Workshop Manuals Factory service & repair Land Rover
Land Rover Discovery II (UK)41 · Panel repairs
41 · General

Front bulkhead assembly

Make
Land Rover
Model
Discovery II (UK)
Section
Repairs › Front bulkhead assembly
Panel repairsFront bulkhead assembly · page 1 of 2

REPAIRS

Front bulkhead 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.
  4. Remove washer reservoir. WIPERS AND WASHERS, REPAIRS, Reservoir - washer - up to 03MY.
  5. Models with A/C: Remove condensor. AIR CONDITIONING, REPAIRS, Condenser.
  6. Diesel models: Remove gearbox fluid cooler.
  7. Remove RH and LH headlamps. LIGHTING, REPAIRS, Headlamp - up to 03MY.
  8. Release headlamp levelling motors and position aside.
  9. Release headlamp wiring and position aside.
  10. Remove battery. CHARGING AND STARTING, REPAIRS, Battery.
  11. Remove battery tray.
  12. Remove air filter assembly. ENGINE MANAGEMENT SYSTEM - Td5, REPAIRS, Air filter assembly. ENGINE MANAGEMENT SYSTEM - V8, REPAIRS, Air cleaner assembly.
  13. Remove 2 earth leads from LH of front bulkhead.
  14. Remove RH horn. ALARM SYSTEM AND HORN, REPAIR, Vehicle horn.
  15. Models with A/C: Release and remove A/C pipes.
  16. Remove RH and LH crush cans.
  17. Remove bonnet release cable.
  18. Support bonnet in open position
  19. Remove bonnet locking mechanism.
  20. Remove VIN plate.
  21. Remove 2 bolts securing front bulkhead assembly to chassis.
  22. Remove centre braces.

Repair

Repair – Remove centre braces.

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 to 45 Nm (33 lbf.ft).

  1. Fit VIN plate.
  2. Fit bonnet locking mechanism.

5. Fit bonnet release cable.

  1. Fit crush cans.

7. Models with A/C: Fit A/C pipes.

  1. Fit RH horn. ALARM SYSTEM AND HORN, REPAIR, Vehicle horn.
  2. Fit 2 earth leads to LH of front bulkhead.

10. Fit air filter assembly. ENGINE MANAGEMENT SYSTEM - Td5, REPAIRS, Air filter assembly. ENGINE MANAGEMENT SYSTEM - V8, REPAIRS, Air cleaner assembly.

  1. Fit battery tray.
  2. Fit battery. Do not connect leads. CHARGING AND STARTING, REPAIRS, Battery.
  3. Fit headlamp wiring and headlamp levelling motors.
  4. Fit RH and LH headlamps. LIGHTING, REPAIRS, Headlamp - up to 03MY.
  5. Diesel models: Fit gearbox fluid cooler.
  6. Models with A/C: Fit condensor. AIR CONDITIONING, REPAIRS, Condenser.
  7. Fit washer reservoir. WIPERS AND WASHERS, REPAIRS, Reservoir - washer - up to 03MY.

Parts & tools for this job For Land Rover Discovery

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