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Discovery 2. Manual - part 268

PANEL REPAIRS

REPAIRS 77-2-33

Front valance assembly - RH

Remove

1. Disconnect battery eath lead.
2. Remove front bulkhead assembly.

PANEL REPAIRS, REPAIRS, Front

bulkhead assembly.

3. Remove engine compartment fusebox and

related wiring.

4. Remove radiator expansion tank from

mountings and position aside.

5. Petrol models: Remove cruise control

actuator mounting bracket.

6. Diesel models: Remove EGR modulator

mounting bracket.

7. RHD models: Remove brake servo.

BRAKES, REPAIRS, Servo - brake.

8. Remove brake pipes from valance assembly.
9. Remove RH road wheel.

10. Remove RH front mud flap.
11. Remove insulation pad from engine bulkhead.
12. Remove windscreen side finisher.

EXTERIOR FITTINGS, REPAIRS,

Side finisher - windscreen.

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 windscreen side finisher.

EXTERIOR FITTINGS, REPAIRS,

Side finisher - windscreen.

2. Fit insulation pad to engine bulkhead.
3. Fit front mud flap.
4. Fit road wheel and tighten nuts to 140 Nm (103

lbf.ft).

5. Fit brake pipes to valance assembly.
6. RHD models: Fit brake servo.
7. Diesel models: Fit EGR modulator mounting

bracket.

8. Petrol models: Fit cruise control actuator

mounting bracket.

9. Fit radiator expansion tank.

10. Fit fusebox and secure wiring.
11. Fit front bulkhead assembly.

PANEL REPAIRS, REPAIRS, Front

bulkhead assembly.

12. Connect battery leads, negative lead last.

M77 1694A

PANEL REPAIRS

77-2-34 REPAIRS

Front valance assembly - LH

Remove

1. Disconnect both battery leads, negative lead

first.

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

PANEL REPAIRS, REPAIRS, Front

bulkhead assembly.

4. Remove ABS modulator unit.

BRAKES, REPAIRS, Modulator unit

- ABS.

5. LHD models: Remove brake servo.

BRAKES, REPAIRS, Servo - brake.

6. Remove brake pipes from valance assembly.
7. Remove PAS/ACE reservoir.
8. Models with A/C: Remove A/C pipes from

valance assembly.

9. Remove wiring harness from valance

assembly.

10. Remove LH front road wheel.
11. Remove LH front mud flap.
12. Remove insulation pad from engine bulkhead.
13. Remove windscreen side finisher.

EXTERIOR FITTINGS, REPAIRS,

Side finisher - windscreen.

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 windscreen side finisher.

EXTERIOR FITTINGS, REPAIRS,

Side finisher - windscreen.

2. Fit insulation pad to engine bulkhead.
3. Fit front mud flap.
4. Fit road wheel and tighten nuts to 140 Nm (103

lbf.ft).

5. Fit wiring harness to valance assembly.
6. Models with A/C: Fit A/C pipes to valance

assembly.

7. Fit PAS/ACE reservoir.
8. Fit brake pipes to valance assembly.
9. LHD models: Fit brake servo.

BRAKES, REPAIRS, Servo - brake.

10. Fit ABS modulator unit.

BRAKES, REPAIRS, Modulator unit

- ABS.

11. Fit front bulkhead assembly.

PANEL REPAIRS, REPAIRS, Front

bulkhead assembly.

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

M77 1742

PANEL REPAIRS

REPAIRS 77-2-35

'A' post assembly

In this procedure, the front wing and the valance
outer reinforcement (rear section) are replaced in
conjunction with the 'A' post assembly. The dash side
assembly can also be replaced in this procedure if
required.

Remove

1. Disconnect both battery leads, negative lead

first.

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

EXTERIOR FITTINGS, REPAIRS,

Wing - front - up to 03MY.

5. Remove RH or LH front door.

DOORS, REPAIRS, Door - front.

6. Remove RH or LH sill finisher.
7. Remove windscreen.

SCREENS, REPAIRS, Windscreen.

8. Diesel models: Remove ECM.

ENGINE MANAGEMENT SYSTEM -

Td5, REPAIRS, Engine control module
(ECM).

9. Remove RH or LH 'A' post inner finishers and

disconnect speaker multiplug (if fitted).

10. Release sunroof drain tube and position aside.
11. Remove RH or LH front seat.

SEATS, REPAIRS, Seat - front.

12. RH side: Remove CD autochanger.

IN CAR ENTERTAINMENT,

REPAIRS, CD autochanger.

13. Remove fascia.

INTERIOR TRIM COMPONENTS,

REPAIRS, Fascia.

14. Driver's side: Remove steering column

support bracket.

15. Remove relevant wiring from 'A' post.
16. Remove tread plate from front door aperture.
17. Release front carpet and position aside.
18. Remove front door aperture seal.
19. Remove engine bulkhead insulation.

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 1751

PANEL REPAIRS

77-2-36 REPAIRS

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.