Discovery 2. Manual — part 683
PANEL REPAIRS
PROCEDURES 77-2-19
3. Use a resistance spot welder where access
permits. Try to ensure weld quality by using a
welding monitor where possible.
4. MIG tack weld butt joints and re-check
alignment and panel contours where
necessary. Ensure that a gap is maintained to
minimise welding distortion, by inserting a
hacksaw blade as an approximate guide.
5. Dress MIG tack welds using a sander with 36
grit disc, or a belt-type sander where access is
limited.
6. MIG seam weld butt joints.
PANEL REPAIRS
77-2-20 PROCEDURES
7. Always use MIG plug welds where excessive
metal thickness or limited access make
resistance spot welding impractical. Make plug
welds either by using holes left by the spot weld
cutter, or through holes punched and drilled for
the purpose.
8. Dress all welds using either a sander with 36
grit disc, or a belt-type sander and/or
impregnated wire brush.
NOTE: Brazing operations, if required, must be
carried out at this point.
PANEL REPAIRS
REPAIRS 77-2-21
REPAIRS
Front bulkhead assembly
Remove
1. Disconnect both battery leads, negative lead
first.
2. Disconnect leads/multiplug from alternator.
3. Remove front wing.
4. Remove washer reservoir.
Reservoir - washer - up to 03MY.
5. Models with A/C: Remove condensor.
6. Diesel models: Remove gearbox fluid cooler.
7. Remove RH and LH headlamps.
LIGHTING, REPAIRS, Headlamp - up
8. Release headlamp levelling motors and
position aside.
9. Release headlamp wiring and position aside.
10. Remove battery.
11. Remove battery tray.
12. Remove air filter assembly.
Td5, REPAIRS, Air filter assembly.
V8, REPAIRS, Air cleaner assembly.
13. Remove 2 earth leads from LH of front
bulkhead.
14. Remove RH horn.
15. Models with A/C: Release and remove A/C
pipes.
16. Remove RH and LH crush cans.
17. Remove bonnet release cable.
18. Support bonnet in open position
19. Remove bonnet locking mechanism.
20. Remove VIN plate.
21. Remove 2 bolts securing front bulkhead
assembly to chassis.
22. Remove centre braces.
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 centre braces.
2. Fit 2 bolts securing bulkhead to chassis and
tighten to 45 Nm (33 lbf.ft).
3. Fit VIN plate.
4. Fit bonnet locking mechanism.
5. Fit bonnet release cable.
6. Fit crush cans.
7. Models with A/C: Fit A/C pipes.
8. Fit RH horn.
9. Fit 2 earth leads to LH of front bulkhead.
10. Fit air filter assembly.
Td5, REPAIRS, Air filter assembly.
V8, REPAIRS, Air cleaner assembly.
11. Fit battery tray.
12. Fit battery. Do not connect leads.
13. Fit headlamp wiring and headlamp levelling
motors.
14. Fit RH and LH headlamps.
LIGHTING, REPAIRS, Headlamp - up
15. Diesel models: Fit gearbox fluid cooler.
16. Models with A/C: Fit condensor.
17. Fit washer reservoir.
PANEL REPAIRS
77-2-22 REPAIRS
18. Fit front wing.
19. Connect leads/multiplug to alternator.
20. Connect battery leads, negative lead last.
Bonnet locking platform
Remove
1. Disconnect both battery leads, negative lead
first.
2. Disconnect leads/multiplug from alternator.
3. Remove front bumper assembly.
4. Models with A/C: Remove condensor.
5. Diesel models: Remove gearbox fluid cooler.
6. Remove RH and LH headlamps.
LIGHTING, REPAIRS, Headlamp - up
7. Remove RH and LH repeater lamps.
LIGHTING, REPAIRS, Lamp - front
8. Release headlamp wiring and position aside.
9. Remove battery.
10. Remove battery tray.
11. Remove air filter assembly.
Td5, REPAIRS, Air filter assembly.
V8, REPAIRS, Air cleaner assembly.
12. Remove RH horn.
13. Remove bonnet release cable.
14. Support bonnet in open position
15. Remove bonnet locking mechanism.
16. Remove VIN plate.
17. Remove centre braces.
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