Discovery (1995+): Body Repair Manual — part 45
77
PANEL REPAIRS
14
REPAIR
14. Working from inside vehicle, remove ten bolts
securing body side panel.
15. Starting from ’D’ post and working towards rear
of vehicle, ease body side panel away from body
to break seal. When seal strength has been
completely broken, push outer panel towards
rear of vehicle to disengage rear quarter panel
from ’E’ post, then lift body side and rear quarter
panel assembly clear.
16. Remove fuel filler pipe (RH body side panel
only).
Cleaning/painting
17. Thoroughly clean all traces of existing sealant
from joint faces on monocoque and panel.
18. Paint cleaned surfaces with etch primer.
Refit
19. Apply a 6 mm (1/4 in) bead of 3M 8537 Super
Seam Sealer to the areas of the monocoque as
shown.
PANEL REPAIRS
15
REPAIR
20. Apply 20 x 20 mm (13/16 x 13/16 in) squares of
3M 8572 Bolted Panel Sealer to inner faces of
six securing screw holes in rear quarter panel.
21. Locate panel on body. Ensure that sealant is
not displaced. Working from inside vehicle,
loosely fit ten bolts securing panel.
22. Loosely fit countersunk, self-tapping screws
securing rear quarter panel to ’E’ post, and body
side panel to ’D’ post.
23. Loosely fit two bolts inside wheel arch and at
lower edge of body side panel.
24. Starting with three bolts securing upper edge of
panel, evenly tighten bolts to draw panel
upwards to its correct location.
25. Tighten remaining bolts and self-tapping screws,
ensuring a satisfactory seal between the joint
faces.
26. Clean off all surplus sealant from exposed
surfaces.
27. Using thumb pressure, apply 3M 8572 Bolted
Panel Sealer to all corners of window aperture to
seal any uneven contours between panels.
28. Apply a bead of 3M 8684 Flexseal to joint at
lower section of ’D’ post. Work the bead to
produce a smooth, cosmetically acceptable
finish.
29. Paint as necessary.
See Panels,
30. Refit capping to ’D’ post and secure with nuts
and washers.
31. Reverse removal operations to refit fuel filler
pipe and breather (where applicable).
32. Reverse operations 1 to 9 to refit associated
parts.
Rear quarter panel replacement
1. Remove body side panel and rear quarter panel
assembly from vehicle.
See this section.
2. Using a suitable high-speed saw, cut off rear
quarter panel. Make the line of cut approximately
30 mm (1 3/16 in) from joint with flange.
CAUTION: Avoid the use of an air chisel as
this could damage the body side panel.
3. Remove flange from body side panel using a
spot weld cutter.
77
PANEL REPAIRS
16
REPAIR
4. Mark centre line of front flange on the
replacement rear quarter panel. Mark and drill
six 6.5 mm (1/4 in) holes at locations shown.
5. Align and clamp rear quarter panel to body side
panel. Using a marker, transfer locations of the
holes on rear quarter panel flange to body side
panel flange.
6. Remove rear quarter panel and drill six 6,5 mm
(1/4 in) holes at locations marked on body side
panel flange.
7. Remove all roughness from edges of holes as
necessary, and apply etch primer to all bare
metal areas.
8. Bolt panels together using M6 X 20 mm (13/16
in) plated bolts, plain nuts, and spring washers.
9. Refit panel assembly to vehicle.
10. Paint as necessary.
See Panels,
PANEL REPAIRS
17
REPAIR
BODY SIDE CLOSING PANEL (3-DOOR)
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair.
5. Disconnect alternator.
6. Remove headlining.
See CHASSIS AND
BODY, Repair.
7. Remove treadplate.
8. Remove door aperture weatherstrip.
9. Remove rear outer seat belt.
See CHASSIS
AND BODY, Repair.
10. Remove front seat belt.
See CHASSIS AND
BODY, Repair.
11. Remove rear passenger seat.
See CHASSIS
AND BODY, Repair.
Refit
NOTE: In this operation, the body side
closing panel is replaced in combination
with a body side outer panel.
12. Prepare and clean panel joint faces. Punch or
drill holes in new closing panel for plug welding
as shown.
13. Reverse removal procedure.
14. Remove stands and lower vehicle.
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