Discovery 2. Manual - part 274

PANEL REPAIRS

TIMES 77-2-57

Combination panel replacement times - Side panels

Panel Description

Total time

Petrol

Diesel

Front wing

Front door

11.2

11.2

Rear door 

Panel bodyside assembly 

19.2 RH

19.1 RH

17.1 LH

17.1 LH

Front door

Rear door

'B/C' Post

19.9 RH

19.8 LH

19.8

Front door

Rear door

'B/C' Post

Front wing

Panel bodyside assembly

33.9 RH

33.9 RH

31.8 LH

31.7 LH

Front door

Front wing

Front wing support bracket

'A' post

23.1 RH

23.0 RH

22.9 LH

22.8 RH

PANEL REPAIRS

77-2-58 TIMES

Combination panel replacement times - Rear end panels

Panel Description

Total time

Petrol

Diesel

Rear bumper 

Panel bodyside assembly 

'E' post assembly 

Crossmember outer rear panel (RH/LH section)

Crossmember closing rear panel

31.9 RH

31.9 RH

30.1 LH

30.1 LH

Rear bumper

Panel bodyside assembly 

Bodyside inner rear assembly

'E' post assembly

'E' post closing assembly

Crossmember outer rear panel (RH/LH section)

Crossmember closing rear panel

Crossmember rear assembly (RH/LH section)

Rear floor (RH/LH section)

Crossmember closing rear brackets

42.9 RH

42.6 RH

41.1 LH

40.7 LH

Rear bumper

Panel bodyside assembly RH & LH

Bodyside inner rear assembly RH & LH

'E' post assembly RH & LH

'E' post closing assembly RH & LH

Crossmember outer rear panel 

Crossmember closing rear panel

Crossmember rear assembly 

Rear floor (rear section)

Crossmember closing rear brackets RH & LH

65.9

65.6

BODY SEALING MATERIALS

MATERIALS AND APPLICATIONS

77-3-1

BODY SEALING MATERIALS

MATERIALS AND APPLICATIONS

Materials applications

1 Between panels - bolted
2 Panel edges - bolted
3 Between panels - spot welded
4 Panel edges - spot welded
5 Between panels - bonded
6 Panel edges - bonded

7 Clinch joints - type (a)
8 Clinch joints - type (b)
9 Clinch joints - type (c)

10 Gaps between panels - type (a)
11 Gaps between panels - type (b)
12 Lap joint

BODY SEALING MATERIALS

77-3-2

MATERIALS AND APPLICATIONS

Approved materials

The following is a table of materials approved by Land Rover for use during body repairs.

Description - Usage

Supplier

Part Number

Cavity waxes

Inner Cavity Wax (Amber)

3M

08901/11/21

Inner Cavity Wax (Transparent)

3M

08909/19/29

Cavity Wax

Croda

PW57

Engine bay waxes/lacquers

Astrolan Engine Bay Wax and Cosmetic Wax 

Astors

DA3243/1 

Engine Bay  Cosmetic Wax/Lacquer

Croda

PW197

Engine Bay  Cosmetic Wax/Lacquer

Dinol

4010

Miscellaneous materials

Aerosol Auto Adhesive (Trim) - impact adhesive for trim parts

3M

08080

Flexible Parts Repair Material - rubber modified polypropylene parts 

3M

05900

Waterproof Cloth Tape - sealing panel apertures

3M

Y387/Y3998

Sound Dampening Foam

Gurit-Essex

Betacore 7999

Water Shedder Repair (Aerosol)

Teroson

Seam sealers

Body Caulking - type (b) gaps between panels

3M

08568

Bolted Panel Sealer - between bolted panels

3M

08572

Drip Chek Clear - bolted, spot welded and bonded panel edges; type (a) and (b) 
gaps between panels; type (c) clinch joints 

3M

08401

Drip Chek Heavy - type (b) gaps between panels; type (c) clinch joints 

3M

08531

Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges; type 
(a) and (b) gaps between panels; type (b) clinch joints

3M

08684/89/94

Polyurethane Sealer (Sachet) - bolted panel edges; type (b) clinch joints

3M

08703/83/88

Sprayable Sealer - lap joints 

3M

08800/23

Super Seam Sealer - lap joints; type (b) clinch joints 

3M

08537

Weld Thru' Sealer - between spot welded panels

3M

08626

Betafill Clinch and Brushable Sealer - type (b) clinch joints

Gurit-Essex

10211/15/20

Clinch, Joint and Underbody Coating  - lap joints

Gurit-Essex

10101/10707

Leak Chek Clear - between bolted panels; spot welded and bonded panel edges; 
type (c) clinch joints; type (a) gaps between panels 

Kent Industries

10075

Putty - type (b) gaps between panels 

Kent Industries

Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges; 
between bonded panels; type (a) and (b) gaps between panels 

PPG

6500

Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges; 
between bonded panels; type (b) gaps between panels 

Teroson

92

Terolan Light Seam Sealer - bolted, spot welded and bonded panel edges; type  
(a) and (b) gaps between panels; between bonded panels; type (c) clinch joints

Teroson

Terolan Special Brushable Seam Sealer - lap joints

Teroson