Discovery 2. Manual — part 688

PANEL REPAIRS

REPAIRS 77-2-39

'B/C' post assembly

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove RH or LH rear door.

+

DOORS, REPAIRS, Door - rear.

4. Remove front door striker from 'B/C' post.
5. Remove RH or LH sill finisher.
6. Remove RH or LH front seat.

+

SEATS, REPAIRS, Seat - front.

7. RH side: Remove power amplifier.

+

IN CAR ENTERTAINMENT,

REPAIRS, Amplifier - power.

8. LH side: Remove CD autochanger.

+

IN CAR ENTERTAINMENT,

REPAIRS, CD autochanger.

9. Remove RH or LH front seat belt.

+

RESTRAINT SYSTEMS, REPAIRS,

Seat belt - front.

10. Remove RH or LH rear seat.

+

SEATS, REPAIRS, Seat - rear.

11. Remove head lining.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Headlining.

12. Remove tread plate from front and rear door

apertures.

13. Release carpet from fixings and position aside.
14. Remove front and rear door door aperture

seals.

15. Release relevant wiring from 'B/C' post and sill

areas and position aside.

16. Remove side drip rail 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.

2. Before welding 'B/C' post to roof, apply

'Heat shrink paste' to roof area to avoid heat
damage to paintwork.

Refit

1. Fit side drip rail finisher.
2. Fit wiring to 'B/C' post and sill areas.
3. Fit front and rear door door aperture seal.
4. Position carpet and secure with fixings.
5. Fit tread plates to front and rear door apertures.
6. Fit head lining.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Headlining.

7. Fit rear seat.

+

SEATS, REPAIRS, Seat - rear.

8. Fit front seat belt.

+

RESTRAINT SYSTEMS, REPAIRS,

Seat belt - front.

9. LH side: Fit CD autochanger.

+

IN CAR ENTERTAINMENT,

REPAIRS, CD autochanger.

10. RH side: Fit power amplifier.

+

IN CAR ENTERTAINMENT,

REPAIRS, Amplifier - power.

11. Fit RH or LH front seat.

+

SEATS, REPAIRS, Seat - front.

12. Fit sill finisher.

PANEL REPAIRS

77-2-40 REPAIRS

13. Fit front door striker to B/C post, fit Torx bolts

and tighten to 26 Nm (19 lbf.ft).

14. Fit rear door.

+

DOORS, REPAIRS, Door - rear.

15. Connect leads/multiplug to alternator.
16. Connect battery leads, negative lead last.

Panel body side assembly

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove loadspace side trim casing.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Trim casing - side - loadspace.

4. Remove head lining rear trim finisher.
5. Remove rear head rests, if fitted.
6. Remove body side rear glass.

+

SCREENS, REPAIRS, Glass - body

side - rear.

7. Remove rear bumper assembly.

+

EXTERIOR FITTINGS, REPAIRS,

Bumper assembly - rear - up to 03MY.

8. Remove rear bumper finisher.
9. Remove rear wheel arch liner.

+

EXTERIOR FITTINGS, REPAIRS,

Liner - wheel arch - rear.

10. Remove mud flap.
11. Remove tread plate from rear door aperture.
12. Remove rear door aperture seal.
13. Remove rear door striker from 'D' post.
14. Remove 'D' post outer trim finisher.
15. Remove wheel arch trim finisher.
16. Remove side drip rail finisher.
17. RH side: Remove tail door.
18. LH side: Remove tail door striker and setting

block from 'E' post.

19. Remove tail door tread plate.
20. Remove loadspace carpet retainer.
21. Remove tail door aperture seal.
22. Remove tail lamp.

+

LIGHTING, REPAIRS, Lamp - tail.

23. RH side: Remove fuel filler flap.
24. RH side: Remove fuel filler tube.

+

FUEL DELIVERY SYSTEM - V8,

REPAIRS, Filler tube - fuel.

25. Remove aerial amplifier.
26. Remove relevant wiring from body side area.

PANEL REPAIRS

REPAIRS 77-2-41

Repair

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

faces and install new panel(s) in accordance
with Panel Replacement Procedure. The panel
body side assembly does not require any
welding, as it is bolted into position.

Refit

1. Position and secure wiring.
2. Fit aerial amplifier.
3. RH side: Fit fuel filler tube.

+

FUEL DELIVERY SYSTEM - V8,

REPAIRS, Filler tube - fuel.

4. RH side: Fit fuel filler flap.
5. Fit tail lamp.

+

LIGHTING, REPAIRS, Lamp - tail.

6. Fit tail door aperture seal.
7. Fit loadspace carpet retainer.
8. Fit tail door tread plate.
9. LH side: Fit tail door striker and setting block to

'E' post, fit Torx bolts and tighten to 26 Nm (19
lbf.ft).

10. RH side: Fit tail door.
11. Fit side drip rail finisher.
12. Fit wheel arch trim finisher.
13. Fit 'D' post outer trim finisher.
14. Fit rear door striker.
15. Fit rear door aperture seal.
16. Fit tread plate to rear door aperture.
17. Fit mud flap.

18. Fit rear wheel arch liner.

+

EXTERIOR FITTINGS, REPAIRS,

Liner - wheel arch - rear.

19. Fit rear bumper finisher.
20. Fit rear bumper assembly.

+

EXTERIOR FITTINGS, REPAIRS,

Bumper assembly - rear - up to 03MY.

21. Fit body side rear glass.

+

SCREENS, REPAIRS, Glass - body

side - rear.

22. Fit rear head rests, if fitted.
23. Fit head lining rear trim finisher.
24. Fit loadspace side trim casing.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Trim casing - side - loadspace.

25. Connect leads/multiplug to alternator.
26. Connect battery leads, negative lead last.

M77 0000

PANEL REPAIRS

77-2-42 REPAIRS

Body side inner rear assembly

In this procedure, the panel body side assembly is
replaced in conjunction with the body side inner rear
assembly.

Remove

1. Disconnect battery eath lead.
2. Disconnect leads/multiplug from alternator.
3. Remove panel body side assembly.

+

PANEL REPAIRS, REPAIRS, Panel

body side assembly.

4. Remove RH or LH rear seat.

+

SEATS, REPAIRS, Seat - rear.

5. Remove loadspace carpet.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Carpet - loadspace.

6. Remove rear side seat belt.

+

RESTRAINT SYSTEMS, REPAIRS,

Seat belt - rear - side.

7. Remove third row seat belt.

+

RESTRAINT SYSTEMS, REPAIRS,

Seat belts - third row.

8. Remove fuel tank.

+

FUEL DELIVERY SYSTEM - V8,

REPAIRS, Tank - fuel.

+

FUEL DELIVERY SYSTEM - Td5,

REPAIRS, Tank - fuel.

9. Remove fuel filler tube.

+

FUEL DELIVERY SYSTEM - V8,

REPAIRS, Filler tube - fuel.

10. RH side: Remove fuel flap release solenoid.

+

FUEL DELIVERY SYSTEM - Td5,

REPAIRS, Solenoid - fuel filler flap release.

+

FUEL DELIVERY SYSTEM - V8,

REPAIRS, Solenoid - fuel filler flap release.

11. RH side: Remove air extractor vent.
12. Remove relevant wiring.

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 and secure wiring.
2. RH side: Fit air extractor vent.
3. RH side: Fit fuel flap release solenoid.

+

FUEL DELIVERY SYSTEM - Td5,

REPAIRS, Solenoid - fuel filler flap release.

+

FUEL DELIVERY SYSTEM - V8,

REPAIRS, Solenoid - fuel filler flap release.

4. Fit fuel filler tube.

+

FUEL DELIVERY SYSTEM - V8,

REPAIRS, Filler tube - fuel.

5. Fit fuel tank.

+

FUEL DELIVERY SYSTEM - V8,

REPAIRS, Tank - fuel.

+

FUEL DELIVERY SYSTEM - Td5,

REPAIRS, Tank - fuel.

6. Fit third row seat belt.

+

RESTRAINT SYSTEMS, REPAIRS,

Seat belts - third row.

7. Fit rear side seat belt.

+

RESTRAINT SYSTEMS, REPAIRS,

Seat belt - rear - side.

8. Fit loadspace carpet.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Carpet - loadspace.

9. Fit rear seat.

+

SEATS, REPAIRS, Seat - rear.

10. Fit panel body side assembly.

+

PANEL REPAIRS, REPAIRS, Panel

body side assembly.

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

M77 1698A

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Текст

Политика конфиденциальности