Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Side Panel Sheet Metal Repairs 'A' Pillar Reinforcement (G1770903) - Installation

  1. Dress the flanges where necessary.
  2. Clean and prepare the panel surfaces.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. Using the old A-pillar reinforcement as a guide, detach the new Apillar reinforcement from the ring frame as indicated.
  2. Separate the joints and remove the A-Pillar reinforcement from the ring frame.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. Cut slots in the A-pillar upper reinforcement where the MIG braze slot welds are to be installed as indicated.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. Drill holes in the new A-pillar reinforcement where the MIG plug welds are to be installed as indicated.
  2. Deburr the drilled holes and slots.
  3. Clean and prepare the panel surfaces including the NVH component.

NOTE:

Make sure that the adhesive is 30mm away from any MIG plug welds to avoid contamination.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. Apply a 5mm bead of Land Rover approved panel bonding adhesive as indicated.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. Apply a 5mm bead of Land Rover approved sealer adhesive to the NVH component as indicated.
  2. Offer up the new A-pillar reinforcement and clamp into position.

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

NOTE:

Do not fully tighten the retaining nut at this stage.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. Install the retaining nut as indicated.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. Tack MIG braze the butt joint as indicated.
  2. MIG braze the slots as indicated.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. Install the NVH component as indicated.

NOTES:

  • The A-pillar reinforcement is fully welded when the A-pillar outer panel is installed.
  • This joint has to be fully spot welded as it contains adhesive.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. Install the spot welds as indicated.

NOTE:

The A-pillar reinforcement is fully welded when the A-pillar outer panel is installed.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. MIG braze the butt joint as indicated.

NOTE:

The A-pillar reinforcement is fully welded when the A-pillar outer panel is installed.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. Install the MIG plug welds as indicated.

Side panel sheet metal repairs 'A' pillar reinforcement (G1770903) - Installation

  1. Tighten the retaining nut to 25Nm as indicated.
  2. Dress all welded joints.
  3. Make sure that any open or exposed panel joints are correctly sealed.
  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 removal procedure.

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