2002 LAND ROVER DISCOVERY Workshop Manual

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
assembly.
4.Remove rear folding step.

+ EXTERIOR FITTINGS, REPAIRS,
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.

+ EXTERIOR FITTINGS, REPAIRS,
Rear folding step.
4.Fit 'E' post assembly.

+ PANEL REPAIRS, REPAIRS, 'E' post
assembly.
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.

+ PANEL REPAIRS, REPAIRS, Cross
member outer rear panel.
4.Remove fuel tank.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
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.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
3.Fit cross member rear outer panel.

+ PANEL REPAIRS, REPAIRS, Cross
member outer rear 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.

+ PANEL REPAIRS, REPAIRS, 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.

+ PANEL REPAIRS, REPAIRS, 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.

+ PANEL REPAIRS, REPAIRS, 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.

+ PANEL REPAIRS, REPAIRS, 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.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
4.Remove rear seats.

+ SEATS, REPAIRS, Seat - rear.
5.Remove rear carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - rear.
6.Remove rear bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
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

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.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - rear - up to 03MY.
12.Fit rear carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - rear.
13.Fit rear seats.

+ SEATS, REPAIRS, Seat - rear.
14.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
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.

+ PANEL REPAIRS, REPAIRS, 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.

+ PANEL REPAIRS, REPAIRS, Cross
member rear assembly.
4.Connect leads/multiplug to alternator.
5.Connect battery leads, negative lead last.

PANEL REPAIRS
77-2-52 REPAIRS
Rear floor (RH/LH section)
In this procedure, the cross member rear assembly,
cross member outer rear panel (RH/LH section),
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 (RH/LH section).
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove cross member rear assembly.

+ PANEL REPAIRS, REPAIRS, 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.
Refit
1. LH side: Fit exhaust heatshield to rear floor.
2.Fit mud flap mounting brackets.
3.Fit cross member rear assembly.

+ PANEL REPAIRS, REPAIRS, Cross
member rear assembly.
4.Connect leads/multiplug to alternator.
5.Connect battery leads, negative lead last.
Roof assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3. Models with sunroof: Remove front sunroof.

+ SUNROOF, REPAIRS, Sunroof -
front.
4. Models with sunroof: Remove rear sunroof.

+ SUNROOF, REPAIRS, Sunroof -
rear.
5. Models with sunroof: Release sunroof drain
tubes and position aside.
6. Models with fixed roof: Remove head lining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
7.Remove front seats.

+ SEATS, REPAIRS, Seat - front.
8.Remove rear seats.

+ SEATS, REPAIRS, Seat - rear.
9.Remove rear headrests, if fitted.
10.Remove roof bars, if fitted.

+ EXTERIOR FITTINGS, REPAIRS,
Roof bars.
11.Remove tread plates from front door apertures.
12.Remove 'A' post lower trim panels.
13.Remove front door aperture seals.
14.Remove tread plates from rear door apertures.
15.Remove rear door aperture seals.
16.Remove 'D' post outer trim finisher.
17.Remove windscreen.

+ SCREENS, REPAIRS, Windscreen.
18.Remove alpine light glass.

+ SCREENS, REPAIRS, Glass - alpine
light.
19.Remove side and rear drip rail finishers.
20.Release relevant wiring and position aside.

PANEL REPAIRS
REPAIRS 77-2-53
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.
2. During welding operations, apply 'Heat
shrink paste' to roof and body side panel to
avoid heat damage to paintwork.Refit
1.Fit and secure wiring.
2.Fit side and rear drip rail finishers.
3.Fit alpine light glass.

+ SCREENS, REPAIRS, Glass - alpine
light.
4.Fit windscreen.

+ SCREENS, REPAIRS, Windscreen.
5.Fit 'D' post outer trim finishers.
6.Fit rear door aperture seals.
7.Fit tread plates to rear door apertures.
8.Fit front door aperture seals.
9.Fit 'A' post lower trim panels.
10.Fit tread plates to front door apertures.
11.Fit roof bars.

+ EXTERIOR FITTINGS, REPAIRS,
Roof bars.
12.Fit rear headrests.
13.Fit rear seats.

+ SEATS, REPAIRS, Seat - rear.
14.Fit front seats.

+ SEATS, REPAIRS, Seat - front.
15. Models with fixed roof: Fit head lining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
16. Models with sunroof: Fit sunroof drain tubes.
17. Models with sunroof: Fit rear sunroof.

+ SUNROOF, REPAIRS, Sunroof -
rear.
18. Models with sunroof: Fit front sunroof.

+ SUNROOF, REPAIRS, Sunroof -
front.
19.Connect leads/multiplug to alternator.
20.Connect battery leads, negative lead last.
M77 1715A

PANEL REPAIRS
77-2-54 REPAIRS

PANEL REPAIRS
TIMES 77-2-55
TIME S
TIME SCHEDULES
The following information shows the time taken to replace damaged panels and assemblies. This time includes
removal of Mechanical, Electrical and Trim (MET) parts, and also time for painting, based on using Clear Over Base
(COB) Metallic paint.
The times shown were generated by Thatcham (the Motor Insurance Repair and Research Centre) and are to be used
as a guide only.
All times shown are in decimal hours.
Single panel/assembly replacement times
Combination panel replacement times - Front end panels
Panel Description Total times
Petrol Diesel
Bonnet 7.4 7.4
Bonnet locking platform 8.4 8.4
Front cross member 9.3 8.1
Front bulkhead assembly 10.5 9.3
Headlamp mounting panel RH 9.3–
Headlamp mounting panel LH 9.4–
Front wing RH 7.2 7.2
Front wing LH 7.1 7.1
Front door – skin 10.8 10.8
Front door 7.9 7.9
Rear door – skin 10.0 10.0
Rear door 7.6 7.6
'A' post assembly RH 11.4–
'A' post assembly LH 11.3–
'B/C' post assembly 11.3–
Sill outer assembly RH 14.8–
Sill outer assembly LH 13.9–
Panel body side assembly RH 15.5 15.5
Panel body side assembly LH 13.4 13.4
Cross member outer rear panel (centre section) 13.4 13.4
Tail door 9.3 9.3
Roof 30.3 30.3
Panel DescriptionTotal time
Petrol Diesel
Front bumper
Bonnet locking platform
Headlamp mounting panel
Front wing
18.5 RH 17.3 RH
18.8 LH 17.5 LH
Front bumper
Front bulkhead assembly
Front wing RH & LH
19.7 18.5
Front bumper
Front bulkhead assembly