battery LAND ROVER DISCOVERY 1999 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 1999Pages: 1529, PDF Size: 34.8 MB
Page 1099 of 1529
PANEL REPAIRS
77-2-32 REPAIRS
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.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 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.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.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - from 03MY.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
M77 1693A
M77 1749
Page 1100 of 1529
PANEL REPAIRS
REPAIRS 77-2-33
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.
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.
M77 1694A
Page 1101 of 1529
PANEL REPAIRS
77-2-34 REPAIRS
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.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.
M77 1742
Page 1102 of 1529
PANEL REPAIRS
REPAIRS 77-2-35
'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.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 1751
Page 1103 of 1529
PANEL REPAIRS
77-2-36 REPAIRS
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.
Page 1104 of 1529
PANEL REPAIRS
REPAIRS 77-2-37
Dash side assembly
NOTE: In this procedure, the front wing, 'A' post
assembly and the valance outer reinforcement (rear
section) are replaced in conjunction with the dash
side assembly.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove 'A' post assembly.
+ PANEL REPAIRS, REPAIRS, 'A' post
assembly.
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 'A' post assembly.
+ PANEL REPAIRS, REPAIRS, 'A' post
assembly.
2.Connect leads/multiplug to alternator.
3.Connect battery leads, negative lead last..
M77 1691
M77 1696B
Page 1105 of 1529
PANEL REPAIRS
77-2-38 REPAIRS
Sill outer assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove RH or LH front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
4.Remove RH or LH front door.
+ DOORS, REPAIRS, Door - front.
5.Remove RH or LH rear door.
+ DOORS, REPAIRS, Door - rear.
6.Remove RH or LH sill finisher.
7.Remove RH or LH 'A' post inner lower
finishers.
8.Remove RH or LH front seat.
+ SEATS, REPAIRS, Seat - front.
9. LH side: Remove power amplifier and EAT
ECU.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
10. RH side: Remove CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
11.Remove rear seats.
+ SEATS, REPAIRS, Seat - rear.
12.Remove RH or LH front seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
13.Remove tread plates from front and rear door
apertures.
14.Release carpet and position aside.
15.Remove front and rear door aperture seals.
16.Release relevant wiring from 'A' post, 'B/C' post
and sill areas, and position aside.
17.Remove loadspace lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
18. RH side: Remove lower ACE accelerometer.
+ FRONT SUSPENSION, REPAIRS,
Accelerometer - ACE - lower.
19. LH side: Remove SLS air compressor unit.
+ REAR SUSPENSION, REPAIRS,
Compressor unit - air - SLS.
20. Models with rear A/C: Recover refrigerant
from A/C system and remove A/C pipes from
LH sill.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
21.Remove 2 bolts securing body 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 bolts securing body to chassis and tighten
to 45 Nm (33 lbf.ft).
2. Models with rear A/C: Fit A/C pipes to sill and
recharge A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3. LH side: Fit SLS air compressor unit.
+ REAR SUSPENSION, REPAIRS,
Compressor unit - air - SLS.
4. RH side: Fit lower ACE accelerometer.
+ FRONT SUSPENSION, REPAIRS,
Accelerometer - ACE - lower.
5.Fit loadspace lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
6.Fit relevant wiring to 'A' post, 'B/C' post and sill
areas.
7.Fit front and rear door door aperture seals.
8.Fit carpet and secure into position.
9.Fit tread plates to front and rear door apertures.
10.Fit front seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
11.Fit rear seats.
+ SEATS, REPAIRS, Seat - rear.
12. LH side: Fit CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
13. RH side: Fit power amplifier and EAT ECU.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
14.Fit front seat.
+ SEATS, REPAIRS, Seat - front.
15.Fit 'A' post inner lower finishers.
M77 1716A
Page 1106 of 1529
PANEL REPAIRS
REPAIRS 77-2-39
16.Fit sill finisher.
17.Fit rear door.
+ DOORS, REPAIRS, Door - rear.
18.Fit front door.
+ DOORS, REPAIRS, Door - front.
19.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
20.Connect leads/multiplug to alternator.
21.Connect battery leads, negative lead last.
Sill inner assembly
NOTE: In this procedure, the sill outer assembly is
replaced in conjunction with the sill inner assembly.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove sill outer assembly.
+ PANEL REPAIRS, REPAIRS, Sill
outer assembly.
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 sill outer assembly.
+ PANEL REPAIRS, REPAIRS, Sill
outer assembly.
2.Connect leads/multiplug to alternator.
3.Connect battery leads, negative lead last.
Page 1107 of 1529
PANEL REPAIRS
77-2-40 REPAIRS
'B/C' post assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove RH or LH rear door.
+ DOORS, REPAIRS, Door - rear.
4.Remove front door striker from 'B/C' post.
5.Remove RH or LH sill finisher.
6.Remove RH or LH front seat.
+ SEATS, REPAIRS, Seat - front.
7. RH side: Remove power amplifier.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
8. LH side: Remove CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
9.Remove RH or LH front seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
10.Remove RH or LH rear seat.
+ SEATS, REPAIRS, Seat - rear.
11.Remove head lining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
12.Remove tread plate from front and rear door
apertures.
13.Release carpet from fixings and position aside.
14.Remove front and rear door door aperture
seals.
15.Release relevant wiring from 'B/C' post and sill
areas and position aside.
16.Remove side drip rail finisher.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. Before welding 'B/C' post to roof, apply
'Heat shrink paste' to roof area to avoid heat
damage to paintwork.
Page 1108 of 1529
PANEL REPAIRS
REPAIRS 77-2-41
Refit
1.Fit side drip rail finisher.
2.Fit wiring to 'B/C' post and sill areas.
3.Fit front and rear door door aperture seal.
4.Position carpet and secure with fixings.
5.Fit tread plates to front and rear door apertures.
6.Fit head lining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
7.Fit rear seat.
+ SEATS, REPAIRS, Seat - rear.
8.Fit front seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
9. LH side: Fit CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
10. RH side: Fit power amplifier.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
11.Fit RH or LH front seat.
+ SEATS, REPAIRS, Seat - front.
12.Fit sill finisher.
13.Fit front door striker to B/C post, fit Torx bolts
and tighten to 26 Nm (19 lbf.ft).
14.Fit rear door.
+ DOORS, REPAIRS, Door - rear.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
Panel body side assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove loadspace side trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
4.Remove head lining rear trim finisher.
5.Remove rear head rests, if fitted.
6.Remove body side rear glass.
+ SCREENS, REPAIRS, Glass - body
side - rear.
7.Remove rear bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - rear - up to 03MY.
8.Remove rear bumper finisher.
9.Remove rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - rear.
10.Remove mud flap.
11.Remove tread plate from rear door aperture.
12.Remove rear door aperture seal.
13.Remove rear door striker from 'D' post.
14.Remove 'D' post outer trim finisher.
15.Remove wheel arch trim finisher.
16.Remove side drip rail finisher.
17. RH side: Remove tail door.
18. LH side: Remove tail door striker and setting
block from 'E' post.
19.Remove tail door tread plate.
20.Remove loadspace carpet retainer.
21.Remove tail door aperture seal.
22.Remove tail lamp.
+ LIGHTING, REPAIRS, Lamp - tail.
23. RH side: Remove fuel filler flap.
24. RH side: Remove fuel filler tube.
+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
25.Remove aerial amplifier.
26.Remove relevant wiring from body side area.