Discovery 2. Manual — part 232

EXTERIOR FITTINGS

REPAIRS

76-2-9

Bonnet

$% 76.16.01.99

Remove

1. Support bonnet in open position.

2. Fit protection covers to wings and mark hinge

outline on bonnet if bonnet is to be refitted.

3. Disconnect windscreen washer tube at elbow

joint.

4. With assistance, remove bolts securing hinges

to bonnet and remove bonnet.

Refit

1. With assistance, position bonnet to hinges. Fit

and lightly tighten bolts.

2. Connect windscreen washer tube.
3. Close bonnet. Check that bonnet is aligned to

both front wings and that gaps are equal. If
necessary, adjust bonnet alignment and/or
gaps.

4. Finally tighten hinge bolts to 25 Nm (18 lbf.ft).

Cable - bonnet release - up to 03MY

$% 76.16.29

Remove

1. Remove front grille.

+

EXTERIOR FITTINGS, REPAIRS,

Grille - front - up to 03MY.

2. Release LH headlamp from adjuster pin

sockets.

3. Disconnect 2 multiplugs from headlamp and

remove headlamp.

4. Drill out 4 rivets securing bonnet lock shield to

bonnet platform and remove shield.

5. Disconnect bonnet release cable inner and

outer from lock.

EXTERIOR FITTINGS

76-2-10 REPAIRS

6. Remove 4 fasteners securing LH fascia closing

panel to fascia and remove panel.

7. Remove 2 nuts securing bonnet release lever

assembly to body.

8. Remove bonnet release cable from lever

assembly.

9. Diesel models: Pull sound insulation away

from bulkhead for access to bonnet release
cable grommet.

10. Remove grommet from engine bulkhead.
11. Tie a draw string to end of bonnet release

cable in passenger compartment.

12. Pull bonnet release cable, from bonnet lock

end, until whole of cable is released.

13. Untie draw string from bonnet release cable

and remove cable.

14. Remove grommet from cable.

Refit

1. Fit grommet to bonnet release cable.
2. Tie draw string to passenger compartment end

of bonnet release cable.

3. Use draw string to pull bonnet release cable

into position.

4. Fit grommet to engine bulkhead.
5. Untie draw string from bonnet release cable.
6. Position bonnet release lever assembly and

connect bonnet release cable to lever.

7. Fit release lever assembly to body and tighten

nuts to 10 Nm (7 lbf.ft) .

8. Connect bonnet release cable to lock.
9. With assistance, operate bonnet release lever

and check for correct operation of lock.

10. Fit fascia closing panel and secure with

fasteners.

11. Fit bonnet lock shield and secure with rivets.
12. Position headlamp to body, connect multiplugs

and fit headlamp to sockets.

13. Fit front grille.

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EXTERIOR FITTINGS, REPAIRS,

Grille - front - up to 03MY.

EXTERIOR FITTINGS

REPAIRS 76-2-11

Cable - bonnet release - from 03MY

$% 76.16.29

Remove

1. Remove the front grille.

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EXTERIOR FITTINGS, REPAIRS,

Grille - front - from 03MY.

2. Drill out 4 rivets securing bonnet lock shield to

the bonnet locking platform and remove the
shield.

3. Disconnect bonnet release cable from the

bonnet lock.

4. Disconnect bonnet release cable from the front

panel retaining clip.

5. Remove 2 nuts securing bonnet release lever

to the 'A' post.

6. Disconnect bonnet release cable from the

bonnet release lever.

7. Remove bonnet release cable grommet from

the bulkhead.

8. Remove the bonnet release cable.
9. Remove grommet from the bonnet release

cable.

Refit

1. Fit grommet to the bonnet release cable.
2. Position bonnet release cable to body and

connect to the bonnet release lever.

3. Position bonnet release lever to 'A' post, fit nuts

and tighten to 10 Nm (7 lbf.ft).

4. Fit bonnet release cable grommet to the

bulkhead.

5. Connect bonnet release cable to the bonnet

lock.

6. Align timing mark on bonnet release cable to

retaining clip and secure to the clip.

7. With assistance operate bonnet release lever

and check for the correct operation of the lock.

8. Fit bonnet lock shield and secure with rivets
9. Fit the front grille.

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EXTERIOR FITTINGS, REPAIRS,

Grille - front - from 03MY.

M76 4573

M76 3029B

M76 4574

EXTERIOR FITTINGS

76-2-12 REPAIRS

Bumper assembly - front

$% 76.22.08

Remove

1. Remove 14 screws securing LH and RH wheel

arch liner extensions to wheel arch liners and
bumper valance and remove extensions.

Note: 18 screws are used on 03 MY onwards.

2. Disconnect multiplugs from fog lamps.

3. Remove 2 nuts securing bumper valance side

mountings to body.

4. Remove 4 nuts securing bumper to crush cans

and remove bumper from body.

5. Remove 3 screws securing bumper to front

cross bar.

6. Models with headlamp wash: Position

container to collect screen washer fluid and
disconnect hose from headlamp washer pump.

Refit

1. Models with headlamp wash: Connect hose

to headlamp washer pump. Refill washer
reservoir with fluid.

2. With assistance position bumper to body.
3. Fit and tighten 3 screws securing bumper to

front cross bar.

4. Tighten nuts securing bumper to crush cans to

13 Nm (10 lbf.ft).

5. Tighten nuts securing bumper to side

mountings to 13 Nm (10 lbf.ft).

6. Connect multiplugs to fog lamps.
7. Fit wheel arch liner extensions and secure with

screws.