Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Roof Sheet Metal Repairs Roof Front Panel (G1770881) - Installation

Land Rover Discovery (2009–2016) Service Manual / Body / Body Repairs and General Information / Roof Sheet Metal Repairs Roof Front Panel (G1770881) / Roof Sheet Metal Repairs Roof Front Panel (G1770881) - Installation

Installation

  1. Dress flanges where necessary.
  2. Clean and prepare the panel surfaces.
  3. Clean out the threads on the captive nut inserts where the roof studs are installed.
  4. Offer up the new roof front panel and clamp into position. Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding.

Roof sheet metal repairs roof front panel (G1770881) - Installation

  1. Using the old roof front panel for reference mark and drill the new roof front panel where the metal inert gas (MIG) plug welds are to be installed as indicated.
  2. Remove the new roof front panel.
  3. Deburr the drilled holes.
  4. Clean and prepare the panel surfaces.

NOTES:

  • Care must be taken not to contaminate the captive nut threads where the roof studs are installed.
  • Make sure a continuous bead of adhesive surrounds fixing holes.

Roof sheet metal repairs roof front panel (G1770881) - Installation

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

Roof sheet metal repairs roof front panel (G1770881) - Installation

  1. Install the new roof studs and tighten to 13Nm as indicated.

NOTE:

Make sure that the spot welds are installed adjacent to the removed SPR's.

Roof sheet metal repairs roof front panel (G1770881) - Installation

  1. Install the spot welds as indicated.

Roof sheet metal repairs roof front panel (G1770881) - Installation

  1. Install the MIG plug welds as indicated.
  2. Remove any excess adhesive.
  3. Dress all welded joints.
  4. Make sure that any open or exposed panel joints are sealed with a Land Rover recommended sealer.
  5. Make sure corrosion protection is applied to all areas affected by repair.
  6. The installation of associated panels and components is the reversal of removal procedure.

Rear end Sheet Metal Repairs/ Description and Operation

GALVANIC CORROSION

For additional information, refer to: Corrosion Protection (501-25B, Description and Operation).

REAR END SERVICE PANELS

REAR END SERVICE PANELS

REAR END SERVICE PANELS

REAR END SERVICE PANELS

TIME SCHEDULES , REAR END SERVICE PANELS

The following information shows the total time taken to install single panels.

These times do not include removal of mechanical, electrical and trim, (MET), items or paint times.

The times shown are to be used as a guide only.

TIME SCHEDULES , REAR END SERVICE PANELS

TIME SCHEDULES , REAR END SERVICE PANELS

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