll pin.

4. Feed door harness through 'B' post and

connect multiplugs.

5. Connect harness sleeve to 'B' post and door.
6. Fit 'B' post lower trim casing.

INTERIOR TRIM COMPONENTS,

REPAIRS, Trim casing - lower - 'B' post.

7. Check door for flush fit to adjacent panels and

door edges for equal gap. If adjustment is
necessary:

a Open door.

b Place a wooden block on jack and position

jack to support door lower edge.

c Loosen 4 bolts securing hinges to door.

d Loosen 2 Torx bolts securing door latch

striker.

e Use jack to assist with door alignment.

f Tighten hinge bolts.

g Remove jack, close door and check for

correct alignment.

h When alignment is correct, tighten door

hinge bolts to 30 Nm (22 lbf.ft).

i Adjust door latch striker and tighten Torx

bolts to 26 Nm (19 lbf.ft).

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

door.

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.

DOORS

76-1-4

REPAIRS

19. Remove 6 bolts securing tail door hinges to

body and, with assistance, remove tail door.

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.