alternator LAND ROVER DISCOVERY 2002 Repair Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2002, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 2002Pages: 1672, PDF Size: 46.1 MB
Page 1293 of 1672
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
Page 1294 of 1672
PANEL REPAIRS
REPAIRS 77-2-45
'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
Page 1295 of 1672
PANEL REPAIRS
77-2-46 REPAIRS
'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.
Page 1296 of 1672
PANEL REPAIRS
REPAIRS 77-2-47
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.
Page 1297 of 1672
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.
Page 1298 of 1672
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.
Page 1299 of 1672
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
Page 1300 of 1672
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.
Page 1301 of 1672
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.
Page 1302 of 1672
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