Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Body Measurements

Measuring options

  • Comparison measurements can also be made on the outside of the body.

    Depending on the damage, comparison measurements and diagonal measurements can be carried out using compass, telescopic rod, tape measure or ruler.


The same reference points must be chosen on both sides when checking for changed dimensions (e.g. bores, edges, beads/swage lines etc.).

All of the important external body dimensions are listed in Tolerance Checks.

For additional information, refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).

  • Measurements with a measuring/straightening jig.
  • A measuring/straightening jig is required for accurate measurements of the body. The measuring systems are categorized by their means of operation:
  • Mechanical measuring system.
  • Optical measuring system

Quick and accurate measuring results can be obtained using computerized measuring systems.

A minimum of three intact measuring points on the body are required for measurements of length, width and height dimensions.

In some cases this may mean making the measuring points accessible. All of these measuring systems can be used to make body measurements, provided all the equipment is available.


The following decisions have to be made before the repairs are started:

  • Does the vehicle need to be put on a straightening jig, or can it be straightened by other means?
  • Does the body need to be measured?
  • Do aggregates like engine or axles need to be removed?


It is preferable to repair body parts rather than to renew them, as this keeps the complete body-shell intact.

Which body parts need to be renewed?

  • Which body parts can be repaired?


To ensure the correct maintenance actions are carried out before and during a repair.

For additional information, refer to: Battery Care Requirements (414-00 Battery and Charging System - General Information, Description and Operation).


The availability of service parts often determines how easily the body repairs can be carried out. The following procedure is recommended:

  • Obtain all the data for the vehicle, including type, vehicle identification number, trim code, engine identification letters, initial registration etc.
  • Establish all of the metal parts that need to be renewed.
  • Establish all of the attached parts that need to be renewed, including small parts like rivets, clips etc.



The use of heat when pulling to straighten body panels, (such as side members), is not recommended. Longitudinal pulling, (hot or cold), is also not recommended. A small amount of side to side pull is permissible, (cold).

When any type of pulling or straightening operation is performed it is important to observe for any movement in adjacent panels.

A panel must retain its strength and integrity, if there is any doubt the panel must be renewed.

Straightening repairs are often required to restore the body to its original shape after an accident. This can be done with:

  • Alignment jigs.
  • Universal straightening and measuring jigs.
  • Welding jig system.

The following points must be followed to ensure that the repairs are carried out professionally and that all the dimensions are correct after the repairs have been carried out.


  • The repair sequence depends on the individual repair plan (taking any necessary disassembly work into account).
  • Clean the attachment areas.
  • Anchor the vehicle free of stress on the relevant system.
  • Support the aggregates to take strain off the body.
  • Decide on at least three measuring/mounting points that are undamaged and as far apart as possible (for basic adjustment).
  • Check the dimensions of the measuring/mounting points


Check dimensions and gaps continuously during straightening.


Check dimensions and gaps continuously during straightening.

A body is always straightened in the opposite direction to that of the impact. Always carry out straightening repairs with the complete body shell assembled (do not cut out any parts beforehand). Carry out the straightening work in several stages. This prevents the risk of over stretching or of welded joints tearing out. During the individual straightening steps, relieve tension by striking with an aluminum hammer while the part is subjected to a tensile load (in the area of predetermined folding points, dents, welded joins etc.).

Special features:

  • Ultra high strength steel cannot be straightened due to its brittleness and must always be replaced.


There are two groups of fixings used, other than conventional nuts and bolts. It is important that the correct procedures are followed for the removal and replacement of these fixings and, where applicable, the correct tools are used.

  • Self-Piercing Rivet (SPR)
  • Breakstem Fastener (BSF)


     Self-piercing Rivet (SPR)

    Self-Piercing Rivets are available in various sizes dependent on the size of the stack of panels to which they are fitted. A stack refers to the combined gauge of the panels being riveted. NOTE: It i

     Torx Screw and Rivnut

    A Torx Screw and Rivnut are used where the fitment of a Breakstem Fastener Type A would give a poor cosmetic appearance. There are also occasions where the Torx Screw and Rivnut replaces a Breakstem

     Panel Beating

    Fundamentals of panel beating Before carrying out any sectional replacements or complete replacements of body panels, always check carefully whether the damaged panel(s) can be rectified by panel


     Warning Devices - Image Processing Control Module (G1881161) / Removal and Installation

    REMOVAL CAUTIONS: Protect the surrounding components. Use a suitable trim tool. Take extra care when removing the component, prevent damage to the mating faces. NOTES: Some variation in the illustrations may occur, but the essential information is always correct. Some components shown remo

     Roof Sheet Metal Repairs Roof Panel (G1770876) - Removal

    NOTE: The roof panel is installed in conjunction with: Windshield Headliner Front seat Rear seat cushion Side air curtain module Roof moulding Liftgate Antenna The roof panel is serviced as indicated. Before commencing this procedure make sure that you are aware of all Health and Saf

    © 2019-2024 Copyright