Discovery 2. Manual - part 267

 

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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

 

 

 

 

 

 

 

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