Glass roof panel (Discovery 3)

Removal

CAUTION: When removing exterior parts, always protect the paintwork and glass from damage.

CAUTION: When removing glass, always protect interior trim parts from damage.

CAUTION: Place the glass on a felt-lined stand. Do not place the glass on its edge as this may cause damage to the edge, which may subsequently develop into cracks.

NOTE: The following equipment is required: l Cutting wire with handles l Straight knife l Glazier's knife l Glass replacement kit l Caulk gun l Suction cups l Felt-lined glass table or stand.

1. Remove the headliner. For more information, refer to Headliner (76.64.15)

2. Remove the roof molding.

• Release the 3 clamps.
• Repeat the above procedure on the other side.

3. Remove the antenna.

• Disconnect the cable.
• Remove 2 screws.

4.

CAUTION: Always wear safety glasses.

With assistance, remove the sunroof glass panel.

• Using a glazier's knife or cutting wire, carefully cut away the sealant.
• Install the suction cups.
• Remove the 11 spacer bushings, remembering the position in which they were installed.

Installation

1. Carefully remove the sealant from the body to create a smooth surface.

2. Install the sunroof glass panel.

• Install spacers at equal distances as shown.
• To simplify subsequent installation, apply marks using masking tape.

3. Remove the sunroof glass panel with assistance. Clean the contact surfaces of the parts.

4. Apply etching primer to clean metal surface.

5. Apply primer over the etching primer.

6. Apply glass primer to the sunroof glass panel seal surface and allow to cure.



7. Apply activator to the old sunroof glass panel seal and allow to cure.

8. Install the nozzle with the orifice on the cartridge with sealant, remove the cap, shake out the solids and install the cartridge on the gun for applying the sealant. Adjust the nozzle so as to obtain a strip of sealant with a right-angled triangle in cross-section having a base of 8 mm and a height of 12 mm.

9. Apply a continuous bead of sealant to the sunroof glass panel as shown.



10. With assistance, install and align the sunroof glass panel. Lightly press the window glass onto the sealant.

11. Check the tightness of the joint, apply additional sealant if necessary. If water is used for testing, do not test until the sealant has hardened. Direct a stream of water at the glass and check for leaks. Mark the location of the leak. Dry the glass and sealant, then apply additional sealant.

12. Install the antenna.

• Tighten the screws.
• Connect the cable.

13. Install the roof moldings. Engage the clamps.

14. Install the headliner. For more information, refer to Headliner (76.64.15)

The original article is located on the website (www.LRman.ru)