Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Rear end Sheet Metal Repairs Quarter Panel (G1770932) - Installation

Installation

  1. Dress the flanges where necessary
  2. Clean and prepare the panel surfaces.

Rear end sheet metal repairs quarter panel (G1770932) - Installation

  1. Using the old quarter panel for reference, mark and cut the new quarter panel where the MIG welded butt joints are to be made as indicated.
  2. Offer up the new quarter panel and clamp into position. Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding.

Rear end sheet metal repairs quarter panel (G1770932) - Installation

  1. Drill holes in the quarter panel where the MIG plug welds are to be installed as indicated.

Rear end sheet metal repairs quarter panel (G1770932) - Installation

  1. Drill holes in the quarter panel where the MIG plug welds are to be installed as indicated.
  2. Remove the new quarter panel.
  3. Deburr the drilled holes.
  4. Deburr the drilled holes.

Rear end sheet metal repairs quarter panel (G1770932) - Installation

  1. Apply a 5mm bead of Land Rover recommended sealer to the NVH components as indicated.

Rear end sheet metal repairs quarter panel (G1770932) - Installation

  1. Apply a 5mm bead of Land Rover recommended sealer to the vehicle assembly as indicated.
  2. Offer up the new quarter panel and clamp into position. Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding.

NOTE:

Make sure that the rocker panel butt joint is MIG brazed due to the location of the boron reinforcements.

Rear end sheet metal repairs quarter panel (G1770932) - Installation

  1. Tack MIG weld and braze the butt joints as indicated.

Rear end sheet metal repairs quarter panel (G1770932) - Installation

  1. Install the spot welds as indicated.

Rear end sheet metal repairs quarter panel (G1770932) - Installation

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

NOTE:

Make sure that the rocker panel butt joint is MIG brazed due to the location of the boron reinforcements.

Rear end sheet metal repairs quarter panel (G1770932) - Installation

  1. MIG weld and braze the butt joints as indicated.
  2. Dress all welded joints.
  3. Make sure that any open or exposed panel joints are correctly sealed.
  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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