Discovery 2. Manual — part 226

RESTRAINT SYSTEMS

REPAIRS

75-29

Rotary coupler

$% 76.74.20

WARNING: It is imperative that before any work
is undertaken on the SRS system the appropriate
information is read thoroughly.

WARNING: Always disconnect both battery leads
before beginning work on the SRS system.
Disconnect the negative battery lead first. Never
reverse connect the battery.

Remove

1. Remove the key from the starter switch.

Disconnect both battery leads, negative lead
first. Wait ten minutes before starting work.

2. Remove steering wheel.

+

STEERING, REPAIRS, Steering

wheel.

3. Remove steering column nacelle.

+

STEERING, REPAIRS, Nacelle -

steering column.

4. Release rotary coupler multiplug from bracket

and disconnect from harness.

5. Disconnect rotary coupler multiplug from

harness.

6. Remove rotary coupler.

Refit

1. Fit rotary coupler to steering column and

connect multiplug to harness.

2. Connect rotary coupler multiplug to harness

and secure to bracket.

3. Fit steering column nacelle.

+

STEERING, REPAIRS, Nacelle -

steering column.

4. Fit steering wheel.

+

STEERING, REPAIRS, Steering

wheel.

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).