Discovery (1995+): Body Repair Manual — part 46
77
PANEL REPAIRS
18
REPAIR
WHEELARCH PANEL (5-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 rear side door treadplate.
7. Remove rear outer seat belt.
See CHASSIS
AND BODY, Repair.
8. Remove rear passenger seat.
See CHASSIS
AND BODY, Repair.
Refit
NOTE: In this operation, the rear body side
outer panel must be removed to enable
access to the wheelarch panel.
9. Prepare and clean panel joint faces. Drill or
punch holes in new panel at lower end for plug
welding as shown, and plug weld to existing
panel at upper end using holes left by spot weld
cutter.
10. Reverse removal procedure.
11. Remove stands and lower vehicle.
PANEL REPAIRS
19
REPAIR
’D’ POST (5-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 rear side door treadplate.
8. Remove rear outer seat belt.
See CHASSIS
AND BODY, Repair.
9. Remove rear passenger seat.
See CHASSIS
AND BODY, Repair.
Refit
NOTE: In this operation, rear body side
outer panel must be removed to enable
access to the ’D’ post.
10. Prepare and clean panel joint faces. Drill or
punch holes in new panel at lower end for plug
welding as shown, and plug weld to existing
panel at centre section using holes left by spot
weld cutter.
11. Reverse removal procedure.
12. Remove stands and lower vehicle.
77
PANEL REPAIRS
20
REPAIR
REAR CORNER PANELS
Remove
1. Disconnect battery earth lead.
2. Raise rear 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 rear bumper assembly.
8. Remove rear side door (RH only).
See
CHASSIS AND BODY, Repair.
9. Remove rear door check stay (RH only).
See
CHASSIS AND BODY, Repair.
10. Rear door striker and catch plate (LH only).
11. Rear grab handle (LH only).
See CHASSIS
AND BODY, Repair.
12. ’E’ post trim casing.
See CHASSIS AND BODY,
Repair.
13. Remove rear door aperture weatherstrip.
14. Remove rear door treadplate.
15. Remove rear door upper trim panel.
See
CHASSIS AND BODY, Repair.
Refit
NOTE: In this operation, the rear corner
panels are replaced in combination with a
rear body side outer panel and rear quarter
panel.
16. Prepare and clean panel joint faces. Punch or
drill holes in new rear corner panels for plug
welding, and cut closing panel to form seam
welded joint with existing panel as shown.
17. Reverse removal procedure.
18. Remove stands and lower vehicle.
PANEL REPAIRS
21
REPAIR
REAR PANEL ASSEMBLY
Remove
1. Disconnect battery earth lead.
2. Raise rear 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 rear bumper assembly.
7. Remove rear door.
See CHASSIS AND BODY,
Repair.
8. Remove rear door check stay.
See CHASSIS
AND BODY, Repair.
9. Remove rear door aperture weatherstrip.
10. Remove rear door treadplate.
Refit
NOTE: In this operation, both outer rear
corner panels must be removed to enable
access to the outer rear panel joints.
11. Prepare and clean panel joint faces. Punch or
drill holes in new assembly front flange for plug
welding as shown.
12. Reverse removal procedure.
13. Remove stands and lower vehicle.
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