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.
- Dress the flanges where necessary
- Clean and prepare the panel surfaces.
CAUTION:
This step requires the aid of another technician as the side
panel is heavy.
- 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](images/books/227/index.104.jpg)
- 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](images/books/227/index.105.jpg)
- 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](images/books/227/index.106.jpg)
- 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](images/books/227/index.107.jpg)
- 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](images/books/227/index.108.jpg)
- 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](images/books/227/index.109.jpg)
- 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](images/books/227/index.110.jpg)
- 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](images/books/227/index.111.jpg)
- 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](images/books/227/index.112.jpg)
- 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](images/books/227/index.113.jpg)
- 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.
- Remove the side panel.
- Deburr the drilled slots and holes.
- Clean and prepare the panel surfaces.
![Side panel sheet metal repairs side panel (G1770901) - Installation](images/books/227/index.114.jpg)
- 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](images/books/227/index.115.jpg)
- 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](images/books/227/index.116.jpg)
- 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](images/books/227/index.117.jpg)
- 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.
- 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](images/books/227/index.118.jpg)
- Install the spot and MIG plug welds as indicated.
![Side panel sheet metal repairs side panel (G1770901) - Installation](images/books/227/index.119.jpg)
- Install the spot welds as indicated.
![Side panel sheet metal repairs side panel (G1770901) - Installation](images/books/227/index.120.jpg)
- Install the spot and MIG plug welds as indicated.
![Side panel sheet metal repairs side panel (G1770901) - Installation](images/books/227/index.121.jpg)
- Install the spot and MIG plug welds as indicated.
![Side panel sheet metal repairs side panel (G1770901) - Installation](images/books/227/index.122.jpg)
- Install the spot welds as indicated.
![Side panel sheet metal repairs side panel (G1770901) - Installation](images/books/227/index.123.jpg)
- Install the spot and MIG plug welds as indicated.
![Side panel sheet metal repairs side panel (G1770901) - Installation](images/books/227/index.124.jpg)
- Install the MIG braze slot welds as indicated.
![Side panel sheet metal repairs side panel (G1770901) - Installation](images/books/227/index.125.jpg)
- Install the MIG braze slot welds as indicated.
![Side panel sheet metal repairs side panel (G1770901) - Installation](images/books/227/index.126.jpg)
- Install the MIG braze slot welds as indicated.
![Side panel sheet metal repairs side panel (G1770901) - Installation](images/books/227/index.127.jpg)
- Install the MIG braze slot welds as indicated.
- Dress all welded joints.
- 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.
- Make sure that any open or exposed panel joints are correctly
sealed.
- 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 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
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:
REMOVAL
NOTE:
The rear bumper retaining rail is installed in conjunction with:
Rear bumper cover
Rear bumper
The rear bumper retaining rail is serviced as indicated.
Before commencing this procedure make sure that you are aware of
all Health and Safety requirements.
Refer to: Health and S
SPECIAL TOOL(S)
PART(S)
REMOVAL
NOTE:
Some variation in the illustrations may occur, but the essential
information is always correct.
WARNING:
Make sure to support the vehicle with axle stands.
Raise and support the vehicle.
CAUTIONS:
To avoid damage to the joint or gaiter, do not allow the