Discovery II
PANEL REPAIRS
77-2-24 REPAIRS
Front cross member
Remove
1. Disconnect both battery leads, negative lead
first.
2. Disconnect leads/multiplug from alternator.
3. Remove washer reservoir.
Reservoir - washer - up to 03MY.
4. Models with A/C: Remove condensor.
5. Diesel models: Remove gearbox fluid cooler.
6. Remove RH and LH headlamps.
LIGHTING, REPAIRS, Headlamp - up
7. Release headlamp levelling motors and
position aside.
8. Release headlamp wiring and position aside.
9. Remove RH horn.
10. Models with A/C: Release and remove A/C
pipes.
11. Remove RH and LH crush cans.
12. Remove 2 bolts securing front bulkhead
assembly to chassis.
13. Remove centre braces.
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 centre braces.
2. Fit 2 bolts securing bulkhead to chassis and
tighten bolts to 45 Nm (33 lbf.ft).
3. Fit crush cans.
4. Models with A/C: Fit A/C pipes.
5. Fit RH horn.
6. Fit headlamp wiring and headlamp levelling
motors.
7. Fit RH and LH headlamps.
LIGHTING, REPAIRS, Headlamp - up
8. Diesel models: Fit gearbox fluid cooler.
9. Models with A/C: Fit condensor.
10. Fit washer reservoir.
Reservoir - washer - up to 03MY.
11. Connect leads/multiplug to alternator.
12. Connect battery leads, negative lead last.
