Take one discovery td5 ES with a perpetually soggy roof and a multitude of drips onto the drivers legs and rear seat and try to find out why its leaking and fix it without trashing all the clips, headlining and panels.
To start with CLEAN ALL YOUR TOOLS.
There is no point trying to prise off plastic clips and manhandling bits of trim if your hands and tools are covered in cv grease. You'll just end up making a mess and really pissing off the wife when she sees the interior covered in black fingerprints.
Next up is to start dismantling everything.
On the Disco 2, the roof lining edges go under the wide panels in the rear, the door trim between the rear and front doors and under the front windscreen trim where the tweeters are mounted. This means to drop the lining you have to remove all the trim pieces.
We started at the back and worked our way forward, using a large tray to collect all the bits nad pieces as we went. We subdivided the interior into 3 areas, so we could keep all the bits and clips together in a logical order - Boot, rear seats, front.
So, first things first:-
Drop the dickie seat headrest down and pull off the plastic trim along the top of the roof surrounding the headrest mounts. There are 2 little slider bits of trim that slot between the headrest and the main trim. Be careful of removing these as they are flimsy peices of cr@p.
Behind this panel are 2 small plastic clips holding the rooflining to the very back of the roof. remove.
Once thats off, move on to the main side rear panels. These are held on by a combination of 5 long plastic pushclips and 2 little screws under plastic covers. The covers snap off really easily so be careful. then just pull off the alarm motion sensor, its held on by 2 metal friction clips and comes off easy enough.
Once you have removed the clips, you need to remove the rear grab handles. Each end of the handle has a little cover. Squeeze the covers between your fingers and they pop open. Behind each handle is a little black plastic spacer.
KEEP THESE REAR HANDLES AWAY FROM THE REST OF THE GRAB HANDLES - as the bolts are alot longer and the other 4 grab handles in the car wont fit in these positions when it comes to refitting!
Now the only thing stopping you removing the panel is the rear dickie seat 3 point seatbelt. Remove the 17mm bottom anchor bolt and then remove the plastic trim covering the whole in the panel that the belt feeds through, there should now be enough room to feed the belt and clip through the hole and the rear panel should now be free,
it isnt easy remove without damaging it, but if you push the bottom of the trim down and pull the top of the trim towards you it will pop out.
Now you have the rear panels out and gathered all the clips and trim together
- move to the back seat.
Remove the grab handles - same as above
Remove the top console next to the sunroof. This has the switch for the rear sunroof and rear courtesy light in it.
All the fittings are hidden!
Prise out the lamp lense. The lamp itself is held directly to the roof by 2 8mm nuts. Remove the bulb first or you will make sparks and possibly let the smoke out of the wiring loom!
Next to the light is a small plastic panel hiding a screw. Prise the panel off and undo.
Prise out the sunroof switch (carefully) and there is a screw hidden under there as well.
the centre console should now drop down with all various wires / connectors hanging down.
now pull off the felt trim that goes round the sunroof aperture and hides the join between the sunroof and the rooflining, and put to one side safely
Now move on the front! Almost there...
Door trim.
all the door trim needs pulling off between the front and rear doors and the front doors and windscreen.
To do this pull off the rubber door seals on all 4 doors. This will give you access to the little clips (about 2mm wide and thin so careful) to go round the edge of the metal door pillars. Using point nosed pliars pull them outwards and then back. I think there were 4 on each panel. The panel is now held on bu 2 large push connectors hidden behind the panel. Just grab hold of the panel and sharply tug it away from the door pillar and it will come away.
The panels between the doors wont come fully away as the front seat belts (and height adjusters) go through them - but pull the belt out a couple of foot and the panels will tuck out of the way behind the front seat headrests.
The front panels between the door and windscreen are also removed in the same way - but dont pull them too hard as the tweeters are built in and the spare wiring that connects to them was very short. Again i just left them dangling as they werent in the way.
Next - roof console above the front seats.
Remove grab handles
Unscrew the 3 screws holding the hinge of each sun visor in place. Be careful pulling the visor away as there are wires and a connector going to each for the vanity lights. The other end of the sun visor has a little hook it clips into. At the front of the hook is a little cover (VERY brittle) that opens a hole through the hook allowing access to the screw holding the clip to the roof. Unscrew and wiggle the hook until it comes out.
next up the map pockets and console.
each map pocket has about 5 screws. pain in the ass to get out cos they`re deeply set in narrow placcy tubes and you cant see or feel if your screwdriver is seated properly.
Prise out the courtesy light lense and remove the buld and unbolt it and remove the light unit.
The whole centre console should now drop down.
Unclip the 3 big connectors to the sunroof switches, the connector and earth on the courtesy light and its all out!
Now, pull the rear of the headlining down and put the dickie seat headrest back up and you can then withdraw the headlining out the back door.
It is a tight squeeze and does involve a bit of pushing and shoving and gentle bending. Dont worry about creases, as long as you dont go overboard no permanent creases will remain in the fabric or fibreglass headlining.
Once its all out it should look like this:-
the problem I found was one of the drain pipes where it pushes onto the plastic tube on the drain cup had snapped. the end of the plastic crain cup was inside the pipe and it was a clean break.
Out came the araldite and glued it back on,
Whilst i was there and had access to all the drain pipes and plastic cups, i made sure all the pipes were obstruction free and re-sealed all the plastic cups to the sunroof frames.
now you will have various piles of bits to put back together
refitting it the reverse of removal!
hahahaha
actually the whole thing was alot more straight forward than i thought it would be. None of the clips broke and appear to be made of stronger stuff than the crappy plastic clips used in the disco 1 and defenders!
Excluding the time it took to clean out the pipes and resealing and gluing - i reckon it took about 3 hours to remove and refit the whole lot.