Discovery (1995+): Body Repair Manual — part 27
76
CHASSIS AND BODY
46
REPAIR
DASH PANEL CENTRAL LOUVRE PANEL
Service repair no - 76.46.42
Remove
1. Disconnect battery negative lead.
2. Remove radio.
See ELECTRICAL, Repair.
3. Release tags securing radio cage to louvre
panel and remove cage.
4. Remove clock.
See ELECTRICAL, Repair.
5. Release 4 coin tray securing tags.
6. Remove coin tray.
7. Remove 3 heater control and blower switch
knob.
8. Remove 2 screws securing heater graphic
display panel and remove panel.
9. Remove 4 screws securing heater control unit to
panel.
10. Working through coin tray aperture, remove
screw securing panel.
11. Working through clock aperture, remove screw
securing panel.
12. Loosen 2 uppermost panel retaining screws.
NOTE: On some models the panel is fitted
with an LED. In this case, manoeuvre LED
from panel and disconnect.
13. Remove panel retaining screw cover.
CHASSIS AND BODY
47
REPAIR
14. Remove 2 screws securing louvre panel.
15. Remove louvre panel from dash panel.
Refit
16. Position louvre panel, feed harness connectors
through their correct apertures,and align to dash
panel.
CAUTION: When refitting avoid trapping of
electrical wiring.
17. Fit and tighten screws securing louvre panel.
18. Fit panel retaining screw cover.
19. Position heater control unit to panel and secure
with screws.
20. Fit heater graphic display panel and secure with
screws.
21. Fit heater control and blower switch knobs.
22. Fit clock.
See ELECTRICAL, Repair.
23. Position coin tray and secure to tags.
24. Position radio cage, feed electrical connectors
and aerial through cage, and position to panel.
25. Bend back radio cage retaining tags.
26. Fit radio.
See ELECTRICAL, Repair.
27. Connect battery negative lead.
DASH PANEL ASSEMBLY
Service repair no - 76.46.23
Remove
1. Move front seats to rearmost position.
2. Disconnect battery negative lead.
3. Disconnect air bag multiplugs under dash panel.
CAUTION: When air bags are fitted,
reference must be made to the Airbag
Supplementary Restraint System section.
4. Remove passenger glove box.
5. Remove driver’s side access panel.
6. Remove centre console assembly.
See this
section.
7. Remove airbag from steering wheel.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair.
8. Remove passenger’s airbag from dash panel.
See SUPPLEMENTARY RESTRAINT SYSTEM,
Repair.
9. Release clamp and lower steering column.
10. Remove steering wheel.
See STEERING,
Repair.
11. Remove column switch.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair.
12. Remove instrument binnacle.
See
ELECTRICAL, Repair.
13. Remove radio.
See ELECTRICAL, Repair.
14. Remove exterior mirrors switch panel.
15. Remove coin tray.
16. Remove switch panel.
17. Remove clock.
18. Undo screw securing mounting bracket and
position passenger’s side relay assembly aside.
19. Set heater controls fully clockwise.
76
CHASSIS AND BODY
48
REPAIR
20. Note position of levers, disconnect heater control
cables from levers and outer cable from retaining
clips.
21. Remove 4 bolts securing dash panel to centre
lower mounting brackets.
22. Remove 4 bolts securing dash panel to side
lower mounting brackets.
23. Undo 4 screws and remove 2 driver’s knee
bolster pads from below steering column.
24. Remove 4 nuts securing instrument mounting
bracket to dash panel.
25. With assistance: Manoeuvre dash panel
partially rearward.
26. Driver’s side: Disconnect 6 multiplugs
connecting dash harness to main harness.
27. Disconnect 3 multiplugs connecting dash
harness to fusebox.
28. With assistance: Lift dash panel rearward to
clear fixings and remove from vehicle.
CHASSIS AND BODY
49
REPAIR
Refit
CAUTION: When refitting avoid trapping
electrical wiring.
29. Reverse removal procedure.
30. With assistance: Position dash panel and
connect dash harness multiplugs to fusebox and
main harness.
31. Reverse removal procedure. Ensure dash panel
upper bracket studs are located before the 4
lower brackets.
32. Reverse removal procedure. Disconnect
glovebox switch Lucars to ease fitting of relay
bracket.
WINDSCREEN GLASS
Service repair no - 76.81.01
Information
The following equipment is required:
•
Cutting wire and handles
•
Windscreen repair kit (see Technical
Bulletin).
See Electrical Trouble Shooting
Manual.Windscreen Glass Replacement.
•
Sealant applicator gun.
•
Suction cup lifters.
The following materials are included in the windscreen
repair kit:
•
Glass cleaning solvent - ’Betawipe’ Glass
activator (yellow cap).
•
Cotton buds.
•
Glass primer - ’Betaprime’(green cap).
•
Body primer - ’Betaprime’ paint/plastic
primer (red cap).
•
Betaseal Adhesive sealant.
NOTE: The adhesive sealant cures in 6 to 8
hours
CAUTION: Once existing sealant is cut, the
exposed surfaces oxidises in
approximately 90 minutes. The refit
procedure must be completed within this time
span to prevent the sealant oxidising, to effect a
satisfactory joint.
CAUTION: If the windscreen aperture body
flange shows signs of corrosion it must be
treated with anti corrosion primer and
repainted. Newly painted areas must then be left
for 8 hours or more before applying adhesive
sealant.
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