2002 LAND ROVER DISCOVERY Workshop Manual

PANEL REPAIRS
77-2-16 PROCEDURES
4.Cut away the bulk of the panel as necessary
using an air saw.
NOTE: On certain panel joints MIG welds and
braze should be removed using a sander where
possible, before cutting out the panel bulk.
5.Separate spot welded joints and remove panel
remnants using hammer, bolster chisel and
pincers.
Prepare old surfaces
1.Remove any remaining sealant using a hot air
gun to minimise the risk of toxic fumes caused
by heat generated during welding.
CAUTION: Care must be taken to avoid
excessive heat build-up when using the hot
air gun.2.Clean all panel joint edges to a bright smooth
finish, using a belt-type sander.
NOTE: As an alternative, a disc sander may be
used.
3.Straighten existing panel joint edges using a
shaping block and hammer.

PANEL REPAIRS
PROCEDURES 77-2-17
Prepare new surfaces
1.Mark out bulk of new panel and trim to size,
leaving approximately 50 mm (1.968 in) overlap
with existing panel. Offer up new panel/section,
align with associated panels (e.g. new body
side panel aligned with door and taildoor).
Clamp into position.
2.Cut new and existing panels as necessary to
form butt, joggle or brace joint as required.
Remove all clamps and metal remnants.3.Prepare new panel joint edges for welding by
sanding to a bright finish. This must include
inner as well as outer faces.
4.Apply suitable weld-through primer, to panel
joint surfaces to be welded, using brush or
aerosol can.

PANEL REPAIRS
77-2-18 PROCEDURES
5.Apply correct sealant or adhesive, as
applicable, to panel joint surfaces.

+ CORROSION PREVENTION AND
SEALING, SEALING, Body Sealing.
Offer up and align
1.Offer up new panel and align with associated
panels. Clamp into position using welding
clamps or Mole grips. Where a joggle or brace
joint is being adopted, make a set in the original
panel joint edge or insert a brace behind the
joint.
NOTE: In cases where access for welding
clamps is difficult, it may be necessary to use
tack welds.Welding
1.Select arms for resistance spot welding and
shape electrode tips using a tip trimmer.
CAUTION: Use arms not exceeding 300 mm
(11.81 in) in length.
NOTE: To maintain weld efficiency, the tips will
require regular cleaning and dressing.
2.Fit resistance spot welding arms and test
equipment for satisfactory operation, using test
coupons. Where monitoring equipment is not
available, verify weld strength by checking that
metal around the weld puddle pulls apart under
tension during pulling.

PANEL REPAIRS
PROCEDURES 77-2-19
3.Use a resistance spot welder where access
permits. Try to ensure weld quality by using a
welding monitor where possible.
4.MIG tack weld butt joints and re-check
alignment and panel contours where
necessary. Ensure that a gap is maintained to
minimise welding distortion, by inserting a
hacksaw blade as an approximate guide.5.Dress MIG tack welds using a sander with 36
grit disc, or a belt-type sander where access is
limited.
6.MIG seam weld butt joints.

PANEL REPAIRS
77-2-20 PROCEDURES
7.Always use MIG plug welds where excessive
metal thickness or limited access make
resistance spot welding impractical. Make plug
welds either by using holes left by the spot weld
cutter, or through holes punched and drilled for
the purpose.
8.Dress all welds using either a sander with 36
grit disc, or a belt-type sander and/or
impregnated wire brush.
NOTE: Brazing operations, if required, must be
carried out at this point.

PANEL REPAIRS
REPAIRS 77-2-21
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
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).
3.Fit VIN plate.
4.Fit bonnet locking mechanism.
5.Fit bonnet release cable.
6.Fit crush cans.
7. Models with A/C: Fit A/C pipes.
8.Fit RH horn.

+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
9.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.
11.Fit battery tray.
12.Fit battery. Do not connect leads.

+ CHARGING AND STARTING,
REPAIRS, Battery.
13.Fit headlamp wiring and headlamp levelling
motors.
14.Fit RH and LH headlamps.

+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
15. Diesel models: Fit gearbox fluid cooler.
16. Models with A/C: Fit condensor.

+ AIR CONDITIONING, REPAIRS,
Condenser.
17.Fit washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.

PANEL REPAIRS
77-2-22 REPAIRS
18.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
19.Connect leads/multiplug to alternator.
20.Connect battery leads, negative lead last.Bonnet locking platform
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
4. Models with A/C: Remove condensor.

+ AIR CONDITIONING, REPAIRS,
Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6.Remove RH and LH headlamps.

+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Remove RH and LH repeater lamps.

+ LIGHTING, REPAIRS, Lamp - front
repeater.
8.Release headlamp wiring and position aside.
9.Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
10.Remove battery tray.
11.Remove air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
12.Remove RH horn.

+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
13.Remove bonnet release cable.
14.Support bonnet in open position
15.Remove bonnet locking mechanism.
16.Remove VIN plate.
17.Remove centre braces.

PANEL REPAIRS
REPAIRS 77-2-23
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 VIN plate.
3.Fit bonnet locking mechanism.
4.Fit bonnet release cable.
5.Fit RH horn.

+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle horn.
6.Fit air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
7.Fit battery tray.
8.Fit battery. Do not connect leads.

+ CHARGING AND STARTING,
REPAIRS, Battery.
9.Fit headlamp wiring.
10.Fit RH and LH repeater lamps.

+ LIGHTING, REPAIRS, Lamp - front
repeater.
11.Fit RH and LH headlamps.

+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
12. Diesel models: Fit gearbox fluid cooler.
13. Models with A/C: Fit condensor.

+ AIR CONDITIONING, REPAIRS,
Condenser.
14.Fit bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
Front cross member
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
4. Models with A/C: Remove condensor.

+ AIR CONDITIONING, REPAIRS,
Condenser.
5. Diesel models: Remove gearbox fluid cooler.
6.Remove RH and LH headlamps.

+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Release headlamp levelling motors and
position aside.
8.Release headlamp wiring and position aside.
9.Remove RH horn.

+ ALARM SYSTEM AND HORN,
REPAIR, Vehicle 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.