Land Rover Discovery: Roof Sheet Metal
Repairs Roof
Panel (G1770876)
- Installation
Installation
NOTE:
SPR installation requires using the Land Rover approved SPR tool.
- Dress the flanges where necessary.
- Clean and prepare the panel surfaces.
- Clean out the threads on the captive nut inserts where the roof
studs are installed.
NOTE:
Mark the locations of removed rivet holes in the rear joint
prior to fitment to aid installation of the new roof panel.
- Using the old roof panel as a guide mark the position on the new
roof panel where the holes for the BSF's are to be drilled as
indicated.
CAUTION:
This step requires the aid of another technician as the roof
panel is heavy.
NOTE:
Do not fully tighten the roof studs at this stage.
- Offer up the new roof panel, loosely install the screw in studs and
clamp into position. Check alignment, if correct, proceed to next
step, if not, rectify and recheck before proceeding as indicated.
NOTE:
Make sure that the holes are drilled through the roof panel
and the roof rear header panel.
- Drill holes where the BSF's are to be installed as indicated.
NOTES:
- Make sure that the holes are drilled from inside the vehicle.
- Make sure that the holes are drilled in the same location as
the SPR's.
- Drill holes where the BSF's are to be installed as indicated.
CAUTION:
This step requires the aid of another technician as the roof
panel is heavy.
- Remove the new roof panel.
- Deburr the drilled holes.
- Clean and prepare the panel surfaces.
NOTES:
- Care must be taken not to contaminate the captive nut
threads where the roof studs are installed.
- Make sure a continuous bead of adhesive surrounds fixing
holes.
- Apply a 5mm bead of Land Rover recommended sealer as
indicated.
CAUTION:
This step requires the aid of another technician as the roof
panel is heavy.
- Offer up the new roof panel and clamp into position. Check
alignment, if correct, proceed to next step, if not rectify and
recheck before proceeding.
NOTES:
- Make sure that new roof studs are installed.
- Do not fully tighten the roof studs at this stage.
- Install the roof studs as indicated.
NOTE:
Make sure that the BSF's are installed from the outside.
- Install the BSF's as indicated.
NOTE:
Make sure that the BSF's are installed from the outside.
- Install the BSF's as indicated.
- Install the SPR's as indicated.
- Tighten the roof studs to 13Nm as indicated.
NOTE:
Make sure that all the rivet heads are sealed to prevent water
ingress.
- Apply a Land Rover recommended sealer to all installed rivet heads.
- Remove any excess adhesive.
- Install a new noise, vibration and harshness (NVH) pad as indicated.
- Make sure that any open or exposed panel joints are sealed with a
Land Rover recommended sealer.
- Make sure corrosion protection is applied to all areas affected by
repair.
- The installation of associated panels and components is the reversal
of removal procedure.
READ NEXT:
NOTE:
The roof front panel is installed in conjunction with:
Windshield
Headliner
Front seat
Side air curtain module
Glass roof panel
The roof front panel is serviced as indicated.
Before
Installation
Dress flanges where necessary.
Clean and prepare the panel surfaces.
Clean out the threads on the captive nut inserts where the roof
studs are installed.
Offer up the new roof front
SEE MORE:
SPECIAL TOOL(S)
REMOVAL
WARNING:
Make sure to support the vehicle with axle stands.
Raise and support the vehicle.
Remove the LH halfshaft.
Refer to: Front Left Halfshaft (205-04 Front Drive Halfshafts,
Removal and Installation).
CAUTIONS:
Take extra care not to damage the mating faces.
Make s
The CJB controls the exterior lighting system through interconnections as
follow:
Left steering column multifunction switch
Side lamp position
Low beam position
Automatic ('AUTO') position (if fitted)
Front fog lamp switch (if fitted)
Rear fog lamp switch
Turn signal indicators
High beam sw