Discovery 2. Manual — part 273

PANEL REPAIRS

REPAIRS 77-2-53

Rear floor (RH/LH section)

In this procedure, the cross member rear assembly,
cross member outer rear panel (RH/LH section),
cross member closing rear panel, 'E' post assembly,
'E' post closing assembly and the panel body side
assembly are replaced in conjunction with the rear
floor (RH/LH section).

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove cross member rear assembly.

+

PANEL REPAIRS, REPAIRS, Cross

member rear assembly.

4. Remove mud flap mounting brackets.
5. LH side: Remove exhaust heatshield from rear

floor.

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. LH side: Fit exhaust heatshield to rear floor.
2. Fit mud flap mounting brackets.
3. Fit cross member rear assembly.

+

PANEL REPAIRS, REPAIRS, Cross

member rear assembly.

4. Connect leads/multiplug to alternator.
5. Connect battery leads, negative lead last.

Roof assembly

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Models with sunroof: Remove front sunroof.

+

SUNROOF, REPAIRS, Sunroof -

front.

4. Models with sunroof: Remove rear sunroof.

+

SUNROOF, REPAIRS, Sunroof -

rear.

5. Models with sunroof: Release sunroof drain

tubes and position aside.

6. Models with fixed roof: Remove head lining.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Headlining.

7. Remove front seats.

+

SEATS, REPAIRS, Seat - front.

8. Remove rear seats.

+

SEATS, REPAIRS, Seat - rear.

9. Remove rear headrests, if fitted.

10. Remove roof bars, if fitted.

+

EXTERIOR FITTINGS, REPAIRS,

Roof bars.

11. Remove tread plates from front door apertures.
12. Remove 'A' post lower trim panels.
13. Remove front door aperture seals.
14. Remove tread plates from rear door apertures.
15. Remove rear door aperture seals.
16. Remove 'D' post outer trim finisher.
17. Remove windscreen.

+

SCREENS, REPAIRS, Windscreen.

18. Remove alpine light glass.

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SCREENS, REPAIRS, Glass - alpine

light.

19. Remove side and rear drip rail finishers.
20. Release relevant wiring and position aside.

PANEL REPAIRS

77-2-54 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.

2. During welding operations, apply 'Heat

shrink paste' to roof and body side panel to
avoid heat damage to paintwork.

Refit

1. Fit and secure wiring.
2. Fit side and rear drip rail finishers.
3. Fit alpine light glass.

+

SCREENS, REPAIRS, Glass - alpine

light.

4. Fit windscreen.

+

SCREENS, REPAIRS, Windscreen.

5. Fit 'D' post outer trim finishers.
6. Fit rear door aperture seals.
7. Fit tread plates to rear door apertures.
8. Fit front door aperture seals.
9. Fit 'A' post lower trim panels.

10. Fit tread plates to front door apertures.
11. Fit roof bars.

+

EXTERIOR FITTINGS, REPAIRS,

Roof bars.

12. Fit rear headrests.
13. Fit rear seats.

+

SEATS, REPAIRS, Seat - rear.

14. Fit front seats.

+

SEATS, REPAIRS, Seat - front.

15. Models with fixed roof: Fit head lining.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Headlining.

16. Models with sunroof: Fit sunroof drain tubes.
17. Models with sunroof: Fit rear sunroof.

+

SUNROOF, REPAIRS, Sunroof -

rear.

18. Models with sunroof: Fit front sunroof.

+

SUNROOF, REPAIRS, Sunroof -

front.

19. Connect leads/multiplug to alternator.
20. Connect battery leads, negative lead last.

M77 1715A

PANEL REPAIRS

TIMES 77-2-55

TIMES

TIME SCHEDULES

The following information shows the time taken to replace damaged panels and assemblies. This time includes
removal of Mechanical, Electrical and Trim (MET) parts, and also time for painting, based on using Clear Over Base
(COB) Metallic paint.

The times shown were generated by Thatcham (the Motor Insurance Repair and Research Centre) and are to be used
as a guide only.

All times shown are in decimal hours.

Single panel/assembly replacement times

Panel Description

Total times

Petrol

Diesel

Bonnet

7.4

7.4

Bonnet locking platform

8.4

8.4

Front cross member

9.3

8.1

Front bulkhead assembly

10.5

9.3

Headlamp mounting panel RH

9.3

–

Headlamp mounting panel LH

9.4

–

Front wing RH

7.2

7.2

Front wing LH

7.1

7.1

Front door – skin

10.8

10.8

Front door

7.9

7.9

Rear door – skin

10.0

10.0

Rear door

7.6

7.6

'A' post assembly RH

11.4

–

'A' post assembly LH

11.3

–

'B/C' post assembly

11.3

–

Sill outer assembly RH

14.8

–

Sill outer assembly LH

13.9

–

Panel body side assembly RH

15.5

15.5

Panel body side assembly LH

13.4

13.4

Cross member outer rear panel (centre section)

13.4

13.4

Tail door

9.3

9.3

Roof

30.3

30.3

PANEL REPAIRS

77-2-56 TIMES

Combination panel replacement times - Front end panels

Panel Description

Total time

Petrol

Diesel

Front bumper

Bonnet locking platform

Headlamp mounting panel

Front wing

18.5 RH

17.3 RH

18.8 LH

17.5 LH

Front bumper

Front bulkhead assembly

Front wing RH & LH

19.7

18.5

Front bumper

Front bulkhead assembly

Front wing

Front valance assembly

Wing support bracket

Valance outer reinforcement

24.0 RH

24.2 LH

22.7

Front bumper

Front bulkhead assembly

Front wing

Wing support bracket

Headlamp closing panel

Valance upper assembly (front section)

Valance outer reinforcement (front section)

22.4 RH

21.1 RH

23.1 LH

21.6 LH