Discovery II
PANEL REPAIRS
77-2-38 REPAIRS
Sill outer assembly
Remove
1. Disconnect both battery leads, negative lead
first.
2. Disconnect leads/multiplug from alternator.
3. Remove RH or LH front wing.
4. Remove RH or LH front door.
5. Remove RH or LH rear door.
6. Remove RH or LH sill finisher.
7. Remove RH or LH 'A' post inner lower
finishers.
8. Remove RH or LH front seat.
9. LH side: Remove power amplifier and EAT
10. RH side: Remove CD autochanger.
11. Remove rear seats.
12. Remove RH or LH front seat belt.
13. Remove tread plates from front and rear door
apertures.
14. Release carpet and position aside.
15. Remove front and rear door aperture seals.
16. Release relevant wiring from 'A' post, 'B/C' post
and sill areas, and position aside.
17. Remove loadspace lower trim casing.
REPAIRS, Trim casing - side - loadspace.
18. RH side: Remove lower ACE accelerometer.
19. LH side: Remove SLS air compressor unit.
20. Models with rear A/C: Recover refrigerant
from A/C system and remove A/C pipes from
LH sill.
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
21. Remove 2 bolts securing body 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 bolts securing body to chassis and tighten
to 45 Nm (33 lbf.ft).
2. Models with rear A/C: Fit A/C pipes to sill and
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3. LH side: Fit SLS air compressor unit.
4. RH side: Fit lower ACE accelerometer.
5. Fit loadspace lower trim casing.
REPAIRS, Trim casing - side - loadspace.
6. Fit relevant wiring to 'A' post, 'B/C' post and sill
areas.
7. Fit front and rear door door aperture seals.
8. Fit carpet and secure into position.
9. Fit tread plates to front and rear door apertures.
10. Fit front seat belt.
11. Fit rear seats.
12. LH side: Fit CD autochanger.
13. RH side: Fit power amplifier and EAT ECU.
14. Fit front seat.
15. Fit 'A' post inner lower finishers.
M77 1716A