Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Rear end Sheet Metal Repairs Rear Bumper Mounting Upper (G1780738) / Removal and Installation

Land Rover Discovery (2009–2016) Service Manual / Body / Body Repairs and General Information / Rear end Sheet Metal Repairs Rear Bumper Mounting Upper (G1780738) / Removal and Installation

REMOVAL

NOTE:

The rear bumper mounting upper is installed in conjunction with:

  • Rear bumper cover
  • Rear bumper
  • Rear lamp assembly
  • Rear lamp panel outer
  • Back panel outer

Rear end sheet metal repairs rear bumper mounting upper (G1780738) removal and installation

  1. The rear bumper mounting upper 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, 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.
  1. For additional information, refer to: Rear Bumper Cover (501-19, Removal and Installation).
  2. For additional information, refer to: Rear Bumper (501-19, Removal and Installation).
  3. For additional information, refer to: Rear Lamp Assembly (417-01, Removal and Installation).
  4. For additional information, refer to: Rear Lamp Panel Outer (501- 30, Removal and Installation).
  5. For additional information, refer to: Back Panel Outer (501-30, Removal and Installation).

Rear end sheet metal repairs rear bumper mounting upper (G1780738) removal and installation

  1. Remove the spot welds as indicated.
  2. Carefully separate the joints and remove the rear bumper mounting upper.

INSTALLATION

  1. Dress the flanges where necessary.
  2. Offer up the new rear bumper mounting upper and clamp into position. Check alignment if correct, proceed to next step, if not, rectify and recheck before proceeding.

Rear end sheet metal repairs rear bumper mounting upper (G1780738) removal and installation

  1. Drill holes in the new rear bumper mounting upper where the metal inert gas (MIG) plug welds are to be installed as indicated.
  2. Remove the rear bumper mounting upper.
  3. Deburr the drilled holes.
  4. Clean and prepare the panel surfaces.
  5. Offer up the new rear bumper mounting upper and clamp into position. Check alignment if correct, proceed to next step, if not, rectify and recheck before proceeding.

Rear end sheet metal repairs rear bumper mounting upper (G1780738) removal and installation

  1. Install the MIG plug welds as indicated.
  2. Dress the MIG plug welds.
  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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