Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Self-piercing Rivet (SPR)

Self-Piercing Rivets are available in various sizes dependent on the size of the stack of panels to which they are fitted. A stack refers to the combined gauge of the panels being riveted.


It is important to identify and select the correct size fixing by referencing this table prior to installation.

Self-piercing rivet (SPR)

Pip die - Jaguar/Land Rover SPR repair kit, SPX/Avdel part number 78230- 050088.

Flat bottom die - Jaguar/Land Rover SPR repair kit, SPX/Avdel part number 78230-050809.


Operating the SPR installation tool with no SPR or material in position will damage the tool die.


The ESN50 is the approved removal tool for Self Piercing Fixings. The ESN50 can be used with an optional, larger, 200mm C frame for improved access. Where tool access is impossible, drill out the remnant using a 5.3mm Cryobit drill bit. Remove all debris.


The ESN50 is the approved installation tool for Self Piercing Fixings. Where the original panel is being refitted, the new fixings should be placed adjacent to the original. Only where the ESN50 cannot be used, or there is insufficient space on the panel, should the fixings be replaced with Breakstem Fastener Type As, unless the repair method dictates otherwise.

Using the ESN50

Make sure there is access for the ESN50 on both sides of the fixing to be removed/installed, including the optional C frame if required.

Removal: Align the plunger and anvil over the fixing and depress the trigger. Depressing the trigger will allow the plunger to act on the fixing and remove it from the panel.


Prior to replacing a self-piercing fixing, a test, using identical materials from waste panels, should be performed, to make sure that all settings are correct and an acceptable joint has been achieved.

Installation: Load new fixing into ESN50. Align the ESN50 over the fixing position and depress the trigger. As the trigger is depressed the ESN50 will clamp itself onto the work piece and install the fixing.

Removal of service SPR

Service SPR's will require the service anvil to have an internal diameter of 9mm, as shown in graphic E152490.

Removal of service SPR

Removal of service SPR


Breakstem Fasteners are used in repair if the joint/stack cannot be accessed from both sides or require a greater load.

  • Breakstem fasteners will cope with joint/stack sizes of 1.5mm to 10.8mm.
  • A pre-drilled 6.5mm hole will be required before fitment.
  • To identify the correct size and part number of structural breakstem fasteners to be used in repair always refer to TOPlx.

Where original rivet holes cannot be used replacement rivets should be positioned close to the original rivet location/hole location.

When riveting, the first location of the first replacement panel is close to the original rivet placement, not in the centre. The same process is followed by the next replacement, again not in the centre between the rivets.



Breakstem Fasteners have the following benefits:

  • Exceptional shear and tensile strength
  • Large blind side bearing area against the rear sheet
  • Interference lock formed by a splined stem
  • Spreads the tail bearing/clamp load on the rear sheet
  • Provides strong, vibration resistant joints
  • No loose stems

When the repair procedure requires the fitment of a breakstem fastener the stack size is identified within the repair procedures (millimetres).


Breakstem Fastener used in production are removed by removing the centre of the fixing using a 4mm punch. Once the centre has been removed, drill out the remnant using a 6.5mm Cryobit drill bit. Remove all debris.

Aftermarket Breakstem Fastener are removed in the same way as Breakstem Fastener used in production.


The Genesis G4 is the approved installation tool for Breakstem Fastener .

Prior to replacement make sure the fixing hole has been drilled to 6.5mm, using a Cryobit drill bit and all debris has been removed.


Using the Genesis G4

Make sure the fixing hole has been drilled to 6.5mm and all debris has been removed. Check that you have the correct size breakstem fastener for replacement and insert it into the Genesis G4. Use the weight of the Genesis G4 to apply light pressure as the breakstem fastener is inserted into its hole. Depress the trigger which will tighten the breakstem fastener in the hole, the wasted stud will be ejected into the Genesis G4 once a predetermined pressure is reached.

When the repair procedure requires the fitment of a breakstem fastener the stack size is identified within the repair procedure (millimetres). The table below identifies the correct breakstem fastener to the stack size.

Using the Genesis G4


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