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

Removal

NOTE:

The front side member and suspension top mount assembly is installed in conjunction with:

• Front bumper cover
• Front bumper
• Front bumper mounting
• Hood
• Hood latch panel
• Radiator
• Condenser
• Front fender
• Fender splash shield
• Fender apron panel
• Fender apron panel reinforcement
• Engine
• Transmission
• Shock absorber and spring assembly
• Front subframe
• Secondary bulkhead

1. The front side member and suspension top mount assembly is serviced as indicated and installed in conjunction with the full front side member panel.
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 that 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 (501-02 Front End Body Panels, Removal and Installation).
7. For additional information, refer to: Hood Latch Panel (501-02 Front End Body Panels, Removal and Installation).
8. For additional information, refer to: Radiator (303-03A Engine Cooling - TD4 2.2L Diesel, Removal and Installation) / Radiator (303-03B Engine Cooling - INGENIUM I4 2.0L Diesel, Removal and Installation).
9. For additional information, refer to: Condenser - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV (412-01 Climate Control, Removal and Installation) / Condenser - TD4 2.2L Diesel (412-01 Climate Control, Removal and Installation).
10. For additional information, refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
11. For additional information, refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
12. For additional information, refer to: Fender Apron Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
13. For additional information, refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
14. For additional information, refer to: Engine - Vehicles With: M66 6- Speed Manual Transmission AWD/M66 6-Speed Manual Transmission FWD (303-01A Engine - TD4 2.2L Diesel, Removal) / Engine - Vehicles With: M66 6-Speed Manual Transmission AWD/M66 6-Speed Manual Transmission FWD (303-01A Engine - TD4 2.2L Diesel, Installation) / Engine - Vehicles With: 9HP48 9- Speed Automatic Transmission - AWD (303-01A Engine - TD4 2.2L Diesel, Removal) / Engine - Vehicles With: 9HP48 9-Speed Automatic Transmission - AWD (303-01A Engine - TD4 2.2L Diesel, Installation) / Engine (303-01C Engine - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV, Removal) / Engine (303-01C Engine - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV, Installation).
15. For additional information, refer to: Transmission - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV (307-01 Automatic Transmission/Transaxle, Removal) / Transmission - TD4 2.2L Diesel (307-01 Automatic Transmission/Transaxle, Removal) / Transmission - GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV (307-01 Automatic Transmission/Transaxle, Installation) / Transmission - TD4 2.2L Diesel (307-01 Automatic Transmission/Transaxle, Installation).
16. For additional information, refer to: Shock Absorber and Spring Assembly (204-01 Front Suspension, Removal and Installation).
17. For additional information, refer to: Front Subframe (502-00, Removal and Installation).
18. For additional information, refer to: Secondary Bulkhead Centre Panel - TD4 2.2L Diesel (501-02 Front End Body Panels, Removal and Installation).

NOTE:

Left hand only.

19. Release the battery junction box and position to one side.

NOTE:

Right hand only.

20. Remove the front side member noise, vibration and harshness (NVH) material.
21. Release the brake pipes and position to one side.
22. Release the wiring harnesses at the a-pillar, bulkhead and the side member and position to one side.

NOTE:

Where access is limited use a belt sander to sand down the spot welds in these areas.

23. Remove the spot welds as indicated.

NOTE:

Where access is limited use a belt sander to sand down the spot welds in these areas.

24. Remove the spot welds as indicated.

NOTE:

Where access is limited use a belt sander to sand down the spot welds in these areas.

25. Remove the spot welds as indicated.

26. Measure and cut the fender apron panel reinforcement as indicated.

NOTE:

Make sure that the spot welds are drilled from the inside to enable the joint to be metal inert gas (MIG) plug welded on installation.

27. Remove the spot welds as indicated.

28. Remove the tube from the A-pillar as indicated.

NOTE:

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

29. Carefully separate the joints and remove the front side member and suspension top mount assembly and the front side member.

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

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