Discovery 2. Manual - part 691
PANEL REPAIRS
REPAIRS 77-2-51
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. 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.
13. Fit rear seats.
14. Fit loadspace carpet.
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.
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.
4. Connect leads/multiplug to alternator.
5. Connect battery leads, negative lead last.