Discovery 2. Manual — part 686

7. Connect leads/multiplug to alternator.
8. Connect battery leads, negative lead last.

Valance upper assembly (front section) -
RH

In this procedure, the front wing and the valance
outer reinforcement (front section) are replaced in
conjunction with the RH valance upper assembly
(front section).

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove front wing.

CHARGING AND STARTING,

4. Remove battery.

REPAIRS, Battery.

5. Remove battery tray.
6. Remove fuse box.
7. Release expansion tank from fixings and

position aside.

8. Release harness from valance and position

aside.

PANEL REPAIRS

77-2-32 REPAIRS

Repair

1. Remove existing panel(s), prepare panel joint

faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

Refit

1. Fit harness to valance.
2. Fit and secure expansion tank to fixings.
3. Fit fuse box.
4. Fit battery tray.
5. Fit battery.

CHARGING AND STARTING,

REPAIRS, Battery.

6. Fit front wing.

7. Connect leads/multiplug to alternator.
8. Connect battery leads, negative lead last.

Front valance assembly - RH

Remove

1. Disconnect battery eath lead.
2. Remove front bulkhead assembly.

BRAKES, REPAIRS, Servo - brake.

3. Remove engine compartment fusebox and

related wiring.

4. Remove radiator expansion tank from

mountings and position aside.

5. Petrol models: Remove cruise control

actuator mounting bracket.

6. Diesel models: Remove EGR modulator

mounting bracket.

7. RHD models: Remove brake servo.

8. Remove brake pipes from valance assembly.
9. Remove RH road wheel.

10. Remove RH front mud flap.
11. Remove insulation pad from engine bulkhead.
12. Remove windscreen side finisher.

Repair

1. Remove existing panel(s), prepare panel joint

faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

Refit

1. Fit windscreen side finisher.

2. Fit insulation pad to engine bulkhead.
3. Fit front mud flap.
4. Fit road wheel and tighten nuts to 140 Nm (103

lbf.ft).

5. Fit brake pipes to valance assembly.

M77 1693A

M77 1749

M77 1694A

PANEL REPAIRS

REPAIRS 77-2-33

6. RHD models: Fit brake servo.
7. Diesel models: Fit EGR modulator mounting

bracket.

8. Petrol models: Fit cruise control actuator

mounting bracket.

9. Fit radiator expansion tank.

10. Fit fusebox and secure wiring.
11. Fit front bulkhead assembly.

12. Connect battery leads, negative lead last.

Front valance assembly - LH

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove front bulkhead assembly.

BRAKES, REPAIRS, Modulator unit

4. Remove ABS modulator unit.

- ABS.

5. LHD models: Remove brake servo.

BRAKES, REPAIRS, Servo - brake.

6. Remove brake pipes from valance assembly.
7. Remove PAS/ACE reservoir.
8. Models with A/C: Remove A/C pipes from

valance assembly.

9. Remove wiring harness from valance

assembly.

10. Remove LH front road wheel.
11. Remove LH front mud flap.
12. Remove insulation pad from engine bulkhead.
13. Remove windscreen side finisher.

Repair

1. Remove existing panel(s), prepare panel joint

faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

M77 1742

PANEL REPAIRS

77-2-34 REPAIRS

Refit

1. Fit windscreen side finisher.

BRAKES, REPAIRS, Servo - brake.

2. Fit insulation pad to engine bulkhead.
3. Fit front mud flap.
4. Fit road wheel and tighten nuts to 140 Nm (103

lbf.ft).

5. Fit wiring harness to valance assembly.
6. Models with A/C: Fit A/C pipes to valance

assembly.

7. Fit PAS/ACE reservoir.
8. Fit brake pipes to valance assembly.
9. LHD models: Fit brake servo.

10. Fit ABS modulator unit.

BRAKES, REPAIRS, Modulator unit

- ABS.

11. Fit front bulkhead assembly.

12. Connect leads/multiplug to alternator.
13. Connect battery leads, negative lead last.

'A' post assembly

In this procedure, the front wing and the valance
outer reinforcement (rear section) are replaced in
conjunction with the 'A' post assembly. The dash side
assembly can also be replaced in this procedure if
required.

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove bonnet.
4. Remove front wing.