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.

3. 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.

4. 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.

5. 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.

6. 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.

7. 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.

8. 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.

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

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

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

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

13. 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.

14. Remove the side panel.
15. Deburr the drilled slots and holes.
16. Clean and prepare the panel surfaces.

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

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

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

20. 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.

21. 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.

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

23. Install the spot welds as indicated.

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

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

26. Install the spot welds as indicated.

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

28. Install the MIG braze slot welds as indicated.

29. Install the MIG braze slot welds as indicated.

30. Install the MIG braze slot welds as indicated.

31. Install the MIG braze slot welds as indicated.
32. Dress all welded joints.
33. 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.
34. Make sure that any open or exposed panel joints are correctly sealed.
35. Make sure corrosion protection is applied to all areas affected by repair.
36. The installation of associated panels and components is the reversal of removal procedure.

Side Panel Sheet Metal Repairs Side Panel (G1770901) - RemovalSide Panel Sheet Metal Repairs Rocker Panel and 'B' Pillar Outer Panel (G1770927)

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