Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Side Panel Sheet Metal Repairs Side Panel (G1770901) - Installation

Installation

NOTE:

Make sure that a zinc rich primer is applied to any bare metal surfaces.

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

CAUTION:

This step requires the aid of another technician as the side panel is heavy.

  1. Offer up the new side panel 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.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Mark the position and cut slots in the new side panel where the Metal Inert Gas (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 side panel (G1770901) - Installation

  1. Mark the position and cut slots in the new side panel where the MIG braze slot welds are to be installed as indicated.

NOTE:

Follow steps 1 to 3 as shown to cut the MIG braze slots.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Mark the position and cut slots in the new side panel where the MIG braze slot welds are to be installed as indicated.

NOTE:

Follow steps 1 to 3 as shown to cut the MIG braze slots.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Mark the position and cut slots in the new side panel 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 side panel (G1770901) - Installation

  1. Mark the position and cut slots in the new side panel 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 side panel (G1770901) - Installation

  1. Mark the position and cut slots in the new side panel where the MIG braze slot welds are to be installed as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Drill holes in the new side panel where the MIG plug welds are to be installed as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Drill holes in the new side panel where the MIG plug welds are to be installed as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Drill holes in the new side panel where the MIG plug welds are to be installed as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Drill holes in the new side panel where the MIG plug welds are to be installed as indicated.

CAUTION:

This step requires the aid of another technician as the side panel is heavy.

  1. Remove the side panel.
  2. Deburr the drilled slots and holes.
  3. Clean and prepare the panel surfaces.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Apply a 5 mm bead of Land Rover recommended sealer to the Noise, Vibration and Harshness (NVH) components as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Apply a 5 mm bead of Land Rover recommended sealer to the NVH components as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Apply a 5 mm bead of Land Rover recommended sealer to the NVH components as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Apply a 5 mm bead of Land Rover recommended sealer to the vehicle assembly as indicated.

CAUTION:

This step requires the aid of another technician as the side panel is heavy.

  1. Offer up the new side 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 side panel (G1770901) - Installation

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

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Install the spot welds as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

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

Side panel sheet metal repairs side panel (G1770901) - Installation

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

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Install the spot welds as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

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

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Install the MIG braze slot welds as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Install the MIG braze slot welds as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Install the MIG braze slot welds as indicated.

Side panel sheet metal repairs side panel (G1770901) - Installation

  1. Install the MIG braze slot welds as indicated.
  2. Dress all welded joints.
  3. 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.
  4. Make sure that any open or exposed panel joints are correctly sealed.
  5. Make sure corrosion protection is applied to all areas affected by repair.
  6. The installation of associated panels and components is the reversal of removal procedure.

    READ NEXT:

     Side Panel Sheet Metal Repairs Rocker Panel and 'B' Pillar Outer Panel (G1770927)

     Side Panel Sheet Metal Repairs Rocker Panel and 'B' Pillar Outer Panel (G1770927) -  Removal

    NOTE: The rocker panel and B-pillar outer is installed in conjunction with: Front bumper cover Front fender Front fender splash shield Front door Rear door Front seat Rear seat cushion Cowl s

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

    Installation Dress the flanges where necessary. 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

    SEE MORE:

     Child seat positioning

    Crash statistics show that children are safest when properly restrained in a child or infant restraint system that is secured in a rear seating position. Seat belts (or suitable child restraints) should be used by all vehicle occupants, for every trip, no matter how short. Failure to do so will grea

     Ball and Roller Bearings

    When removing and installing bearings, make sure that the following practices are observed to make sure component serviceability: CAUTION: Service tools have been developed for removing the majority of bearings; these must always be used where specified. Remove all traces from bearing under inspec

    © 2019-2024 Copyright www.lrdisc.com