Land Rover Discovery: Rear end Sheet Metal Repairs Rear Side Member Lower Side Extension (G1771166) / Removal and Installation

REMOVAL

NOTE:

The rear side member lower side extension is installed in conjunction with:

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

1. The rear side member lower side extension 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.

4. For additional information, refer to: Rear Bumper Cover (501-19, Removal and Installation).
5. For additional information, refer to: Rear Bumper (501-19, Removal and Installation).
6. For additional information, refer to: Back Panel Outer (501-30, Removal and Installation).
7. For additional information, refer to: Back Panel Inner (501-30, Removal and Installation).
8. For additional information, refer to: Rear Lamp Panel Outer (501- 30, Removal and Installation).

9. Remove the spot welds as indicated.
10. Carefully separate the joints and remove the panel.

INSTALLATION

1. Dress the flanges where necessary.

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

6. Install the MIG plug welds as indicated.
7. Dress all welds.

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.

8. Prepare the new panel and install the weld studs in their original locations as indicated.
9. Make sure that any open or exposed panel joints are correctly sealed.
10. Make sure corrosion protection is applied to all areas affected by repair.
11. The installation of associated panels and components is the reversal of the removal procedure.

Rear end Sheet Metal Repairs Rear Side Member Section (G1770933) - InstallationRear end Sheet Metal Repairs Rear Side Member Closing Panel (G1780740) / Removal and Installation

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