Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Front end Sheet Metal Repairs Front Side Member (G1770867) /Removal and Installation

Land Rover Discovery (2009–2016) Service Manual / Body / Body Repairs and General Information / Front end Sheet Metal Repairs Front Side Member (G1770867) /Removal and Installation

REMOVAL

NOTE:

The front side member is installed in conjunction with:

  • 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
  • Front suspension
  • Front subframe
  • Secondary bulkhead

NOTE:

The service panel is serviced not fully spot welded.

Front end sheet metal repairs front side member (G1770867) removal and installation

  1. The front side member 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 that the vehicle is correctly aligned it must be placed on a Land Rover approved alignment jig.
  1. For additional information, refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
  2. For additional information, refer to: Front Armature (501-19 Bumpers, Removal and Installation).
  3. For additional information, refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
  4. For additional information, refer to: Hood Latch Panel (501-02 Front End Body Panels, Removal and Installation).
  5. 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).
  6. 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).
  7. For additional information, refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
  8. For additional information, refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
  9. For additional information, refer to: Fender Apron Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
  10. For additional information, refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
  11. 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, Removal) / 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, Removal) / Engine (303-01B, Removal) / Engine (303-01B, Installation).
  12. For additional information, refer to: Front Subframe (502-00, Removal and Installation).
  13. For additional information, refer to: Secondary Bulkhead Centre Panel - TD4 2.2L Diesel (501-02 Front End Body Panels, Removal and Installation) / Secondary Bulkhead Centre Panel - GTDi 2.0L Petrol (501-02 Front End Body Panels, Removal and Installation).

NOTE:

Left hand only.

  1. Release the battery junction box (BJB) and position to one side.

NOTE:

Right hand only.

  1. Remove the front side member noise, vibration and harshness (NVH) material.
  2. Release the brake pipes and position to one side.
  3. Release the wiring harness and position to one side.

CAUTION:

Care should be taken not to cut through into the inner reinforcements.

NOTE:

The left hand and right hand front side member joint locations are both 15mm forward of the laser weld.

Front end sheet metal repairs front side member (G1770867) removal and installation

  1. Mark out the position where the front side member metal inert gas (MIG) butt joint is to be made and cut through the front side member as indicated.

Front end sheet metal repairs front side member (G1770867) removal and installation

  1. Remove the spot welds as indicated.

NOTE:

Retain old front side member section for reference on installation.

  1. Carefully separate the joints and remove the front side member from the vehicle assembly.

INSTALLATION

  1. Dress flanges where necessary.

NOTE:

The left hand and right hand front side member joint locations are both 15mm forward of the laser weld.

Front end sheet metal repairs front side member (G1770867) removal and installation

  1. Using the old front side member as a guide mark out the position where the front side member MIG butt joint is to be made. Cut through the new front side member as indicated.

NOTE:

The drilled out spot welds must be installed with MIG plug welds in the same quantities.

Front end sheet metal repairs front side member (G1770867) removal and installation

  1. Using the old front side member as a guide drill holes in the new front side member where the MIG plug welds are to be installed as indicated.
  2. Deburr the drilled holes.
  3. Clean and prepare the panel surfaces.
  4. Offer up the new front side member and clamp into position. Check alignment if correct, proceed to next step, if not, rectify and recheck before proceeding.

Front end sheet metal repairs front side member (G1770867) removal and installation

  1. Tack MIG weld the front side member butt joint as indicated.

Front end sheet metal repairs front side member (G1770867) removal and installation

  1. Install the MIG plug welds as indicated.

Front end sheet metal repairs front side member (G1770867) removal and installation

  1. MIG weld the front side member 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/installed 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 (G1770867) removal and installation

  1. Prepare the new front side member and install the weld studs in their original locations as indicated.
  2. Dress all welded joints.
  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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