Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Roof Sheet Metal Repairs Roof Rear Panel (G1770883) - Installation

 Installation

NOTE:

BSF installation involves using the Land Rover approved BSF installation tool and requires a hole diameter of 6.5mm.

  1. Dress flanges where necessary.
  2. Clean and prepare the panel surfaces.
  3. Clean out the threads on the captive nut inserts where the new roof studs are to be installed.

NOTE:

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

Roof sheet metal repairs roof rear panel (G1770883)  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.

NOTE:

Do not fully tighten the roof studs at this stage.

Roof sheet metal repairs roof rear panel (G1770883)  Installation

  1. Offer up the new roof rear panel, loosely install the roof 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 rear panel and the roof rear header panel.

Roof sheet metal repairs roof rear panel (G1770883)  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 rear panel (G1770883)  Installation

  1. Drill holes where the BSF's are to be installed as indicated.
  2. Remove the new roof rear 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 rear panel (G1770883)  Installation

  1. Apply a 5mm bead of Land Rover recommended sealer as indicated.
  2. Offer up the new roof rear 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 rear panel (G1770883)  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 rear panel (G1770883)  Installation

  1. Install the BSF's as indicated.

Roof sheet metal repairs roof rear panel (G1770883)  Installation

  1. Install the spot welds as indicated.

Roof sheet metal repairs roof rear panel (G1770883)  Installation

  1. Install the roof studs and tighten 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.
  3. Make sure that any open or exposed panel joints are sealed with a Land Rover recommended sealer.
  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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