Land Rover Discovery: Front end Sheet Metal Repairs Front Side Member and Suspension Top Mount Assembly (G1770869) - Installation

Installation

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

1. Dress the flanges where necessary.

2. Using the old fender apron panel reinforcement as a guide measure and cut the new fender apron panel reinforcement that is attached to the new front side member and suspension top mount assembly as indicated.

3. Remove the spot welds and detach the rear section of the fender apron panel reinforcement from the new front side member and suspension top mount as indicated.

NOTE:

This step will require the aid of another person as the panel will be heavy.

4. Offer up the new front side member and suspension top mount assembly and the new front side member and clamp into position.

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

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

5. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

6. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

7. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

8. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

9. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

10. Using the old panels as a guide mark and drill the new panels where the MIG plug welds are to be installed as indicated.

NOTE:

This step will require the aid of another person as the panel will be heavy.

11. Remove the new front side member and suspension top mount assembly and the new front side member.
12. Deburr the drilled holes.
13. Clean and prepare the panel surfaces.

NOTE:

This step will require the aid of another person as the panel will be heavy.

14. Offer up the new front side member and suspension top mount assembly and the new front side member and clamp into position.

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

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

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

16. Tack MIG weld the fender apron panel reinforcement butt joint as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

17. Install the MIG plug welds as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

18. Install the MIG plug welds as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

19. Install the MIG plug welds as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

20. Install the MIG plug welds as indicated.

NOTE:

Make sure that the drilled out spot welds are replaced with MIG plug welds in the same quantities.

21. Install the MIG plug welds as indicated.

22. Install the A-pillar tube as indicated.

23. MIG weld the fender apron panel reinforcement butt joint as indicated.

NOTES:

• Right hand only.
• The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

24. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

• Right hand only.
• The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

25. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

• Right hand only.
• The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

26. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

• Right hand only.
• The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

27. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

• Right hand only.
• The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

28. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

• Left hand only.
• The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

29. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

• Left hand only.
• The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

30. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

• Left hand only.
• The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

31. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

• Left hand only.
• The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

32. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.

NOTES:

• Left hand only.
• The measurements provided in the graphic are to be used as a guide only, the components that are located/fixed to these weld studs must be offered up and cross checked for alignment prior to the installation of the weld studs to the new panel.

33. Prepare the new front side member and suspension top mount assembly and install the weld studs in their original locations as indicated.
34. Dress the butt welds.
35. Make sure that any open or exposed panel joints are sealed with a Land Rover recommended sealer.
36. Make sure corrosion protection is applied to all areas affected by repair.
37. The installation of associated panels and components is the reversal of removal procedure.

Front end Sheet Metal Repairs Front Side Member and Suspension Top Mount Assembly (G1770869) - RemovalFront end Sheet Metal Repairs Front Side Member (G1770867) /Removal and Installation

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