2002 LAND ROVER DISCOVERY Workshop Manual

PANEL REPAIRS
77-2-8 REPLACEMENT PANELS
Rear end panels
1'E' post assemblies
2'E' post closing assemblies
3Crossmember outer rear panel
4Crossmember closing rear panel
5Crossmember rear assembly
6Crossmember closing rear brackets

PANEL REPAIRS
REPLACEMENT PANELS 77-2-9
Front and rear doors
1Front door assembly
2Front door skin panel
3Rear door assembly
4Rear door skin panel

PANEL REPAIRS
77-2-10 REPLACEMENT PANELS
Taildoor
1Taildoor complete assembly

PANEL REPAIRS
REPLACEMENT PANELS 77-2-11
Roof panels
1Roof panel with sunroofs and roof bar holes
2Roof panel with roof bar holes only
3Roof panel with sunroofs only
4Roof panel
M77 1674A
1
2
3
4

PANEL REPAIRS
77-2-12 REPLACEMENT PANELS
Replacement panels
The previous illustrations show some of the service panels which feature in the Body Repairs procedures. Additional
panels and full body shells are also available. See Parts Fiche for details.

PANEL REPAIRS
PROCEDURES 77-2-13
PROCEDURES
General welding precautions
General
For ease of reference, the diagrams on the following pages show only the type of weld used in repair where it varies
from that used in production.
The replacement welds in the welding diagrams are denoted by the following symbols:
a = Single/Multiple thickness plug welds
b = MIG seam weld
When NOT carrying out welding operations the following criteria must be observed:
lWhere resistance spot welds have been used in production, these must be reproduced with new spot welds in
replacement where possible. All such reproduction spot welds must be spaced 30 mm (1.181 in) apart;
lWhen spot welding, it is recommended that test coupons of the same metal gauges and materials are produced
to carry out peel tests to ensure that welding equipment being used can produce a satisfactory joint. Plug welds
must be used if a satisfactory spot weld cannot be produced;
lThe electrode arms on hand-held spot welding guns must not exceed 300 mm (11.811 in) in length;
lSingle-side spot welding is not acceptable;
lBrazing and gas welding are not acceptable EXCEPT where they have been specified in production;
lWhere 3 metal thicknesses or more are to be welded together it is imperative to use MIG plug welds to ensure
joint strength;
lMIG plug welds must be used in repair joints where there is no access for a resistance spot welder. To replace
each production spot weld a hole must be drilled and/or punched, and a MIG plug weld then made in its place.
The number of plug welds must match exactly the number of spot welds which have been removed;
lWhere holes are left in an existing panel after removal of the spot welds, a single MIG plug weld will be made in
each hole as appropriate.
Seat belt anchorages
Seat belt anchorages are safety critical. When making repairs in these areas, it is essential to follow design
specifications. Note that High Strength Low Alloy (HSLA) steel may be used for seat belt anchorages.
Where possible, the original production assembly should be used, complete with its seat belt anchorages, or the cut
line should be so arranged that the original seat belt anchorage is not disturbed.
All welds within 250 mm (9.842 in) of seat belt anchorages must be carefully checked for weld quality, including
spacing of spot welds.

PANEL REPAIRS
77-2-14 PROCEDURES
Electronic control units
The electronic control units (ECU) fitted to vehicles make it advisable to follow suitable precautions prior to carrying
out welding repair operations. Harsh conditions of heat and vibration may be generated during these operations which
could cause damage to the units.
In particular, it is essential to follow the appropriate precautions when disconnecting or removing the airbag DCU.
Supplementary Restraint System Precautions
Any work undertaken which involves the removal or replacement of any item of the Supplementary Restraint System
(SRS), requires extreme caution and the appropriate precautions must be followed.

+ GENERAL INFORMATION, Supplementary Restraint System Precautions.
Equipment
Prior to commencing any test procedure on the vehicle, ensure that the relevant test equipment is working correctly
and any harness or connectors are in good condition. This particularly applies to electronic control units.

PANEL REPAIRS
PROCEDURES 77-2-15
PROCEDURES
Panel replacement procedure
This procedure is designed to explain the basic panel
removal and replacement method. The main criterion
in removal and replacement of body panels is that
the original standard is maintained as far as possible.
While individual repairs will differ in detail, this
procedure has been devised placing emphasis on
ease of repair and the elimination of unnecessary
work.
Body panels are being increasingly manufactured in
high strength steels to meet design requirements for
safety and weight saving. As panels in high strength
steels cannot be visually identified, and as they are
more sensitive to excess heat than panels
manufactured from low carbon steel, it is advisable
that the following procedure be observed at all times.
Remove panel
1.Expose resistance spot welds. For those spot
welds which are not obviously visible, use a
rotary impregnated wire brush fitted to an air
drill, or alternatively a hand held wire brush.
NOTE: In wheel arch areas it may be necessary
to soften underbody coating, using a hot air
gun, prior to exposing spot welds.2.Cut out welds using a cobalt drill.
3.Alternatively, use a clamp-type spot weld
remover.