LAND ROVER DISCOVERY 1999 Workshop Manual

PANEL REPAIRS
77-2-4 REPLACEMENT PANELS
Body side panels
1Dash side assembly
2'A' post assembly
3'B/C' post assembly4Sill inner assembly
5Sill outer assembly

PANEL REPAIRS
REPLACEMENT PANELS 77-2-5
Body side assembly
1Panel body side assembly

PANEL REPAIRS
77-2-6 REPLACEMENT PANELS
'D'-post assembly
1'D' post outer assembly
2'D' post closing assembly3Wheelarch rear outer assembly
4Bodyside inner rear assembly

PANEL REPAIRS
REPLACEMENT PANELS 77-2-7
Rear floor assembly.
1Rear floor assembly
M77 1673C
1

PANEL REPAIRS
77-2-8 REPLACEMENT PANELS
Rear end panels
1'E' post assemblies
2'E' post closing assemblies
3Crossmember outer rear panel4Crossmember 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 panel3Rear 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 only3Roof 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.