Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Roof Sheet Metal Repairs Roof Panel (G1770876) - Installation

 Installation

NOTE:

SPR installation requires using the Land Rover approved SPR tool.

  1. Dress the 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.

NOTE:

Mark the locations of removed rivet holes in the rear joint prior to fitment to aid installation of the new roof panel.

Roof sheet metal repairs roof panel (G1770876) - Installation

  1. Using the old roof panel as a guide mark the position on the new roof panel where the holes for the BSF's are to be drilled as indicated.

CAUTION:

This step requires the aid of another technician as the roof panel is heavy.

NOTE:

Do not fully tighten the roof studs at this stage.

Roof sheet metal repairs roof panel (G1770876) - Installation

  1. Offer up the new roof panel, loosely install the screw in studs and clamp into position. Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding as indicated.

NOTE:

Make sure that the holes are drilled through the roof panel and the roof rear header panel.

Roof sheet metal repairs roof panel (G1770876) - Installation

  1. Drill holes where the BSF's are to be installed as indicated.

NOTES:

  • Make sure that the holes are drilled from inside the vehicle.
  • Make sure that the holes are drilled in the same location as the SPR's.

Roof sheet metal repairs roof panel (G1770876) - Installation

  1. Drill holes where the BSF's are to be installed as indicated.

CAUTION:

This step requires the aid of another technician as the roof panel is heavy.

  1. Remove the new roof panel.
  2. Deburr the drilled holes.
  3. 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 panel (G1770876) - Installation

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

CAUTION:

This step requires the aid of another technician as the roof panel is heavy.

  1. Offer up the new roof panel and clamp into position. Check alignment, if correct, proceed to next step, if not rectify and recheck before proceeding.

NOTES:

  • Make sure that new roof studs are installed.
  • Do not fully tighten the roof studs at this stage.

Roof sheet metal repairs roof panel (G1770876) - Installation

  1. Install the roof studs as indicated.

NOTE:

Make sure that the BSF's are installed from the outside.

Roof sheet metal repairs roof panel (G1770876) - Installation

  1. Install the BSF's as indicated.

NOTE:

Make sure that the BSF's are installed from the outside.

Roof sheet metal repairs roof panel (G1770876) - Installation

  1. Install the BSF's as indicated.

Roof sheet metal repairs roof panel (G1770876) - Installation

  1. Install the SPR's as indicated.

Roof sheet metal repairs roof panel (G1770876) - Installation

  1. Tighten the roof studs to 13Nm as indicated.

NOTE:

Make sure that all the rivet heads are sealed to prevent water ingress.

  1. Apply a Land Rover recommended sealer to all installed rivet heads.
  2. Remove any excess adhesive.

Roof sheet metal repairs roof panel (G1770876) - Installation

  1. Install a new noise, vibration and harshness (NVH) pad as indicated.
  2. Make sure that any open or exposed panel joints are sealed with a Land Rover recommended sealer.
  3. Make sure corrosion protection is applied to all areas affected by repair.
  4. The installation of associated panels and components is the reversal of removal procedure.

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