Land Rover Discovery: Front end Sheet Metal Repairs Front Bumper Mounting (G1775677) / Removal and Installation

REMOVAL

NOTE:

The front bumper mounting is installed in conjunction with:

• Front bumper cover
• Front bumper
• Hood latch panel
• Radiator
• Windshield washer reservoir

1. The front bumper mounting is serviced as indicated
2. Before commencing this procedure make sure that you are aware of all Health and Safety requirements.

   For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).

3. For further information on the methods, tools and fixings used in this procedure refer to the body repairs - general information section.

NOTES:

• Any joints sealed as part of vehicle manufacture must be sealed as part of the repair.
• Make sure a zinc rich primer is applied to any bare metal surfaces.
• To make sure the vehicle is correctly aligned. It must be placed on a Land Rover approved alignment jig.

4. For additional information, refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
5. For additional information, refer to: Front Armature (501-19 Bumpers, Removal and Installation).
6. For additional information, refer to: Hood Latch Panel (501-02 Front End Body Panels, Removal and Installation).
7. For additional information, refer to: Radiator (303-03A Engine Cooling - TD4 2.2L Diesel, Removal and Installation).

NOTE:

Right hand only.

8. For additional information, refer to: Windshield Washer Reservoir (501-16 Wipers and Washers, Removal and Installation).

NOTE:

Left hand only.

9. For additional information, refer to: Air Cleaner Intake Pipe (303- 12C Intake Air Distribution and Filtering - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV, Removal and Installation).

NOTE:

Right hand only.

10. Release and position the noise, vibration, harshness (NVH) material to one side.
11. Release and position the wiring harness to one side.

12. Remove the spot welds as indicated.
13. Carefully separate the joints and remove the front bumper mounting.

INSTALLATION

1. Dress the flanges where necessary.

2. Drill holes in the new front bumper mounting where the metal inert gas (MIG) plug welds are to be installed as indicated.
3. Deburr the drilled holes.
4. Clean and prepare the old and new panel surfaces.
5. Offer up the new front bumper mounting and clamp into position.

   Check alignment if correct, proceed to next step, if not, rectify and recheck before proceeding.

6. Install the MIG plug welds as indicated.
7. Dress all welds.
8. Make sure that any open or exposed panel joints are correctly sealed.
9. Make sure corrosion protection is applied to all areas affected by repair.
10. The installation of associated panels and components is the reversal of removal procedure.

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