Discovery 2. Manual — part 266

PANEL REPAIRS

REPAIRS 77-2-25

Headlamp mounting panel - RH

Remove

1. Disconnect both battery leads, negative lead

first.

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

+

EXTERIOR FITTINGS, REPAIRS,

Bumper assembly - front.

4. Models with A/C: Remove condensor.

+

AIR CONDITIONING, REPAIRS,

Condenser.

5. Diesel models: Remove gearbox fluid cooler.
6. Remove RH headlamp.

+

LIGHTING, REPAIRS, Headlamp - up

to 03MY.

7. Remove RH repeater lamp.

+

LIGHTING, REPAIRS, Lamp - front

repeater - up to 03MY.

8. Release headlamp levelling motor and position

aside.

9. Release headlamp wiring and position aside.

10. Remove battery and battery tray.

+

CHARGING AND STARTING,

REPAIRS, Battery.

11. Remove horn.

+

ALARM SYSTEM AND HORN,

REPAIR, Vehicle horn.

12. Remove RH crush can.
13. Remove 2 bolts securing front bulkhead

assembly to chassis.

14. Remove RH centre brace.

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 brace.
2. Fit 2 bolts securing bulkhead to chassis and

tighten bolts to 45 Nm (33 lbf.ft).

3. Fit crush can.
4. Models with A/C: Fit A/C pipes.
5. Fit horn.

+

ALARM SYSTEM AND HORN,

REPAIR, Vehicle horn.

6. Fit battery and battery tray. Do not connect

leads.

+

CHARGING AND STARTING,

REPAIRS, Battery.

7. Fit headlamp wiring and headlamp levelling

motors.

8. Fit repeater lamp.

+

LIGHTING, REPAIRS, Lamp - front

repeater - up to 03MY.

M77 1741A

PANEL REPAIRS

77-2-26 REPAIRS

9. Fit headlamp.

+

LIGHTING, REPAIRS, Headlamp - up

to 03MY.

10. Diesel models: Fit gearbox fluid cooler.
11. Models with A/C: Fit condensor.

+

AIR CONDITIONING, REPAIRS,

Condenser.

12. Fit bumper assembly.

+

EXTERIOR FITTINGS, REPAIRS,

Bumper assembly - front.

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

Headlamp mounting panel - LH

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove washer reservoir.

+

WIPERS AND WASHERS, REPAIRS,

Reservoir - washer - up to 03MY.

4. Models with A/C: Remove condensor.

+

AIR CONDITIONING, REPAIRS,

Condenser.

5. Diesel models: Remove gearbox fluid cooler.
6. Remove headlamp.

+

LIGHTING, REPAIRS, Headlamp - up

to 03MY.

7. Remove repeater lamp.

+

LIGHTING, REPAIRS, Lamp - front

repeater - up to 03MY.

8. Release headlamp levelling motor and position

aside.

9. Release headlamp wiring and position aside.

10. Remove air filter assembly.

+

ENGINE MANAGEMENT SYSTEM -

Td5, REPAIRS, Air filter assembly.

+

ENGINE MANAGEMENT SYSTEM -

V8, REPAIRS, Air cleaner assembly.

11. Remove 2 earth leads from LH of front

bulkhead.

12. Release and remove A/C pipes.
13. Remove crush can.
14. Remove bonnet release cable.
15. Remove 2 bolts securing front bulkhead

assembly to chassis.

16. Remove centre brace.

PANEL REPAIRS

REPAIRS 77-2-27

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 brace.
2. Fit 2 bolts securing bulkhead to chassis and

tighten bolts to 45 Nm (33 lbf.ft).

3. Fit bonnet release cable.
4. Fit crush can.
5. Models with A/C: Fit A/C pipes.
6. Fit 2 earth leads to LH of front bulkhead.
7. Fit air filter assembly.

+

ENGINE MANAGEMENT SYSTEM -

Td5, REPAIRS, Air filter assembly.

+

ENGINE MANAGEMENT SYSTEM -

V8, REPAIRS, Air cleaner assembly.

8. Fit battery tray.
9. Fit headlamp wiring and headlamp levelling

motors.

10. Fit repeater lamp.

+

LIGHTING, REPAIRS, Lamp - front

repeater - up to 03MY.

11. Fit headlamp.

+

LIGHTING, REPAIRS, Headlamp - up

to 03MY.

12. Diesel models: Fit gearbox fluid cooler.
13. Models with A/C: Fit condensor.

+

AIR CONDITIONING, REPAIRS,

Condenser.

14. Fit washer reservoir.

+

WIPERS AND WASHERS, REPAIRS,

Reservoir - washer - up to 03MY.

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

PANEL REPAIRS

77-2-28 REPAIRS

Valance upper assembly - LH

In this procedure, the front wing, the valance outer
reinforcement and the bonnet alarm switch mounting
bracket are replaced in conjunction with the LH
valance upper assembly.

Remove

1. Disconnect both battery leads, negative lead

first.

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

+

EXTERIOR FITTINGS, REPAIRS,

Wing - front - up to 03MY.

+

EXTERIOR FITTINGS, REPAIRS,

Wing - front - from 03MY.

4. Remove air filter assembly.

+

ENGINE MANAGEMENT SYSTEM -

V8, REPAIRS, Air cleaner assembly.

+

ENGINE MANAGEMENT SYSTEM -

Td5, REPAIRS, Air filter assembly.

5. Remove PAS/ACE reservoir.
6. Remove ABS modulator.

+

BRAKES, REPAIRS, Modulator unit

- ABS.

7. Remove brake pipes from valance.
8. Release harness from valance and position

aside.

9. Models with A/C: Depressurise A/C system

and remove pipes from valance.

+

AIR CONDITIONING, REFRIGERANT

RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.

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 1743

M77 1690A