Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Body Repairs - General Information - Introduction

The body plays a significant role in the increasing trend of ever more rapidly changing model variants. The different customer groups are strongly influenced by the design and shape of the body. At the same time the stability of the body plays the most important part in ensuring passenger and driver safety. Lightweight construction, alternative materials, composite materials, plastics and appropriate joining processes are all design features that characterize modern Land Rover vehicle bodies.

In terms of manufacturing technology, modern safety cell bodies can be produced almost without any problems. Land Rover guarantee high quality standards by ensuring that mechanical strength properties are tried and tested in numerous computer simulations, crash tests, by testing materials and by employing sophisticated manufacturing technologies. In the event of repairs it is vital that the production quality standards are upheld. This requires a well-equipped workshop, and places particular emphasis on the qualifications of the workshop technicians. Up-to-date knowledge of current manufacturing technologies and continuous training on new repair methods and techniques are vital for high-quality body repairs. The model-specific repair manuals and the general repair techniques provide valuable support when undertaking body repairs.

Always follow the repair instructions published in this manual. Failure to observe this instruction can result in serious impairment of vehicle safety. All specified safety requirements must be met after the work has been carried out.

Accident damage and diagnosis

General notes

  • Exact diagnosis of the extent of the damage enables proper repair planning
  • All body repairs must be carried out in accordance with the guidelines in this Body Repair Manual
  • The stability and strength properties of the body must be taken into account during body repairs. The body has exact defined deformation patterns that must not be affected by any repair work
  • For instance, the crumple zones absorb the bulk of the impact energy. If any unprofessional repair techniques or methods are used in these areas then this can pose a fundamental threat to vehicle safety

Hidden damage

  • As well as looking at external indicators like flaked off paint, it is vital to check for hidden body damage or deformation that is not visible from the outside. Large attached parts like bumpers and inner fenders often need to be removed to allow accurate assessment of damage to underlying body parts
  • Gap dimensions offer another alternative for diagnosis by visual inspection. If any changes or misaligned edges are apparent, then this usually indicates that the dimensions of the affected part are incorrect


Galvanic corrosion is the cross-contamination of dissimilar metals, in this case aluminum and steel. Avoidance of galvanic corrosion is an important issue to be considered in the repair of aluminum bodied vehicles.

Precautions to prevent the contamination of exposed bare aluminum surfaces should be taken. Good housekeeping and cleanliness should be adopted throughout repairs and especially prior to welding, pre-treatment and adhesive bonding. The repair environment requires control and protection from dust and debris from conventional steel body repairs. All equipment must be clearly identified and used solely on aluminum. Tools should be kept clean and in good order. Steel fastenings are coated to prevent galvanic corrosion. Fastenings should be examined during repairs and where damaged or suspect must be renewed. The use of graphite, penetrating oil, or copper based anti-seize compounds upon the steel fixings is not recommended.

For additional information, refer to: Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation).


The body

The body is manufactured like a conventional monocoque. Two monosides are welded to the floor, roof and bulkheads, creating a strong, single structure. Dual Phase (DP), Bake Hardened (BH) and BORON (VHSS) steels are used in the side panel reinforcements. DP steel is also used for the rear of the front side member, for added strength in front and side impacts. The roof structure can accommodate a glass roof panel. When a glass roof is not fitted, the outer roof panel is a single large aluminum pressing with styled swages to add strength.

The safety of the driver and the passengers is paramount for every body design. There are two key safety aspects in the body:

  • Safety passenger cell
  • Crumple zones

Safety passenger cell

  • Stable pillars, rocker panel and door profiles.
  • Side impact protection in the doors.
  • Doors are designed to open even in the event of extreme deformation.

Crumple zone

  • Dynamic absorption of deforming forces.
  • Protection of the passenger cell.





     High Strength Steels

    Most modern vehicles are constructed from a number of different steels, partly to obtain an optimized body, (collision, safety, rigidity, fuel economy, etc.). Steels are divided into several groups a

     Accident Damage and Diagnosis

    General notes Exact diagnosis of the extent of the damage enables proper repair planning. All body repairs must be carried out in accordance with the guidelines in this Body Repair Manual. The

     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,


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