Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Rear end Sheet Metal Repairs Rear Wheelhouse Outer (G1770944) - Installation

Land Rover Discovery (2009–2016) Service Manual / Body / Body Repairs and General Information / Rear end Sheet Metal Repairs Rear Wheelhouse Outer (G1770944) / Rear end Sheet Metal Repairs Rear Wheelhouse Outer (G1770944) - Installation

Installation

  1. Dress flanges where necessary.

Rear end sheet metal repairs rear wheelhouse outer (G1770944) - Installation

  1. Remove the bracket from the new rear wheelhouse outer as indicated.

Rear end sheet metal repairs rear wheelhouse outer (G1770944) - Installation

  1. Drill holes where the metal inert gas (MIG) plug welds are to be installed as indicated.
  2. Offer up the new rear wheelhouse outer 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 wheelhouse outer (G1770944) - Installation

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

Rear end sheet metal repairs rear wheelhouse outer (G1770944) - Installation

  1. Cut slots in the rocker panel inner reinforcement where the MIG braze slot welds are to be installed as indicated.
  2. Remove the rear wheelhouse outer.
  3. Deburr the drilled holes.
  4. Clean and prepare the old and new panel surfaces.

NOTE:

Make sure that the adhesive is 30mm away from any MIG plug welds to avoid contamination.

  1. Apply a 5mm bead of Land Rover approved sealer as indicated.

Rear end sheet metal repairs rear wheelhouse outer (G1770944) - Installation

  1. Offer up the new rear wheelhouse outer and clamp into position.

    Check alignment if correct, proceed to next step, if not, rectify and recheck before proceeding.

  2. Install the spot welds as indicated.

Rear end sheet metal repairs rear wheelhouse outer (G1770944) - Installation

Rear end sheet metal repairs rear wheelhouse outer (G1770944) - Installation

  1. Install the MIG plug welds as indicated.
  2. Offer up the new bracket 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 wheelhouse outer (G1770944) - Installation

  1. Install the MIG plug welds as indicated.

Rear end sheet metal repairs rear wheelhouse outer (G1770944) - Installation

  1. MIG braze the slots as indicated.
  2. Dress the welds.

Rear end sheet metal repairs rear wheelhouse outer (G1770944) - Installation

  1. Install the retaining nuts and tighten to 25Nm as indicated.
  2. Clean and prepare the inner quarter panel upper.
  3. Offer up the inner quarter panel upper 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 rear wheelhouse outer (G1770944) - Installation

  1. Tack MIG weld the inner quarter panel upper butt joint as indicated.

Rear end sheet metal repairs rear wheelhouse outer (G1770944) - Installation

  1. Install the spot welds as indicated.

Rear end sheet metal repairs rear wheelhouse outer (G1770944) - Installation

  1. MIG weld the butt joint as indicated.
  2. Dress the 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 the removal procedure.
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