Discovery 2. Manual - part 272

Rear folding step.

5. LH side: Remove exhaust tailpipe heatshield.
6. Remove relevant wiring.

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 and secure wiring.
2. LH side: Fit exhaust tailpipe heatshield.
3. Fit rear folding step.

PANEL REPAIRS, REPAIRS, 'E' post

Rear folding step.

4. Fit 'E' post assembly.

assembly.

5. Connect leads/multiplug to alternator.
6. Connect battery leads, negative lead last.

Cross member closing rear panel

In this procedure, the cross member outer rear panel
is replaced in conjunction with the cross member
closing rear panel. The cross member rear assembly
can also be replaced, if required.

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove cross member outer rear panel.

member outer rear panel.

4. Remove fuel tank.

FUEL DELIVERY SYSTEM - V8,

FUEL DELIVERY SYSTEM - Td5,

FUEL DELIVERY SYSTEM - V8,

5. Remove 2 rear bolts securing body rear 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 rear bolts securing body rear to chassis

and tighten to 45 Nm (33 lbf.ft).

2. Fit fuel tank.

FUEL DELIVERY SYSTEM - Td5,

3. Fit cross member rear outer panel.

member outer rear panel.

4. Connect leads/multiplug to alternator.
5. Connect battery leads, negative lead last.

PANEL REPAIRS

77-2-50 REPAIRS

Cross member rear assembly

In this procedure, the cross member outer rear panel,
cross member closing rear panel, 'E' post assembly
and the panel body side assembly are replaced in
conjunction with the cross member rear assembly.

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove cross member closing rear panel.

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 cross member closing rear panel.

2. Connect leads/multiplug to alternator.
3. Connect battery leads, negative lead last.

Cross member rear assembly
RH/LH section)

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove cross member closing rear panel.

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 cross member closing rear panel.

2. Connect leads/multiplug to alternator.
3. Connect battery leads, negative lead last.

PANEL REPAIRS

REPAIRS 77-2-51

Rear floor complete assembly

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove loadspace carpet.

REPAIRS, Carpet - loadspace.

4. Remove rear seats.

SEATS, REPAIRS, Seat - rear.

5. Remove rear carpet.

REPAIRS, Carpet - rear.

6. Remove rear bumper assembly.

Bumper assembly - rear - up to 03MY.

7. Remove RH and LH mud flap and brackets.
8. Remove exhaust tail pipe heatshields.
9. Remove tread plates from rear door apertures.

10. Remove rear door aperture seal.
11. Remove tail door tread plate.
12. Remove loadspace carpet retainer.
13. Remove head lining rear trim finisher.
14. Remove tail door aperture seal.
15. Remove bolts securing body to chassis.
16. Remove relevant wiring from floor area.

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 1712A

M77 1721A

PANEL REPAIRS

77-2-52 REPAIRS

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.

REPAIRS, Carpet - rear.

13. Fit rear seats.

SEATS, REPAIRS, Seat - rear.

14. Fit loadspace carpet.

REPAIRS, Carpet - loadspace.

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.

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.