Discovery I (LJ) V8-4.0L (1996)
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10. Prepare cutting wire in handle 'A'. Bend end of wire to handle and tape over end.
11. Force cutting wire through sealer from inside and 100 mm from a top corner. Use a needle if necessary to make a pilot hole.
12. Attach handle 'B'. Allow 200 mm of wire between handles, tape over end of wire.
13. With an assistant on the inside: Wedge the tube of the handle 'A' between glass and body flange 100 mm ahead of hole in sealer.
14. From the outside: Carefully cut sealer from flange using a straight pull away from the glass. Continue in 100 mm steps around the glass, use a
sawing action at the corners.
CAUTION: Along the bottom edge, great care must be taken to cut up to the 2 supports, positions indicated on the obscuration band (See
item 18 in the image below).
15. Remove handle 'B', withdraw the cutting wire and insert it through the sealer between the supports. Refit handle 'B'.
16. Cut through sealer between the supports. It heated front screen: Cut through the 2 wires each side of the supports. Tape cut wires and panels to
prevent damage to bodywork when screen is removed.
17. Attach suction cups to glass and lift glass from body flange, cut sealer free around supports as necessary.
WARNING: If glass has splintered: Protect eyes and operate demister blower at maximum speed to remove any glass from ducts. Use a
vacuum cleaner to remove glass particles from inside the vehicle.
Refit
18. Check condition of supports, renew if necessary. Locating studs must be at right angle to flange.
NOTE: The supports were fitted to early vehicles and now replaced with nylon sheaths.
19. Carefully cut back old sealant around body flange to obtain a smooth surface 2 mm thick. DO NOT cut down to flange.
20. If refitting original glass: It must be free from chips or cracks. Cut back old sealant around glass to obtain a smooth surface 2 mm thick. DO
NOT cut down to glass surface.
CAUTION: Lay glass on felt covered supports, do not stand on edge. Any chipping of glass edge may develop into cracks.
