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Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
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PANEL REPAIRS -4 REPLACEMENT PANELS Body side inner 1Body side inner assembly 2Front header side extension 3Drain tube - front - sunroof 4Drain tube - rear - sunroof
PANEL REPAIRS REPLACEMENT PANELS -5 Sunroof drain tubes Section A-A and B-B show the approximate position of each drain tube in the body side closing panel. The letters A, B and C highlight the position, and type of clips used, to hold the drain tubes in place. lA = Metal clip, welded to the panel lB = Plastic clip lC = Expanding foam block, clipped to the panel M77 2181A Section A - ASection B - B BBA A AA B B BBB C B
PANEL REPAIRS -6 REPLACEMENT PANELS Rear inner body side panels 1Rear quarter inner - upper 2D Post inner 3Wheel arch assembly 4Wheel arch reinforcement assembly 5Outer rear wheelarch assembly 6Rear quarter front lower reinforcement 7Tail lamp mounting panel 8Tail lamp mounting panel 9Tail lamp mounting panel - inner 10Tail lamp mounting bracket - upper 11Tail lamp mounting bracket - lower
PANEL REPAIRS REPLACEMENT PANELS -7 Roof assemblies 1Fixed roof assembly 2Sun roof assembly
PANEL REPAIRS -8 REPLACEMENT PANELS Rear end panels 1Spare wheel well assembly 2Floor longitudinal - RH 3Floor longitudinal - LH 4Rear floor extension panel - RH 5Rear floor extension panel - LH 6Mounting bush - front - rear sub-frame 7Mounting bush - rear - rear sub-frame 8Spare wheel mounting bracket 9Floor longitudinal closing panel - RH 10Floor longitudinal closing panel - LH 11Body rear outer panel 12Body rear assembly
PANEL REPAIRS REPLACEMENT PANELS -9 Door assemblies The doors are serviced as complete assemblies only. The door skins are not available for service. 1Front door assembly (minus hinges) 2Rear door assembly (minus hinges)
PANEL REPAIRS -10 REPLACEMENT PANELS Door assemblies 1Tail gate upper assembly (minus hinges) 2Tail gate lower assembly (minus hinges)
PANEL REPAIRS WELDING PROCEDURES -11 WE LDING PROCEDURE S 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 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) 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 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, an 8 mm (0.314) approx. 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. 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. 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 -12 WELDING PROCEDURES 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) of seat belt anchorages must be carefully checked for weld quality, including spacing of spot welds. WARNING: Body parts incorporating seat belt anchorages MUST be renewed completely if damaged beyond repair, as the welds in these areas are safety critical and cannot be disturbed. High Strength Steels 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 by the repairer, and as they can be more sensitive to excess heat than would be the case with low carbon steels, it is advisable that the following procedure be observed at all times. While individual repairs will differ in detail, the following Panel Replacement Procedure has been devised placing emphasis on ease of repair and the elimination of unnecessary work. Where replacement of a particular panel involves departure from the Panel Replacement Procedure, a note to that effect is included in the relevant panel replacement operation. Straightening Whenever possible, structural members should be cold straightened under tension. Do not attempt to straighten with a single pull but rework the damaged area using a series of pulls, releasing tension between each stage and using the opportunity to check alignment Body jig Unless damage is limited to cosmetic panels, all repair work to body members must be carried out on a body jig, to ensure that impact damage has not spread into more remote parts of the structure. Mounting on a jig will also ensure that the straightening and panel replacement procedures do not cause further distortion. If original dimensions cannot be satisfactorily restored by these methods, damaged structural members should be replaced. WARNING: Damaged areas should be cut away using a high speed saw, NOT an oxy-acetylene torch. As a rule, body dimensions are symmetrical about the centre line. A good initial check for distortion is therefore to measure diagonally and to investigate apparent differences in dimensions. Inspection Every accident produces individual variations in damage. Each repair is influenced by the extent of the damage and the facilities and equipment available for its rectification. Most accident damage can be visually inspected and the approximate extent of damage assessed. Sometimes deformation will extend beyond the directly damaged area, and the severity of this must be accurately established so that steps can be taken to restore critical body components to their original dimensions. An initial check can be carried out by means of drop checks or, preferably, trammels. Gauges are available which will accurately check for body twist. Where repairs necessitate renewal of a critical body component it is recommended that a body jig is used.
PANEL REPAIRS PROCEDURES -13 PROCEDURES Panel replacement procedure This information is designed to explain the basic panel removal and replacement method. This standard method might vary slightly from one vehicle to another. The main criterion in removable and replacement of body panels is that Land Rover`s original standard is maintained as far as possible. Remove panel 1.Expose resistance spot welds. For those spot welds which are not obviously visible, use a rotary drum sander or 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. 4.Cut away the bulk of the panel as necessary using an air saw. NOTE: On certain panel joints MIG welds and braze should be removed using a sander where possible, before cutting out the panel bulk.