battery replacement LAND ROVER DISCOVERY 1999 Owner's Manual

PANEL REPAIRS
77-2-42 REPAIRS
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. The panel
body side assembly does not require any
welding, as it is bolted into position.Refit
1.Position and secure wiring.
2.Fit aerial amplifier.
3. RH side: Fit fuel filler tube.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
4. RH side: Fit fuel filler flap.
5.Fit tail lamp.

+ LIGHTING, REPAIRS, Lamp - tail.
6.Fit tail door aperture seal.
7.Fit loadspace carpet retainer.
8.Fit tail door tread plate.
9. LH side: Fit tail door striker and setting block to
'E' post, fit Torx bolts and tighten to 26 Nm (19
lbf.ft).
10. RH side: Fit tail door.
11.Fit side drip rail finisher.
12.Fit wheel arch trim finisher.
13.Fit 'D' post outer trim finisher.
14.Fit rear door striker.
15.Fit rear door aperture seal.
16.Fit tread plate to rear door aperture.
17.Fit mud flap.
18.Fit rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - rear.
19.Fit rear bumper finisher.
20.Fit rear bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - rear - up to 03MY.
21.Fit body side rear glass.

+ SCREENS, REPAIRS, Glass - body
side - rear.
22.Fit rear head rests, if fitted.
23.Fit head lining rear trim finisher.
24.Fit loadspace side trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
25.Connect leads/multiplug to alternator.
26.Connect battery leads, negative lead last.
M77 0000

PANEL REPAIRS
REPAIRS 77-2-43
Body side inner rear assembly
In this procedure, the panel body side assembly is
replaced in conjunction with the body side inner rear
assembly.
Remove
1.Disconnect battery eath lead.
2.Disconnect leads/multiplug from alternator.
3.Remove panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
4.Remove RH or LH rear seat.

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

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
6.Remove rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - side.
7.Remove third row seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
8.Remove fuel tank.

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

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
9.Remove fuel filler tube.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
10. RH side: Remove fuel flap release solenoid.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Solenoid - fuel filler flap release.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Solenoid - fuel filler flap release.
11. RH side: Remove air extractor vent.
12.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. RH side: Fit air extractor vent.
3. RH side: Fit fuel flap release solenoid.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Solenoid - fuel filler flap release.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Solenoid - fuel filler flap release.
4.Fit fuel filler tube.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
5.Fit fuel tank.

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

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
6.Fit third row seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
7.Fit rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - side.
8.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
9.Fit rear seat.

+ SEATS, REPAIRS, Seat - rear.
10.Fit panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
11.Connect leads/multiplug to alternator.
12.Connect battery leads, negative lead last.
M77 1698A

PANEL REPAIRS
77-2-44 REPAIRS
'D' post outer assembly
In this procedure, the panel body side assembly is
also replaced in conjunction with the 'D' post
assembly. The 'D' post inner closing panel 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 panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
4.Remove RH or LH sill finisher.
5.Remove front seat.

+ SEATS, REPAIRS, Seat - front.
6. RH side: Remove power amplifier.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
7. LH side: Remove CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
8.Remove 'B/C' post lower trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
9.Remove rear seat.

+ SEATS, REPAIRS, Seat - rear.
10.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
11.Release carpet for access to 'D' post assembly
and position aside.
12.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.Position and secure carpet into position.
3.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
4.Fit rear seat.

+ SEATS, REPAIRS, Seat - rear.
5.Fit 'B/C' post lower trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
6. LH side: Fit CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
7. RH side: Fit power amplifier.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
8.Fit front seat.

+ SEATS, REPAIRS, Seat - front.
9.Fit RH or LH sill finisher.
10.Fit panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
11.Connect leads/multiplug to alternator.
12.Connect battery leads, negative lead last.
M77 1699B

PANEL REPAIRS
REPAIRS 77-2-45
Wheelarch rear outer assembly
In this procedure, the panel body side assembly is
replaced in conjunction with the wheelarch rear outer
assembly.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
4.Remove front seat.

+ SEATS, REPAIRS, Seat - front.
5. RH side: Remove power amplifier.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
6. LH side: Remove CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
7.Remove 'B/C' post lower trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
8.Remove rear seat.

+ SEATS, REPAIRS, Seat - rear.
9.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
10.Release carpet for access to 'D' post assembly
and position aside.
11.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.Position and secure carpet into position.
3.Fit loadspace carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
4.Fit rear seat.

+ SEATS, REPAIRS, Seat - rear.
5.Fit 'B/C' post lower trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
6. LH side: Fit CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
7. RH side: Fit power amplifier.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
8.Fit front seat.

+ SEATS, REPAIRS, Seat - front.
9.Fit panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
10.Connect leads/multiplug to alternator.
11.Connect battery leads, negative lead last.
M77 1700A

PANEL REPAIRS
77-2-46 REPAIRS
'E' post assembly
In this procedure, the panel body side assembly and
tail door are replaced in conjunction with the 'E' post
assembly. If required the 'E' post closing assembly
can also be replaced.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
4.Remove rear seats.

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

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
6.Remove third row seat belts.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
7.Remove relevant wiring.
8.Remove rear 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.Refit
1.Fit rear drip rail finisher.
2.Fit and secure wiring.
3.Fit third row seat belts.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
4.Fit loadspace carpet.

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

+ SEATS, REPAIRS, Seat - rear.
6.Fit panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
7.Connect leads/multiplug to alternator.
8.Connect battery leads, negative lead last.
M77 1701A

PANEL REPAIRS
REPAIRS 77-2-47
'E' post closing assembly
In this procedure, the panel body side assembly, tail
door and 'E' post assembly are replaced in
conjunction with the 'E' post closing assembly.
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.
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 'E' post assembly.

+ PANEL REPAIRS, REPAIRS, 'E' post
assembly.
2.Connect leads/multiplug to alternator.
3.Connect battery leads, negative lead last.
Cross member outer rear panel
In this procedure, the panel body side assembly and
the 'E' post assembly are replaced in conjunction
with 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.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.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.

PANEL REPAIRS
77-2-48 REPAIRS
Cross member outer rear panel (centre
section)
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 bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - rear - up to 03MY.
5.Remove rear folding step.

+ EXTERIOR FITTINGS, REPAIRS,
Rear folding step.
6.Remove exhaust tailpipe heatshield.
7.Remove tail door tread plate.
8.Remove head lining rear trim finisher.
9.Remove tail door aperture seal.
10.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.Fit tail door aperture seal.
3.Fit head lining rear trim finisher.
4.Fit tail door tread plate.
5.Fit exhaust tailpipe heatshield.
6.Fit rear folding step.

+ EXTERIOR FITTINGS, REPAIRS,
Rear folding step.
7.Fit rear bumper assembly.

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

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
9.Connect leads/multiplug to alternator.
10.Connect battery leads, negative lead last.

PANEL REPAIRS
REPAIRS 77-2-49
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
77-2-50 REPAIRS
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
REPAIRS 77-2-51
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
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 1712A
M77 1721A