Discovery 2. Manual - part 701

 

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Discovery 2. Manual - part 701

 

 

PAINTING

PROCEDURES

77-5-1

PAINTING 

PROCEDURES

Panel preparation

General
Replacement panels are supplied with a cathodic primer coating as part of the panel protection and in compliance 
with the vehicle's Corrosion Warranty, where applicable. DO NOT remove the primer before paint refinishing. In 
the event of localised surface damage or imperfections, ensure that only the minimum of primer is removed 
during rectification work for effective repair.

Rectify damage as far as possible by panel beating or straightening. To remove corrosion or paint runs on outer 
surfaces, abrade the primer coat in the affected area as necessary, then follow the procedure below:

Clean the panel using a solvent wipe
Treat exposed areas of metal with an etch phosphate process
Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer, or an integrated etch 

primer/filler

Panel preparation
The following procedures should be followed when repairing panels.

Welded panels
When replacing welded panels the following procedure must be observed:

Remove primer from the immediate vicinity of new and existing panel flanges, cleaning to bright metal finish
On joints to be spot welded, apply weld-through zinc rich primer to joint faces of both flanges. Make spot welds 

while primer is still wet or according to the manufacturer's instructions

Dress accessible weld joints
Clean panel using solvent wipe
Treat bare metal with an etch phosphate process
Re-treat repaired areas 

Sectioned panels
When replacing part or sectioned panels, the basic procedure is the same as for welded panels described above, with 
the following variations:

Remove primer from both new and existing joint faces, cleaning to a bright metal finish
Where an overlap joint with the existing panel is to be spot welded, apply weld-through, zinc rich primer to both 

joint faces and spot weld while the primer is still wet, or according to the manufacturer's instructions

MIG weld butt joints where applicable
Dress weld joints
Clean the panel with a solvent wipe.
Treat bare metal areas using an etch phosphate process
Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer, or an integrated etch 

primer/filler

Treat the inner faces of lap or butt joints with a suitable cavity wax 

 

 + 

 PANEL REPAIRS, PROCEDURES, Panel replacement procedure.

Clinched panels
When replacing clinched panels the following procedure must be observed:

Abrade primer on new and existing panel joint faces, and clean using a solvent wipe
Apply metal-to-metal adhesive where applicable
Where joints are to be spot welded, apply suitable weld-through, zinc rich primer to weld areas
Where joints are to be MIG, arc or gas welded, apply zinc rich primer in adjacent areas but leave the welded 

area untreated

To retain the panel while clinching the flanges, tack spot weld or plug weld as appropriate
Clean the panel with a solvent wipe
Treat bare metal areas with a suitable etch phosphate process
Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer, or an integrated etch 

primer/filler

PAINTING

77-5-2

PROCEDURES

Paint preparation

Paint refinishing
The following process must be adhered to for paint refinishing operations.

Seal required exterior and interior seams with an approved seam sealer 

 

 + 

 BODY SEALING MATERIALS, MATERIALS AND APPLICATIONS, Approved materials.

Repair any damage to underbody sealers 

 

 + 

 CORROSION PREVENTION AND SEALING, CORROSION PREVENTION, Corrosion prevention. 

Apply a two-pack paint refinishing system
Apply cavity wax to all interior surfaces which have not received refinish paint 

Paint repairs
Before carrying out paintwork repairs, clean the vehicle thoroughly using either a steam cleaner or high-pressure 
washer. 

Wash locally repaired areas using a mild water-mixable detergent and wipe them clean with solvent, immediately 
before paint application.

Ensure that damaged paintwork which has led to exposed metal is abraded until the metal is clean, extending beyond 
the area of the original damage. Treat the bare metal with an etch phosphate to remove all traces of rust and to provide 
a key for new paint coats. Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer 
or an integrated etch primer/filler, and follow with a two-pack paint system. Treat those surfaces not receiving paint 
using an approved cavity wax, following paint operations. 

Two-pack top coat

Two-pack primer filler and etch primer

Etch phosphate

When heat curing paint repairs, the temperature must not exceed 65

°

C (149

°

F). Temperatures above this 

figure will cause the reflective elements within the headlamps and taillamps to distort.

HEATING AND VENTILATION

DESCRIPTION AND OPERATION

80-1

HEATING AND VENTILATION

DESCRIPTION AND OPERATION

Heating and ventilation component 
layout

RH drive shown, LH drive similar

Control panel
Outlet vent
Rear footwell ducts
Front footwell duct
Air inlet duct
Heater assembly

HEATING AND VENTILATION

80-2

DESCRIPTION AND OPERATION

Fuel burning heater component layout

RH drive shown, LH drive similar

FBH fuel line connection
FBH unit
Air temperature sensor
FBH pump

 

 

 

 

 

 

 

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