Discovery (1995+): Body Repair Manual — part 41
77
PANEL REPAIRS
6
PROCEDURES
12. Apply adhesive sealant to panel joint surfaces.
See GENERAL SPECIFICATION DATA,
Information
Offer Up and Align
Offer up new panel and align with associated panels.
Clamp into position using welding clamps or Mole
grips. Where a joggle or brace joint is being adopted,
make a set in the original panel joint edge or insert a
brace behind the joint.
NOTE: In cases where access for welding
clamps is difficult, it may be necessary to
use tack welds.
Welding
13. Select arms for resistance spot welding and
shape electrode tips using a tip trimmer.
NOTE: To maintain efficiency, the tips will
require regular cleaning with emery cloth.
CAUTION: Use electrode arms not
exceeding 300mm (12 in) in length.
14. Fit resistance spot welding arms and test
equipment for satisfactory operation, using test
coupons. Where monitoring equipment is not
available, verify weld strength by checking that
metal around the weld puddle pulls apart under
tension during pulling.
PANEL REPAIRS
7
PROCEDURES
15. Use a resistance spot welder where access
permits. Try to ensure weld quality by using a
weld monitor where possible.
16. MIG tack weld butt joints and re-check alignment
and panel contours where necessary. Ensure
that a gap is maintained to minimise welding
distortion, by inserting a hacksaw blade as an
approximate guide.
17. Dress MIG tack welds using a sander with 36 grit
disc, or a belt-type sander where access is
limited.
77
PANEL REPAIRS
8
PROCEDURES
18. MIG seam weld butt joints.
19. Always use MIG plug welds where excessive
metal thickness or lack of access make
resistance spot welding impractical. Make plug
welds either by using holes left by the spot weld
cutter, or through holes punched or drilled for the
purpose.
20. Dress all welds using a sander with 36 grit disc,
or a belt-type sander and/or impregnated wire
brush.
NOTE: Brazing operations, if required,
must be carried out at this point.
Body Trim
The following panel repair operations itemise body
trim components which must be removed for access
during each repair.
Because of the unpredictable nature of accident
damage, the items listed make no allowance for any
difficulties which may be found in removal and only
apply to an undamaged vehicle. No allowance is
made for any difficulties which may be found during
panel removal. Damaged body trim items must be
renewed as necessary following body repairs.
PANEL REPAIRS
1
REPAIR
FRONT PANEL ASSEMBLY
Remove
1. Disconnect both battery leads.
2. Raise front 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 both headlights.
7. Remove both front direction indicators.
8. Remove battery at RH inner wing.
9. Remove both wings [fenders].
See CHASSIS
AND BODY, Repair.
10. Remove bonnet lock.
11. Remove bonnet safety catch bracket.
12. Remove front bumper assembly.
13. Remove front grille.
14. Remove radiator.
15. Remove power steering fluid reservoir and
bracket at LH of radiator.
16. Remove ignition coil and bracket at LH of
radiator (petrol engine vehicles).
17. Remove owner jack and jack cover at LH inner
wing.
18. Remove engine air cleaner box at LH inner wing.
19. Remove battery.
Refit
20. Prepare and clean panel joint faces. Punch or
drill holes in new front panel assembly for plug
welding at both sides as shown.
21. Reverse removal procedure.
22. Remove stands and lower vehicle.
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