wheel LAND ROVER DISCOVERY 2002 Workshop Manual

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
77-2-40 REPAIRS
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.

PANEL REPAIRS
REPAIRS 77-2-41
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
77-2-44 REPAIRS
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

BODY SEALING MATERIALS
MATERIALS AND APPLICATIONS 77-3-7
Ensure that the nylon tube of the lance is kept away from the edges of the access hole to eliminate abrasion and
extend the life of the tube. Take care to ensure that spraying ceases just before the nozzle emerges from the access
hole. To assist in this process paint the final 30 mm (1.181 in) of the nozzle with RED paint.
Hook nozzle on flexible lance
The rigid hook produces a highly atomised, forward-directed, fully conical spray pattern having long range and good
dispersion characteristics. This combination has good directional capabilities for treating short, narrow sections, and
may also be used for direct spraying of inner wheel arches etc.
In use, position the flat area at the end of the lance at 180
° to the nozzle spray direction. This will help to guide the
spray more accurately when it is concealed in a box section or access hole.
For general spraying, move the nozzle in an arc from side to side as required, to ensure full coverage.
NOTE: Always clean gun after use with appropriate solvent to maintain efficiency.

CORROSION PREVENTION AND SEALING
77-4-6 CORROSION PREVENTION
Corrosion prevention
Factory treatments
During production, vehicle bodies are treated with the following anti-corrosion materials:
lA PVC-based underbody sealer which is sprayed onto the underside of the main floor, rear floor, front and rear
wheelarches and the front valance assembly;
lAn application of cavity wax which is sprayed into the sill panels, 'A' post, 'B-C' post, fuel filler aperture, body rear
panel and the lower areas of the door panels;
lA coating of underbody wax which is applied to the entire underbody inboard of the sill vertical flanges, and
covers all moving and flexible components EXCEPT for wheels, tyres, brakes and exhaust;
lA coat of protective wax applied to the engine bay area.
Whenever body repairs are carried out, ensure the anti-corrosion materials in the affected area are repaired or
renewed as necessary using the approved materials.

+ BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.
Precautions during body repairs and handling
Take care when handling the vehicle in the workshop. Underbody sealers, seam sealers, underbody wax and body
panels may be damaged if the vehicle is carelessly lifted.

+ LIFTING AND TOWING, LIFTING.
Proprietary anti-corrosion treatments
The application of proprietary anti-corrosion treatments, in addition to the factory-applied treatment, could invalidate
the Corrosion Warranty and should be discouraged. This does not apply to Rover approved, compatible, preservative
waxes which may be applied on top of existing coatings.
Fitting approved accessories
When fitting accessories ensure that the vehicle's corrosion protection is not affected, either by breaking the protective
coating or by introducing a moisture trap.
Do not screw self-tapping screws directly into body panels. Fit suitable plastic inserts to the panel beforehand. Always
ensure that the edges of holes drilled into panels, chassis members and other body parts are protected with a suitable
zinc rich or acid etch primer, and follow with a protective wax coating brushed onto the surrounding area.
Do not attach painted metal surfaces of any accessory directly to the vehicle's bodywork unless suitably protected.
Where metal faces are bolted together always interpose a suitable interface material such as weldable zinc rich
primer, extruded strip, or zinc tape.
Steam cleaning and dewaxing
Due to the high temperatures generated by steam cleaning equipment, there is a risk that certain trim components
could be damaged and some adhesives and corrosion prevention materials softened or liquified.
Adjust the equipment so that the nozzle temperature does not exceed 90
° C (194° F). Take care not to allow the steam
jet to dwell on one area, and keep the nozzle at least 300 mm (11.811 in) from panel surfaces.
DO NOT remove wax or lacquer from underbody or underbonnet areas during repairs. Should it be necessary to
steam clean these areas, apply a new coating of wax or underbody protection as soon as possible.
Inspections during maintenance servicing
It is a requirement of the Corrosion Warranty that the vehicle body is checked for corrosion by an authorised Land
Rover Dealer at least once a year, to ensure that the factory-applied protection remains effective.
Service Job Sheets include the following operations to check bodywork for corrosion:
lWith the vehicle on a lift, carry out visual check of underbody sealer for damage;
lWith the vehicle lowered, inspect exterior paintwork for damage and body panels for corrosion.
It will be necessary for the vehicle to be washed by the Dealer prior to inspection of bodywork if the customer has
offered the vehicle in a dirty condition.

CORROSION PREVENTION AND SEALING
CORROSION PREVENTION 77-4-7
The checks described above are intended to be visual only. It is not intended that the operator should remove trim
panels, finishers, rubbing strips or sound-deadening materials when checking the vehicle for corrosion and paint
damage.
With the vehicle on a lift, and using an inspection or spot lamp, visually check for the following:
lCorrosion damage and damaged paintwork, condition of underbody sealer on front and rear lower panels, sills
and wheel arches;
lDamage to underbody sealer. Corrosion in areas adjacent to suspension mountings and fuel tank fixings.
NOTE: The presence of small blisters in the underbody sealer is acceptable, providing they do not expose bare metal.
Pay special attention to signs of damage caused to panels or corrosion protection material by incorrect jack
positioning.
WARNING: It is essential to follow the correct jacking and lifting procedures.
With the vehicle lowered, visually check for evidence of damage and corrosion on all visible painted areas, in
particular the following:
lFront edge of bonnet;
lVisible flanges in engine compartment;
lLower body and door panels.
Rectify any bodywork damage or evidence of corrosion found during inspection as soon as is practicable, both to
minimise the extent of the damage and to ensure the long term effectiveness of the factory-applied corrosion
prevention treatment. Where the cost of rectification work is the owner's responsibility, the Dealer must advise the
owner and endorse the relevant documentation accordingly.
Where corrosion has become evident and is emanating from beneath a removable component (e.g. trim panel,
window glass, seat etc.), remove the component as required to permit effective rectification.
Underbody protection repairs
Whenever body repairs are carried out, ensure that full sealing and corrosion protection treatments are reinstated.
This applies both to the damaged areas and also to areas where protection has been indirectly impaired, as a result
either of accident damage or repair operations.
Remove corrosion protection from the damaged area before straightening or panel beating. This applies in particular
to panels coated with wax, PVC underbody sealer, sound deadening pads etc.
WARNING: DO NOT use oxy-acetylene gas equipment to remove corrosion prevention materials. Large
volumes of fumes and gases are liberated by these materials when they burn.
NOTE: Equipment for the removal of tough anti-corrosion sealers offers varying degrees of speed and effectiveness.
The compressed air-operated scraper (NOT an air chisel) offers a relatively quiet mechanical method using an
extremely rapid reciprocating action. Move the operating end of the tool along the work surface to remove the material.
The most common method of removal is by means of a hot air blower with integral scraper.
Another tool, and one of the most efficient methods, is the rapid-cutting 'hot knife'. This tool uses a wide blade and is
quick and versatile, able to be used easily in profiled sections where access is otherwise difficult.
Use the following procedure when repairing underbody coatings:
1Remove existing underbody coatings
2After panel repair, clean the affected area with a solvent wipe, and treat bare metal with an etch phosphate
material
3Re-prime the affected area
CAUTION: DO NOT, under any circumstances, apply underbody sealer directly to bare metal surfaces.
4Replace all heat-fusible plugs which have been disturbed. Where such plugs are not available use rubber
grommets of equivalent size, ensuring that they are embedded in sealer
5Mask off all mounting faces from which mechanical components, hoses and pipe clips, have been removed.
Underbody sealer must be applied before such components are refitted
6Brush sealer into all exposed seams
7Spray the affected area with an approved service underbody sealer
8Remove masking from component mounting faces, and touch-in where necessary. Allow adequate drying time
before applying underbody wax

CORROSION PREVENTION AND SEALING
SEALING 77-4-9
SEALING
Body Sealing
Underbody sealer treatment areas
Underfloor areas and sill outer panels are treated with a Plastisol PVC underbody sealer. This material is not suitable
for re-treatment. When repairing areas of underbody sealer, strip the factory-applied underbody sealer back to a
suitable break point. Ensure that a clean metal surface is exposed and that the edge of the existing sealer adheres
soundly to the panel.
Apply new underbody sealer between primer and surfacer paint operations. Apply seam sealer as necessary before
application of underbody sealer. Ensure that blanking plugs and grommets in the floor pan (except those used for wax
injection) are fitted before underbody sealer application. Refit any heat-fusible plugs which have been disturbed in
repair with the aid of a hot air blower, or replace with rubber grommets.
CAUTION: Ensure that suspension units, wheels, tyres, power unit, propeller shafts, exhaust and brakes
(including all mounting points) are shielded prior to application of fresh underbody sealer.

CORROSION PREVENTION AND SEALING
77-4-18 SEALING
Structural adhesive
Adhesive on rear wheel arch outer assembly.
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads to all joints shown.
Metal-to-metal adhesive is applied to critical joint areas during factory assembly. The material used is a high-
temperature, heat cured, nitrile phenolic which serves to bond two metal surfaces and also to seal the joint against
ingress of dust, moisture and fumes. This material is not suitable for service use and, during repair, should be
substituted by an approved Structural Adhesive.

+ BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.
Those joints which require the application of structural adhesive are detailed in the following figures. Only joints
applicable to service panels are included. Apply structural adhesive where indicated or to the mating panel surface.
CAUTION: When separating a joint treated with metal-to-metal adhesive, it is important to avoid distortion.
Heat the joint gradually until the bond weakens sufficiently to permit panel separation.
NOTE: When spot welding through metal-to-metal adhesive, take particular care to adjust the transformer setting to
ensure a reliable weld.
M77 1684A

HEATING AND VENTILATION
DESCRIPTION AND OPERATION 80-7
Distribution ducts
Separate distribution ducts are installed for the front and rear footwell outlets. Distribution ducts for the face level,
windscreen and side windows outlets are integrated into the fascia. The front footwell ducts are attached to ports at
the sides of the heater assembly. The rear footwell ducts locate in ports at the rear of the heater assembly and extend
along each side of the centre console to vent into the rear footwells from below the cubby box.
Vent assemblies in the fascia allow occupants to control the flow and direction of face level air. Each vent assembly
incorporates a thumbwheel to regulate flow and moveable vanes to control direction.