Land Rover Discovery: Front end Sheet Metal
Repairs Front
Side Member and
Suspension Top
Mount
Assembly (G1770869) - Removal
Removal
NOTE:
The front side member and suspension top mount assembly is
installed in conjunction with:
- Front bumper cover
- Front bumper
- Front bumper mounting
- Hood
- Hood latch panel
- Radiator
- Condenser
- Front fender
- Fender splash shield
- Fender apron panel
- Fender apron panel reinforcement
- Engine
- Transmission
- Shock absorber and spring assembly
- Front subframe
- Secondary bulkhead
![Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Removal](images/books/227/index(5).34.jpg)
- The front side member and suspension top mount assembly is
serviced as indicated and installed in conjunction with the full front
side member panel.
- Before commencing this procedure make sure that you are aware of
all Health and Safety requirements.
For additional information, refer to: Health and Safety Precautions
(100-00 General Information, Description and Operation).
- For further information on the methods, tools and fixings used in
this procedure refer to the body repairs - general information
section.
NOTES:
- Any joints sealed as part of vehicle manufacture must be sealed as
part of the repair.
- Make sure a zinc rich primer is applied to any bare metal surfaces.
- To make sure that the vehicle is correctly aligned, it must be placed
on a Land Rover approved alignment jig.
- For additional information, refer to: Front Bumper Cover (501-19
Bumpers, Removal and Installation).
- For additional information, refer to: Front Armature (501-19
Bumpers, Removal and Installation).
- For additional information, refer to: Hood (501-02 Front End Body
Panels, Removal and Installation).
- For additional information, refer to: Hood Latch Panel (501-02 Front
End Body Panels, Removal and Installation).
- For additional information, refer to: Radiator (303-03A Engine
Cooling - TD4 2.2L Diesel, Removal and Installation) / Radiator
(303-03B Engine Cooling - INGENIUM I4 2.0L Diesel, Removal and
Installation).
- For additional information, refer to: Condenser - GTDi 2.0L
Petrol/GTDi 2.0L Petrol - SULEV (412-01 Climate Control, Removal
and Installation) / Condenser - TD4 2.2L Diesel (412-01 Climate
Control, Removal and Installation).
- For additional information, refer to: Fender (501-02 Front End Body
Panels, Removal and Installation).
- For additional information, refer to: Fender Splash Shield (501-02
Front End Body Panels, Removal and Installation).
- For additional information, refer to: Fender Apron Panel (501-27
Front End Sheet Metal Repairs, Removal and Installation).
- For additional information, refer to: Fender Apron Panel
Reinforcement (501-27 Front End Sheet Metal Repairs, Removal
and Installation).
- For additional information, refer to: Engine - Vehicles With: M66 6-
Speed Manual Transmission AWD/M66 6-Speed Manual
Transmission FWD (303-01A Engine - TD4 2.2L Diesel, Removal) /
Engine - Vehicles With: M66 6-Speed Manual Transmission
AWD/M66 6-Speed Manual Transmission FWD (303-01A Engine -
TD4 2.2L Diesel, Installation) / Engine - Vehicles With: 9HP48 9-
Speed Automatic Transmission - AWD (303-01A Engine - TD4 2.2L
Diesel, Removal) / Engine - Vehicles With: 9HP48 9-Speed
Automatic Transmission - AWD (303-01A Engine - TD4 2.2L Diesel,
Installation) / Engine (303-01C Engine - GTDi 2.0L Petrol/GTDi 2.0L
Petrol - SULEV, Removal) / Engine (303-01C Engine - GTDi 2.0L
Petrol/GTDi 2.0L Petrol - SULEV, Installation).
- For additional information, refer to: Transmission - GTDi 2.0L
Petrol/GTDi 2.0L Petrol - SULEV (307-01 Automatic
Transmission/Transaxle, Removal) / Transmission - TD4 2.2L Diesel
(307-01 Automatic Transmission/Transaxle, Removal) / Transmission
- GTDi 2.0L Petrol/GTDi 2.0L Petrol - SULEV (307-01 Automatic
Transmission/Transaxle, Installation) / Transmission - TD4 2.2L Diesel
(307-01 Automatic Transmission/Transaxle, Installation).
- For additional information, refer to: Shock Absorber and Spring
Assembly (204-01 Front Suspension, Removal and Installation).
- For additional information, refer to: Front Subframe (502-00,
Removal and Installation).
- For additional information, refer to: Secondary Bulkhead Centre
Panel - TD4 2.2L Diesel (501-02 Front End Body Panels, Removal
and Installation).
NOTE:
Left hand only.
- Release the battery junction box and position to one side.
NOTE:
Right hand only.
- Remove the front side member noise, vibration and harshness
(NVH) material.
- Release the brake pipes and position to one side.
- Release the wiring harnesses at the a-pillar, bulkhead and the side
member and position to one side.
NOTE:
Where access is limited use a belt sander to sand down the
spot welds in these areas.
![Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Removal](images/books/227/index(5).35.jpg)
- Remove the spot welds as indicated.
NOTE:
Where access is limited use a belt sander to sand down the
spot welds in these areas.
![Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Removal](images/books/227/index(5).36.jpg)
- Remove the spot welds as indicated.
NOTE:
Where access is limited use a belt sander to sand down the
spot welds in these areas.
![Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Removal](images/books/227/index(5).37.jpg)
- Remove the spot welds as indicated.
![Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Removal](images/books/227/index(5).38.jpg)
- Measure and cut the fender apron panel reinforcement as
indicated.
NOTE:
Make sure that the spot welds are drilled from the inside to
enable the joint to be metal inert gas (MIG) plug welded on
installation.
![Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Removal](images/books/227/index(5).39.jpg)
- Remove the spot welds as indicated.
![Front end sheet metal repairs front side member and suspension top mount assembly (G1770869) - Removal](images/books/227/index(5).40.jpg)
- Remove the tube from the A-pillar as indicated.
NOTE:
This step will require the aid of another person as the panel
will be heavy.
- Carefully separate the joints and remove the front side member and
suspension top mount assembly and the front side member.
READ NEXT:
Installation
NOTE:
Make sure that the drilled out spot welds are replaced with MIG plug
welds in the same quantities.
Dress the flanges where necessary.
Using the old fender apron panel reinfor
REMOVAL
NOTE:
The front side member is installed in conjunction with:
Front bumper
Front bumper mounting
Hood
Hood latch panel
Radiator
Condenser
Front fender
Fender splash shield
Fender apr
REMOVAL
NOTE:
The front fender mounting panel is installed in conjunction with:
Front fender
Front door
The front fender mounting panel is serviced as indicated.
Before commencing this proced
SEE MORE:
The AWDCM is located at the front right side of the RDU, adjacent to the
drive flange. The AWDCM is attached to the RDU casing and secured with
screws.
Two electrical connectors provide the interface between the AWD valve
block and the vehicle systems. The upper connector provides the
connections
Diesel Exhaust Fluid (DEF) tank module
Diesel Exhaust Fluid (DEF) level sensor
Diesel Exhaust Fluid (DEF) tank module electrical connection
Diesel Exhaust Fluid (DEF) pressure line connection
Diesel Exhaust Fluid (DEF) injection pump electrical connection
Diesel Exhaust Fluid (DEF) heater el