Discovery 2. Manual — part 687
PANEL REPAIRS
REPAIRS 77-2-35
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 insulation pad to engine bulkhead.
2. Fit front door aperture seal.
3. Position front carpet and fit tread plate to front
door aperture.
4. Fit wiring to 'A' post.
5. Driver's side: Fit steering column support
bracket.
6. Fit fascia.
7. RH side: Fit CD autochanger.
8. Fit RH or LH front seat.
9. Fit sunroof drain tube.
10. Connect multiplug to speaker (if fitted) and fit
finisher to 'A' post.
11. Diesel models: Fit ECM.
Td5, REPAIRS, Engine control module
(ECM).
12. Fit windscreen.
13. Fit sill finisher.
14. Fit front door.
15. Fit front wing.
16. Fit bonnet.
17. Connect leads/multiplug to alternator.
18. Connect battery leads, negative lead last.
M77 1751
PANEL REPAIRS
77-2-36 REPAIRS
Dash side assembly
NOTE: In this procedure, the front wing, 'A' post
assembly and the valance outer reinforcement (rear
section) are replaced in conjunction with the dash
side assembly.
Remove
1. Disconnect both battery leads, negative lead
first.
2. Disconnect leads/multiplug from alternator.
3. Remove 'A' post assembly.
PANEL REPAIRS, REPAIRS, 'A' post
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 'A' post assembly.
PANEL REPAIRS, REPAIRS, 'A' post
2. Connect leads/multiplug to alternator.
3. Connect battery leads, negative lead last..
M77 1691
M77 1696B
PANEL REPAIRS
REPAIRS 77-2-37
Sill outer assembly
Remove
1. Disconnect both battery leads, negative lead
first.
2. Disconnect leads/multiplug from alternator.
3. Remove RH or LH front wing.
4. Remove RH or LH front door.
5. Remove RH or LH rear door.
6. Remove RH or LH sill finisher.
7. Remove RH or LH 'A' post inner lower
finishers.
8. Remove RH or LH front seat.
9. LH side: Remove power amplifier and EAT
10. RH side: Remove CD autochanger.
11. Remove rear seats.
12. Remove RH or LH front seat belt.
13. Remove tread plates from front and rear door
apertures.
14. Release carpet and position aside.
15. Remove front and rear door aperture seals.
16. Release relevant wiring from 'A' post, 'B/C' post
and sill areas, and position aside.
17. Remove loadspace lower trim casing.
REPAIRS, Trim casing - side - loadspace.
18. RH side: Remove lower ACE accelerometer.
19. LH side: Remove SLS air compressor unit.
20. Models with rear A/C: Recover refrigerant
from A/C system and remove A/C pipes from
LH sill.
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
21. Remove 2 bolts securing body to chassis.
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 2 bolts securing body to chassis and tighten
to 45 Nm (33 lbf.ft).
2. Models with rear A/C: Fit A/C pipes to sill and
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3. LH side: Fit SLS air compressor unit.
4. RH side: Fit lower ACE accelerometer.
5. Fit loadspace lower trim casing.
REPAIRS, Trim casing - side - loadspace.
6. Fit relevant wiring to 'A' post, 'B/C' post and sill
areas.
7. Fit front and rear door door aperture seals.
8. Fit carpet and secure into position.
9. Fit tread plates to front and rear door apertures.
10. Fit front seat belt.
11. Fit rear seats.
12. LH side: Fit CD autochanger.
13. RH side: Fit power amplifier and EAT ECU.
14. Fit front seat.
15. Fit 'A' post inner lower finishers.
M77 1716A
PANEL REPAIRS
77-2-38 REPAIRS
16. Fit sill finisher.
17. Fit rear door.
18. Fit front door.
19. Fit front wing.
20. Connect leads/multiplug to alternator.
21. Connect battery leads, negative lead last.
Sill inner assembly
NOTE: In this procedure, the sill outer assembly is
replaced in conjunction with the sill inner assembly.
Remove
1. Disconnect both battery leads, negative lead
first.
2. Disconnect leads/multiplug from alternator.
3. Remove sill outer assembly.
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 sill outer assembly.
2. Connect leads/multiplug to alternator.
3. Connect battery leads, negative lead last.
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