Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Front end Sheet Metal Repairs Front Side Member and Suspension Top Mount Assembly (G1770869) - Installation

Installation

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

  1. Dress the flanges where necessary.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Using the old fender apron panel reinforcement as a guide measure and cut the new fender apron panel reinforcement that is attached to the new front side member and suspension top mount assembly as indicated.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Remove the spot welds and detach the rear section of the fender apron panel reinforcement from the new front side member and suspension top mount as indicated.

NOTE:

This step will require the aid of another person as the panel will be heavy.

  1. Offer up the new front side member and suspension top mount assembly and the new front side member and clamp into position.

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

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

This step will require the aid of another person as the panel will be heavy.

  1. Remove the new front side member and suspension top mount assembly and the new front side member.
  2. Deburr the drilled holes.
  3. Clean and prepare the panel surfaces.

NOTE:

This step will require the aid of another person as the panel will be heavy.

  1. Offer up the new front side member and suspension top mount assembly and the new front side member and clamp into position.

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

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Install the spot and MIG plug welds as indicated.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Tack MIG weld the fender apron panel reinforcement butt joint as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Install the MIG plug welds as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Install the MIG plug welds as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Install the MIG plug welds as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Install the MIG plug welds as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Install the MIG plug welds as indicated.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Install the A-pillar tube as indicated.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. MIG weld the fender apron panel reinforcement butt joint as indicated.

NOTES:

  • Right hand only.
  • The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

  • Right hand only.
  • The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

  • Right hand only.
  • The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

  • Right hand only.
  • The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

  • Right hand only.
  • The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

  • Left hand only.
  • The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

  • Left hand only.
  • The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

  • Left hand only.
  • The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

  • Left hand only.
  • The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

  • Left hand only.
  • The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Installation

  1. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.
  2. Dress the butt welds.
  3. Make sure that any open or exposed panel joints are sealed with a Land Rover recommended sealer.
  4. Make sure corrosion protection is applied to all areas affected by repair.
  5. The installation of associated panels and components is the reversal of removal procedure.

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