Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Side Panel Sheet Metal Repairs Rocker Panel and 'B' Pillar Outer Panel (G1770927) -  Installation

Installation

  1. Dress the flanges where necessary.
  2. Using the old rocker panel and B-pillar outer for reference measure, mark and cut the new rocker panel and B-pillar outer where the Metal Inert Gas (MIG) butt joints are to be made as indicated.

Side panel sheet metal repairs rocker panel and 'B' pillar outer panel (G1770927) -  Installation

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

NOTE:

Follow Steps 1 and 2 as shown to cut the MIG braze slots.

  1. Cut slots in the new rocker panel and B-pillar outer where the MIG braze slot welds are to be installed as indicated.

Side panel sheet metal repairs rocker panel and 'B' pillar outer panel (G1770927) -  Installation

NOTE:

Follow Steps 1 and 2 as shown to cut the MIG braze slots.

Side panel sheet metal repairs rocker panel and 'B' pillar outer panel (G1770927) -  Installation

  1. Cut slots in the new rocker panel and B-pillar outer where the MIG braze slot welds are to be installed as indicated.

NOTE:

Follow Steps 1 and 2 as shown to cut the MIG braze slots.

Side panel sheet metal repairs rocker panel and 'B' pillar outer panel (G1770927) -  Installation

  1. Cut slots in the new rocker panel and B-pillar outer where the MIG braze slot welds are to be installed as indicated.

Side panel sheet metal repairs rocker panel and 'B' pillar outer panel (G1770927) -  Installation

  1. Drill holes in new rocker panel and B-pillar outer where the MIG plug welds are to be installed as indicated.
  2. Remove the new rocker panel and B-pillar outer.
  3. Deburr the drilled holes and slots.
  4. Clean and prepare the panel surfaces including the Noise, Vibration and Harshness (NVH) component.
  5. Apply a 5 mm bead of Land Rover recommended sealer to the NVH component as indicated.

Side panel sheet metal repairs rocker panel and 'B' pillar outer panel (G1770927) -  Installation

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

Side panel sheet metal repairs rocker panel and 'B' pillar outer panel (G1770927) -  Installation

  1. Tack MIG weld the butt joints as indicated.

Side panel sheet metal repairs rocker panel and 'B' pillar outer panel (G1770927) -  Installation

  1. Install the spot and MIG plug welds as indicated.

Side panel sheet metal repairs rocker panel and 'B' pillar outer panel (G1770927) -  Installation

  1. Install the MIG braze slot welds as indicated.

Side panel sheet metal repairs rocker panel and 'B' pillar outer panel (G1770927) -  Installation

  1. Install the MIG braze slot welds as indicated.

Side panel sheet metal repairs rocker panel and 'B' pillar outer panel (G1770927) -  Installation

  1. MIG weld the butt joints as indicated.
  2. Dress all welds.
  3. Install the front door lower door hinge and tighten the bolts to 30 Nm.
  4. Install the rear door upper and lower hinges and tighten the bolts to 30 Nm.
  5. Apply a Land Rover recommended sealer and seal the panel flange edges of the MIG braze slot welds in the door aperture areas to prevent water ingress.
  6. Make sure that any open or exposed panel joints are correctly sealed.
  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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