Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Rear end Sheet Metal Repairs Rear Side Member Closing Panel (G1780740) / Removal and Installation

Land Rover Discovery (2009–2016) Service Manual / Body / Body Repairs and General Information / Rear end Sheet Metal Repairs Rear Side Member Closing Panel (G1780740) / Removal and Installation

REMOVAL

NOTE:

The rear side member closing panel is installed in conjunction with:

  • Rear bumper cover
  • Rear bumper
  • Rear lamp assembly
  • Rear lamp panel outer
  • Back panel outer
  • Back panel inner
  • Rear floor side extension
  • Rear side member lower side extension
  • Rear bumper mounting upper
  • Spare wheel well

Rear end sheet metal repairs rear side member closing panel (G1780740) removal and installation

  1. The rear side member closing panel 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.
  • 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: 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).
  6. For additional information, refer to: Back Panel Inner (501-30, Removal and Installation).
  7. For additional information, refer to: Rear Floor Side Extension (501- 30, Removal and Installation).
  8. For additional information, refer to: Rear Side Member Lower Side Extension (501-30, Removal and Installation).
  9. For additional information, refer to: Rear Bumper Mounting Upper (501-30, Removal and Installation).
  10. For additional information, refer to: Spare Wheel Well - Vehicles Without: 7 Seats (501-30, Removal and Installation) / Spare Wheel Well - Vehicles With: 7 Seats (501-30, Removal and Installation).

CAUTION:

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

Rear end sheet metal repairs rear side member closing panel (G1780740) removal and installation

  1. Using a combination of the new rear side member closing panel and the measurements mark the position where the metal inert gas (MIG) welded butt joint is to be made and cut the panel as indicated.

Rear end sheet metal repairs rear side member closing panel (G1780740) removal and installation

  1. Remove the spot welds as indicated.
  2. Carefully separate the joints and remove the panel.

INSTALLATION

  1. Dress the flanges where necessary..

Rear end sheet metal repairs rear side member closing panel (G1780740) removal and installation

Using the old rear side member closing panel as a guide mark, measure and cut the new rear side member closing panel where the MIG butt joint is to be installed as indicated.

  1. Clean and prepare the panel surfaces.
  2. Offer up the new rear side member closing panel rear 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 side member closing panel (G1780740) removal and installation

  1. Tack MIG weld the rear side member closing panel butt joint as indicated.

Rear end sheet metal repairs rear side member closing panel (G1780740) removal and installation

  1. Install the spot welds as indicated.

Rear end sheet metal repairs rear side member closing panel (G1780740) removal and installation

  1. MIG weld the butt joint as indicated.

NOTE:

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.

Rear end sheet metal repairs rear side member closing panel (G1780740) removal and installation

  1. Prepare the new panel and install the weld studs in their original locations as indicated.
  2. Dress the MIG welded butt weld.
  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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