engine LAND ROVER DISCOVERY 2002 Workshop Manual

PANEL REPAIRS
77-2-26 REPAIRS
Headlamp mounting panel - LH
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 headlamp.

+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
7.Remove repeater lamp.

+ LIGHTING, REPAIRS, Lamp - front
repeater.
8.Release headlamp levelling motor and position
aside.
9.Release headlamp wiring and position aside.
10.Remove air filter assembly.

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

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
11.Remove 2 earth leads from LH of front
bulkhead.
12.Release and remove A/C pipes.
13.Remove crush can.
14.Remove bonnet release cable.
15.Remove 2 bolts securing front bulkhead
assembly to chassis.
16.Remove centre brace.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 brace.
2.Fit 2 bolts securing bulkhead to chassis and
tighten bolts to 45 Nm (33 lbf.ft).
3.Fit bonnet release cable.
4.Fit crush can.
5. Models with A/C: Fit A/C pipes.
6.Fit 2 earth leads to LH of front bulkhead.
7.Fit air filter assembly.

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

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
8.Fit battery tray.
9.Fit headlamp wiring and headlamp levelling
motors.
10.Fit repeater lamp.

+ LIGHTING, REPAIRS, Lamp - front
repeater.

PANEL REPAIRS
REPAIRS 77-2-27
11.Fit headlamp.

+ 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 washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
Valance upper assembly - LH
In this procedure, the front wing, the valance outer
reinforcement and the bonnet alarm switch mounting
bracket are replaced in conjunction with the LH
valance upper 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 air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
5.Remove PAS/ACE reservoir.
6.Remove ABS modulator.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
7.Remove brake pipes from valance.
8.Release harness from valance and position
aside.
9. Models with A/C: Depressurise A/C system
and remove pipes from valance.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.

PANEL REPAIRS
77-2-28 REPAIRS
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. Models with A/C: Fit A/C pipes and recharge
A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Fit harness to valance.
3.Fit brake pipes to valance.
4.Fit ABS modulator.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
5.Fit PAS/ACE reservoir, refill fluids to correct
levelsand bleed ACE system.

+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Fluids.6.Fit air filter assembly.

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
7.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
8.Connect leads/multiplug to alternator.
9.Connect battery leads, negative lead last.
M77 1743
M77 1690A

PANEL REPAIRS
77-2-30 REPAIRS
Valance upper assembly (front section) -
LH
In this procedure, the front wing, the valance outer
reinforcement (front section) and the bonnet alarm
switch mounting bracket are replaced in conjunction
with the LH valance upper assembly (front section).
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 air filter assembly.

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

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
5.Remove PAS/ACE reservoir.
6.Remove ABS modulator.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
7.Release harness from valance and position
aside.
8. Models with A/C: Depressurise A/C system
and remove pipes from valance.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.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. Models with A/C: Fit A/C pipes and recharge
A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Fit harness to valance.
3.Fit ABS modulator.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
4.Fit PAS/ACE reservoir and refill fluids to correct
levels.

+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Fluids.
M77 1744
M77 1689A

PANEL REPAIRS
REPAIRS 77-2-31
5.Fit air filter assembly.

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

+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
6.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
Valance upper assembly (front section) -
RH
In this procedure, the front wing and the valance
outer reinforcement (front section) are replaced in
conjunction with the RH valance upper assembly
(front section).
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 battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
5.Remove battery tray.
6.Remove fuse box.
7.Release expansion tank from fixings and
position aside.
8.Release harness from valance and position
aside.

PANEL REPAIRS
77-2-32 REPAIRS
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 harness to valance.
2.Fit and secure expansion tank to fixings.
3.Fit fuse box.
4.Fit battery tray.
5.Fit battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
6.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
Front valance assembly - RH
Remove
1.Disconnect battery eath lead.
2.Remove front bulkhead assembly.

+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
3.Remove engine compartment fusebox and
related wiring.
4.Remove radiator expansion tank from
mountings and position aside.
5. Petrol models: Remove cruise control
actuator mounting bracket.
6. Diesel models: Remove EGR modulator
mounting bracket.
7. RHD models: Remove brake servo.

+ BRAKES, REPAIRS, Servo - brake.
8.Remove brake pipes from valance assembly.
9.Remove RH road wheel.
10.Remove RH front mud flap.
11.Remove insulation pad from engine bulkhead.
12.Remove windscreen side finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
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 windscreen side finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
2.Fit insulation pad to engine bulkhead.
3.Fit front mud flap.
4.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
5.Fit brake pipes to valance assembly.
M77 1693A
M77 1749
M77 1694A

PANEL REPAIRS
REPAIRS 77-2-33
6. RHD models: Fit brake servo.
7. Diesel models: Fit EGR modulator mounting
bracket.
8. Petrol models: Fit cruise control actuator
mounting bracket.
9.Fit radiator expansion tank.
10.Fit fusebox and secure wiring.
11.Fit front bulkhead assembly.

+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
12.Connect battery leads, negative lead last.
Front valance assembly - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front bulkhead assembly.

+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
4.Remove ABS modulator unit.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
5. LHD models: Remove brake servo.

+ BRAKES, REPAIRS, Servo - brake.
6.Remove brake pipes from valance assembly.
7.Remove PAS/ACE reservoir.
8. Models with A/C: Remove A/C pipes from
valance assembly.
9.Remove wiring harness from valance
assembly.
10.Remove LH front road wheel.
11.Remove LH front mud flap.
12.Remove insulation pad from engine bulkhead.
13.Remove windscreen side finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
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.
M77 1742

PANEL REPAIRS
77-2-34 REPAIRS
Refit
1.Fit windscreen side finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
2.Fit insulation pad to engine bulkhead.
3.Fit front mud flap.
4.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
5.Fit wiring harness to valance assembly.
6. Models with A/C: Fit A/C pipes to valance
assembly.
7.Fit PAS/ACE reservoir.
8.Fit brake pipes to valance assembly.
9. LHD models: Fit brake servo.

+ BRAKES, REPAIRS, Servo - brake.
10.Fit ABS modulator unit.

+ BRAKES, REPAIRS, Modulator unit
- ABS.
11.Fit front bulkhead assembly.

+ PANEL REPAIRS, REPAIRS, Front
bulkhead assembly.
12.Connect leads/multiplug to alternator.
13.Connect battery leads, negative lead last.
'A' post assembly
In this procedure, the front wing and the valance
outer reinforcement (rear section) are replaced in
conjunction with the 'A' post assembly. The dash side
assembly can also be replaced in this procedure if
required.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove bonnet.
4.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
5.Remove RH or LH front door.

+ DOORS, REPAIRS, Door - front.
6.Remove RH or LH sill finisher.
7.Remove windscreen.

+ SCREENS, REPAIRS, Windscreen.
8. Diesel models: Remove ECM.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Engine control module
(ECM).
9.Remove RH or LH 'A' post inner finishers and
disconnect speaker multiplug (if fitted).
10.Release sunroof drain tube and position aside.
11.Remove RH or LH front seat.

+ SEATS, REPAIRS, Seat - front.
12. RH side: Remove CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
13.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
14. Driver's side: Remove steering column
support bracket.
15.Remove relevant wiring from 'A' post.
16.Remove tread plate from front door aperture.
17.Release front carpet and position aside.
18.Remove front door aperture seal.
19.Remove engine bulkhead insulation.

PANEL REPAIRS
REPAIRS 77-2-35
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 insulation pad to engine bulkhead.
2.Fit front door aperture seal.
3.Position front carpet and fit tread plate to front
door aperture.
4.Fit wiring to 'A' post.
5. Driver's side: Fit steering column support
bracket.
6.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
7. RH side: Fit CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
8.Fit RH or LH front seat.

+ SEATS, REPAIRS, Seat - front.
9.Fit sunroof drain tube.
10.Connect multiplug to speaker (if fitted) and fit
finisher to 'A' post.
11. Diesel models: Fit ECM.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Engine control module
(ECM).
12.Fit windscreen.

+ SCREENS, REPAIRS, Windscreen.
13.Fit sill finisher.
14.Fit front door.

+ DOORS, REPAIRS, Door - front.
15.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
16.Fit bonnet.
17.Connect leads/multiplug to alternator.
18.Connect battery leads, negative lead last.
M77 1751

BODY SEALING MATERIALS
77-3-2 MATERIALS AND APPLICATIONS
Approved materials
The following is a table of materials approved by Land Rover for use during body repairs.
Description - Usage Supplier Part Number
Cavity waxes
Inner Cavity Wax (Amber) 3M 08901/11/21
Inner Cavity Wax (Transparent) 3M 08909/19/29
Cavity Wax Croda PW57
Engine bay waxes/lacquers
Astrolan Engine Bay Wax and Cosmetic Wax Astors DA3243/1
Engine Bay Cosmetic Wax/Lacquer Croda PW197
Engine Bay Cosmetic Wax/Lacquer Dinol 4010
Miscellaneous materials
Aerosol Auto Adhesive (Trim) - impact adhesive for trim parts 3M 08080
Flexible Parts Repair Material - rubber modified polypropylene parts 3M 05900
Waterproof Cloth Tape - sealing panel apertures 3M Y387/Y3998
Sound Dampening Foam Gurit-Essex Betacore 7999
Water Shedder Repair (Aerosol) Teroson
Seam sealers
Body Caulking - type (b) gaps between panels 3M 08568
Bolted Panel Sealer - between bolted panels 3M 08572
Drip Chek Clear - bolted, spot welded and bonded panel edges; type (a) and
(b) gaps between panels; type (c) clinch joints 3M 08401
Drip Chek Heavy - type (b) gaps between panels; type (c) clinch joints 3M 08531
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges;
type (a) and (b) gaps between panels; type (b) clinch joints3M 08684/89/94
Polyurethane Sealer (Sachet) - bolted panel edges; type (b) clinch joints 3M 08703/83/88
Sprayable Sealer - lap joints 3M 08800/23
Super Seam Sealer - lap joints; type (b) clinch joints 3M 08537
Weld Thru' Sealer - between spot welded panels 3M 08626
Betafill Clinch and Brushable Sealer - type (b) clinch joints Gurit-Essex 10211/15/20
Clinch, Joint and Underbody Coating - lap joints Gurit-Essex 10101/10707
Leak Chek Clear - between bolted panels; spot welded and bonded panel
edges; type (c) clinch joints; type (a) gaps between panels Kent Industries 10075
Putty - type (b) gaps between panels Kent Industries
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges;
between bonded panels; type (a) and (b) gaps between panels PPG 6500
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges;
between bonded panels; type (b) gaps between panels Teroson 92
Terolan Light Seam Sealer - bolted, spot welded and bonded panel edges;
type (a) and (b) gaps between panels; between bonded panels; type (c)
clinch jointsTeroson