Discovery (1995+): Body Repair Manual — part 44
77
PANEL REPAIRS
10
REPAIR
Cleaning/painting
18. Thoroughly clean all traces of existing sealant
from joint faces of body monocoque and panel.
19. Paint all cleaned surfaces with etch primer.
20. Apply a 6 mm (1/4 in) bead of 3M 8537 Super
Seam Sealer to the monocoque as shown.
21. 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,
and strips of sealer to inner faces of panel as
shown.
CAUTION: Allow sufficient clearance at
lower edge of panel to prevent the
blockage of drain holes.
Refit
22. Locate panel on body. Ensure that sealant is
not displaced. Working from inside vehicle,
loosely fit twenty-one bolts securing panel.
23. Loosely fit six countersunk, self-tapping screws
securing rear quarter panel to ’E’ post, also three
screws securing lower section of body side
panel.
24. Starting with five bolts securing upper edge of
panel, tighten bolts evenly to draw panel
upwards to its correct location.
25. Tighten remaining bolts and six screws at ’E’
post, ensuring a satisfactory seal between the
joint faces.
26. Clean off all surplus sealant from exposed
surfaces.
PANEL REPAIRS
11
REPAIR
27. Using thumb pressure, apply 3M 8572 Bolted
Panel Sealer to all corners of window apertures
to seal any uneven contours between panels.
28. Apply a bead of 3M 8684 Flexseal to joint at
lower section of ’BC’ post. Work the bead to
produce a smooth, cosmetically acceptable
finish.
29. Paint as necessary.
See Panels,
30. Refit capping to ’BC’ post.
31. Refit fuel filler pipe and breather (where
applicable).
32. Reverse operations 1 to 11 to refit windows and
associated parts.
77
PANEL REPAIRS
12
REPAIR
BODY SIDE PANEL (5-DOOR)
Remove
NOTE: In this operation, the body side
panel is replaced in combination with a
rear quarter panel. The procedure for
replacing a RH or LH body side panel is the same,
except that the fuel filler pipe must be
disconnected when fitting a RH panel.
1. Disconnect battery negative lead.
2. Remove rear bumper assembly.
3. Working inside vehicle, remove fold down rear
seat.
See CHASSIS AND BODY, Repair.
4. Remove rear side and ’D’ post trim panels.
Remove alpine light trim casing.
See CHASSIS
AND BODY, Repair.
5. If renewing body side panel remove rear side
fixed window and mounting rubber.
See
CHASSIS AND BODY, Repair.
6. Remove rear light unit and release rubber boot
from outer panel.
7. Drill out two pop rivets securing rear speaker
mounting bracket to body side panel.
CAUTION: Prior to disconnecting the fuel
filler and breather hoses, check level of
fuel in tank. Drain as necessary to prevent
spillage.
8. Working beneath vehicle, loosen worm drive
clips securing filler and breather hoses, and
disconnect hoses from tank (RH body side panel
only).
9. Disconnect fuel filler negative lead (RH body
side panel only).
PANEL REPAIRS
13
REPAIR
10. Working through the three apertures in ’D’ post,
remove nuts and washers, and detach ’D’ post
capping.
11. Remove three countersunk self-tapping screws
securing body side panel to ’D’ post.
12. Remove six countersunk self-tapping screws
securing rear quarter panel to ’E’ post.
13. Remove two bolts; one inside wheel arch and
one at lower edge of body side panel.
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