Discovery 2. Manual — part 690
PANEL REPAIRS
REPAIRS 77-2-47
Cross member outer rear panel (centre
section)
Remove
1. Disconnect both battery leads, negative lead
first.
2. Disconnect leads/multiplug from alternator.
3. Remove loadspace carpet.
4. Remove rear bumper assembly.
Bumper assembly - rear - up to 03MY.
5. Remove rear folding step.
6. Remove exhaust tailpipe heatshield.
7. Remove tail door tread plate.
8. Remove head lining rear trim finisher.
9. Remove tail door aperture seal.
10. 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. Fit tail door aperture seal.
3. Fit head lining rear trim finisher.
4. Fit tail door tread plate.
5. Fit exhaust tailpipe heatshield.
6. Fit rear folding step.
7. Fit rear bumper assembly.
Bumper assembly - rear - up to 03MY.
8. Fit loadspace carpet.
9. Connect leads/multiplug to alternator.
10. Connect battery leads, negative lead last.
PANEL REPAIRS
77-2-48 REPAIRS
Cross member outer rear panel (RH/LH
section)
In this procedure, the panel body side assembly and
the 'E' post assembly are replaced in conjunction
with either the RH or LH section of the cross member
outer rear panel.
Remove
1. Disconnect both battery leads, negative lead
first.
2. Disconnect leads/multiplug from alternator.
3. Remove 'E' post assembly.
PANEL REPAIRS, REPAIRS, 'E' post
4. Remove 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.
4. Fit 'E' post assembly.
PANEL REPAIRS, REPAIRS, 'E' post
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.
4. Remove fuel tank.
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.
3. Fit cross member rear outer panel.
4. Connect leads/multiplug to alternator.
5. Connect battery leads, negative lead last.
PANEL REPAIRS
REPAIRS 77-2-49
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)
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.
PANEL REPAIRS
77-2-50 REPAIRS
Rear floor complete assembly
Remove
1. Disconnect both battery leads, negative lead
first.
2. Disconnect leads/multiplug from alternator.
3. Remove loadspace carpet.
4. Remove rear seats.
5. Remove rear carpet.
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
M77 1712A
M77 1721A
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