Discovery 2. Manual — part 691
PANEL REPAIRS
REPAIRS 77-2-51
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. Position and secure wiring.
2. Fit and tighten bolts securing body to chassis to
45 Nm (33 lbf.ft).
3. Fit tail door aperture seal.
4. Fit head lining rear trim finisher.
5. Fit loadspace carpet retainer.
6. Fit tail door tread plate.
7. Fit rear door aperture seals.
8. Fit tread plate to rear door apertures.
9. Fit exhaust tail pipe heatshields.
10. Fit mud flap bracklets and mud flaps.
11. Fit rear bumper assembly.
Bumper assembly - rear - up to 03MY.
12. Fit rear carpet.
13. Fit rear seats.
14. Fit loadspace carpet.
15. Connect leads/multiplug to alternator.
16. Connect battery leads, negative lead last.
Rear floor (rear section)
In this procedure, the cross member rear assembly,
cross member outer rear panel, 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 (rear
section).
Remove
1. Disconnect both battery leads, negative lead
first.
2. Disconnect leads/multiplug from alternator.
3. Remove 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. Welds for RH side are symmetrically
opposite to those shown.
Refit
1. LH side: Fit exhaust heatshield to rear floor.
2. Fit mud flap mounting brackets.
3. Fit cross member rear assembly.
4. Connect leads/multiplug to alternator.
5. Connect battery leads, negative lead last.
PANEL REPAIRS
77-2-52 REPAIRS
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.
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.
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.
4. Models with sunroof: Remove rear sunroof.
5. Models with sunroof: Release sunroof drain
tubes and position aside.
6. Models with fixed roof: Remove head lining.
7. Remove front seats.
8. Remove rear seats.
9. Remove rear headrests, if fitted.
10. Remove roof bars, if fitted.
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.
18. Remove alpine light glass.
SCREENS, REPAIRS, Glass - alpine
19. Remove side and rear drip rail finishers.
20. Release relevant wiring and position aside.
PANEL REPAIRS
REPAIRS 77-2-53
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
4. Fit 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.
12. Fit rear headrests.
13. Fit rear seats.
14. Fit front seats.
15. Models with fixed roof: Fit head lining.
16. Models with sunroof: Fit sunroof drain tubes.
17. Models with sunroof: Fit rear sunroof.
18. Models with sunroof: Fit front sunroof.
19. Connect leads/multiplug to alternator.
20. Connect battery leads, negative lead last.
M77 1715A
PANEL REPAIRS
77-2-54 REPAIRS
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