Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Side Panel Sheet Metal Repairs Rocker Panel (G1770907) - Installation

Land Rover Discovery (2009–2016) Service Manual / Body / Body Repairs and General Information / Side Panel Sheet Metal Repairs Rocker Panel (G1770907) / Side Panel Sheet Metal Repairs Rocker Panel (G1770907) - Installation

  1. Dress the flanges where necessary.
  2. Offer up the new rocker panel 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 (G1770907) - Installation

  1. Drill holes in new rocker panel where the Metal Inert Gas (MIG) plug welds are to be installed as indicated.

Side panel sheet metal repairs rocker panel (G1770907) - Installation

  1. Cut slots in the new rocker panel where the MIG braze slot welds are to be installed as indicated.
  2. Cut slots in the new rocker panel where the MIG braze slot welds are to be installed as indicated.

Side panel sheet metal repairs rocker panel (G1770907) - Installation

  1. Remove the new rocker panel.
  2. Deburr the drilled holes.
  3. Clean and prepare the old and new panel joint surfaces including the Noise, Vibration and Harshness (NVH) components.
  4. Apply a 5 mm bead of Land Rover recommended sealer to the NVH components as indicated.

Side panel sheet metal repairs rocker panel (G1770907) - Installation

  1. Offer up the new rocker panel and clamp into position. Check alignment if correct, proceed to next step, if not, rectify and recheck before proceeding.
  2. Tack MIG weld the A pillar butt joint.
  3. Tack MIG weld the B pillar butt joint.
  4. Tack MIG weld the quarter panel butt joint.

Side panel sheet metal repairs rocker panel (G1770907) - Installation

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

Side panel sheet metal repairs rocker panel (G1770907) - Installation

  1. Install the MIG braze slot welds as indicated.

Side panel sheet metal repairs rocker panel (G1770907) - 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 lower door hinge and tighten the bolts to 30 Nm.
  5. Make sure that any open or exposed panel joints are correctly sealed.
  6. Make sure corrosion protection is applied to all areas affected by repair.
  7. The installation of associated panels and components is the reversal of removal procedure.
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