Discovery 2. Manual — part 267

PANEL REPAIRS

REPAIRS 77-2-29

Refit

1. Models with A/C: Fit A/C pipes and recharge

A/C system.

+

AIR CONDITIONING, REFRIGERANT

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

2. Fit harness to valance.
3. Fit brake pipes to valance.
4. Fit ABS modulator.

+

BRAKES, REPAIRS, Modulator unit

- ABS.

5. Fit PAS/ACE reservoir, refill fluids to correct

levelsand bleed ACE system.

+

FRONT SUSPENSION,

ADJUSTMENTS, ACE hydraulic system
bleeding.

+

CAPACITIES, FLUIDS,

LUBRICANTS AND SEALANTS, Fluids.

6. Fit air filter assembly.

+

ENGINE MANAGEMENT SYSTEM -

V8, REPAIRS, Air cleaner assembly.

+

ENGINE MANAGEMENT SYSTEM -

Td5, REPAIRS, Air filter assembly.

7. Fit front wing.

+

EXTERIOR FITTINGS, REPAIRS,

Wing - front - up to 03MY.

+

EXTERIOR FITTINGS, REPAIRS,

Wing - front - from 03MY.

8. Connect leads/multiplug to alternator.
9. Connect battery leads, negative lead last.

Valance upper assembly - RH

In this procedure, the front wing and the valance
outer reinforcement are replaced in conjunction with
the RH 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 battery.

+

CHARGING AND STARTING,

REPAIRS, Battery.

5. Remove battery tray.
6. Remove fuse box.
7. Release expansion tank from fixings and

position aside.

8. Release harness from valance and position

aside.

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 1692A

M77 1750

PANEL REPAIRS

77-2-30 REPAIRS

Refit

1. Fit harness to valance.
2. Fit and secure expansion tank to fixings.
3. Fit fuse box.
4. Fit battery tray.
5. Fit battery.

+

CHARGING AND STARTING,

REPAIRS, Battery.

6. Fit front wing.

+

EXTERIOR FITTINGS, REPAIRS,

Wing - front - up to 03MY.

+

EXTERIOR FITTINGS, REPAIRS,

Wing - front - from 03MY.

7. Connect leads/multiplug to alternator.
8. Connect battery leads, negative lead last.

Valance upper assembly (front section) -
LH

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

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 -

Td5, REPAIRS, Air filter assembly.

+

ENGINE MANAGEMENT SYSTEM -

V8, REPAIRS, Air cleaner assembly.

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

+

BRAKES, REPAIRS, Modulator unit

- ABS.

7. Release harness from valance and position

aside.

8. 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.

PANEL REPAIRS

REPAIRS 77-2-31

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. Models with A/C: Fit A/C pipes and recharge

A/C system.

+

AIR CONDITIONING, REFRIGERANT

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

2. Fit harness to valance.
3. Fit ABS modulator.

+

BRAKES, REPAIRS, Modulator unit

- ABS.

4. Fit PAS/ACE reservoir and refill fluids to correct

levels.

+

FRONT SUSPENSION,

ADJUSTMENTS, ACE hydraulic system
bleeding.

+

CAPACITIES, FLUIDS,

LUBRICANTS AND SEALANTS, Fluids.

5. Fit air filter assembly.

+

ENGINE MANAGEMENT SYSTEM -

Td5, REPAIRS, Air filter assembly.

+

ENGINE MANAGEMENT SYSTEM -

V8, REPAIRS, Air cleaner assembly.

6. Fit front wing.

+

EXTERIOR FITTINGS, REPAIRS,

Wing - front - up to 03MY.

+

EXTERIOR FITTINGS, REPAIRS,

Wing - front - from 03MY.

7. Connect leads/multiplug to alternator.
8. Connect battery leads, negative lead last.

M77 1744

M77 1689A

PANEL REPAIRS

77-2-32 REPAIRS

Valance upper assembly (front section) -
RH

In this procedure, the front wing and the valance
outer reinforcement (front section) are replaced in
conjunction with the RH valance upper assembly
(front section).

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 battery.

+

CHARGING AND STARTING,

REPAIRS, Battery.

5. Remove battery tray.
6. Remove fuse box.
7. Release expansion tank from fixings and

position aside.

8. Release harness from valance and position

aside.

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 harness to valance.
2. Fit and secure expansion tank to fixings.
3. Fit fuse box.
4. Fit battery tray.
5. Fit battery.

+

CHARGING AND STARTING,

REPAIRS, Battery.

6. Fit front wing.

+

EXTERIOR FITTINGS, REPAIRS,

Wing - front - up to 03MY.

+

EXTERIOR FITTINGS, REPAIRS,

Wing - front - from 03MY.

7. Connect leads/multiplug to alternator.
8. Connect battery leads, negative lead last.

M77 1693A

M77 1749