Land Rover Discovery: Roof Sheet Metal Repairs Windshield Header Panel (G1770878) / Removal and Installation

REMOVAL

NOTE:

The windshield header panel is installed in conjunction with:

• Headliner
• Roof moulding
• Side air curtain module
• Roof panel
• Roof front panel
• Glass roof panel
• Windshield glass

1. The windshield header panel 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: Headliner (501-05, Removal and Installation).
5. For additional information, refer to: Roof Moulding - 5-Door (501- 08, Removal and Installation).
6. For additional information, refer to: Side Air Curtain Module (501- 20B, Removal and Installation).
7. For additional information, refer to: Roof Panel (501-28, Removal and Installation).
8. For additional information, refer to: Roof Front Panel (501-28, Removal and Installation).
9. For additional information, refer to: Glass Roof Panel (501-11, Removal and Installation).
10. For additional information, refer to: Windshield Glass (501-11, Removal and Installation).
11. Release and position the wiring harness to one side.
12. Remove the spot welds as indicated.

13. Remove the spot welds as indicated.

14. Carefully separate the joints and remove the windshield header panel.

INSTALLATION

1. Dress flanges where necessary.
2. Clean and prepare the panel surfaces.
3. Offer up the new windshield header panel and clamp into position.

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

4. Install the spot welds as indicated.

5. Install the spot welds as indicated.
6. Make sure that any open or exposed panel joints are sealed with a Land Rover recommended sealer.
7. Make sure corrosion protection is applied to all areas affected by repair.
8. The installation of associated panels and components is the reversal of removal procedure.

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