Discovery 3 lights - removal of old lights

You cannot gain access to the base of the panel welds without removing the bumper - I did not want to do this so used some metal snips to cut along the bottom of the panel as shown in the photographs. When working on the passenger side of the car, you will find that the bottom of this panel acts as a mount for the screenwash tank so it has to remain in place anyway.

The photographs show the various locations of the welds and the panel being removed. Once the panel has been removed, the vertical seam nearest to the front wing (this also holds the front panel of the car to the inner wing) and lip at top of wing must be preferably re-welded together or at the very least bolted together. Welding is recommended but remember if using a MIG, disconnect the ECUs, alternator and battery to avoid damage. If the metal cutting disc is used, this would not be necessary.

A cut must also be made in the top of the front panel to accommodate the shape of the new headlight, again it is advisable to weld in a metal brace at the back of the light to retain panel strength.

Now is a good time to trial fit the light, some minor repositioning of cables/connectors at the back may be necessary. Treat all exposed metal with paint to avoid later rusting.

TOP PANEL REQUIRES TO BE CUT OUT AT BOTH DRIVER AND PASSENGER SIDE (SHOWN RED) TO ACCOMMODATE BODY OF HEADLIGHT - THIS TOP PANEL SLIDES INTO THE GROOVE IN THE TOP OF THE HEADLIGHT. SUGGEST METAL BRACE WELDED IN AT AREA SHOWN GREEN