Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual

							PANEL REPAIRS
-24 REPAIRS
Front sidemember assembly
In this procedure, the front sidemember and 
suspension turret is replaced as an assembly.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator. 
3.Remove underbelly panel. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Undertray - front.
4.Remove front bumper assembly. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
5.Remove front armature. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
6.Remove radiator. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
7. LH side: Remove radiator expansion tank. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
8.Recover refrigerant from A/C system.
 
 +  AIR CONDITIONING, REFRIGERANT 
RECOVERY, RECYCLING AND 
RECHARGING, Refrigerant recovery - 
recycling and recharge.
NOTE: Receiver drier need only be changed 
under the following circumstances. There is dirt 
in the refrigerant circuit ( e.g. compressor 
seizure ). The system is leaking and refrigerant 
has been lost to atmosphere.  Refrigerant 
circuit has been open more than 24 hours due 
to repair.
9.Remove A/C pipes from sidemember. 
10.Remove engine.
11. RH side: Remove gearbox fluid cooler. 
 
 +  AUTOMATIC TRANSMISSION - GM 
5L40-E, REPAIRS, Gearbox fluid cooler.
12. Diesel models: Release and remove 
intercooler pipes.
13. Diesel models: Remove FBH.
14. Diesel models: Remove FBH fuel pump.
15.Remove air intake plenum. 
 
 +  HEATING AND VENTILATION, 
REPAIRS, Plenum - air intake.
16.Remove windscreen lower finisher. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Lower finisher - windscreen.
17.Remove plenum chamber drain tube.
18.Remove throttle pedal.
19.Remove front wing. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Wing - front.20.Remove front wheel arch liner. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Liner - front wheel arch.
21.Remove PAS pipes to access panel.
22. LH side: Remove windscreen washer 
reservoir.
23. Remove alternator. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Alternator - Td6.
24.Remove ABS modulator. 
 
 +  BRAKES, REPAIRS, ABS Modulator 
unit.
25.Remove brake servo. 
 
 +  BRAKES, REPAIRS, Servo 
assembly.
26.Remove fuel pipes from sidemember.
27. LH side: Remove fuel filter. 
 
 +  FUEL DELIVERY SYSTEM - Td6, 
REPAIRS, Filter.
28. LH side: Remove battery carrier. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Carrier - battery.
29. Remove air spring assembly. 
 
 +  FRONT SUSPENSION, REPAIRS, Air 
spring assembly.
30. RH side: Remove air suspension reservoir. 
 
 +  FRONT SUSPENSION, REPAIRS, Air 
reservoir.
31. Remove fuel and brake pipes. 
32.Disconnect wiring harnesses and position 
aside. 
33.Remove insulation from dash lower.
34.Remove heatshield from tunnel.
35.Remove fascia carrier. 
 
 +  INTERIOR FITTINGS, REPAIRS, 
Fascia - carrier.
36.Release front carpet to access welds. 
						

							PANEL REPAIRS
REPAIRS -25
Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. The panel shaded in the illustration 
must also be removed in this procedure. 
Refit
1.Fit insulation pads to dash lower.
2.Position front carpet.
3.Fit fascia carrier. 
 
 +  INTERIOR FITTINGS, REPAIRS, 
Fascia - carrier.
4.Fit heatshield to tunnel.
5.Fit and secure wiring harnesses. 
6.Fit fuel and brake pipes. 
7.Fit air spring assembly. 
 
 +  FRONT SUSPENSION, REPAIRS, Air 
spring assembly.
8. RH side: Fit air suspension reservoir. 
 
 +  FRONT SUSPENSION, REPAIRS, Air 
reservoir.
9. LH side: Fit fuel filter. 
 
 +  FUEL DELIVERY SYSTEM - Td6, 
REPAIRS, Filter.10. LH side: Fit battery carrier. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Carrier - battery.
11.Fit fuel pipes to sidemember.
12.Fit ABS modulator. 
 
 +  BRAKES, REPAIRS, ABS Modulator 
unit.
13.Fit brake servo. 
 
 +  BRAKES, REPAIRS, Servo 
assembly.
14.Fit alternator. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Alternator - Td6.
15.Fit front wheel arch liner. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Liner - front wheel arch.
16.Fit front wing. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Wing - front.
17.Fit PAS pipes.
18.Fit plenum chamber drain tube.
19.Fit windscreen lower finisher. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Lower finisher - windscreen.
20.Fit throttle pedal.
21.Fit engine.
22. Diesel models: Fit FBH.
23. Diesel models: Fit FBH fuel pump.
24. Diesel models: Position and connect 
intercooler pipes.
25.Fit A/C pipes to sidemember.
26. RH side: Fit gearbox fluid cooler.
27. LH side: Fit radiator expansion tank. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
28.Fit air intake plenum. 
 
 +  HEATING AND VENTILATION, 
REPAIRS, Plenum - air intake.
29. LH side: Fit windscreen washer reservoir.
30.Fit radiator. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
31.Fit front armature.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
32.Fit front bumper assembly. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
33.Fit underbelly panel. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Undertray - front.
34.Recharge A/C system.
 
 +  AIR CONDITIONING, REFRIGERANT 
RECOVERY, RECYCLING AND 
RECHARGING, Refrigerant recovery - 
recycling and recharge.
35.Connect alternator. 
36.Connect battery earth lead.
M77 2236 
						

							PANEL REPAIRS
-26 REPAIRS
Valance outer
This panel can be changed on its own if necessary.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator. 
3.Remove front wing. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Wing - front.
4. RH side: Remove ECU housing. 
5. LH side: Remove windscreen washer 
reservoir.
Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. 
Refit
1. RH side: Fit ECU housing. 
2. LH side: Fit windscreen washer reservoir.
3.Fit front wing. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Wing - front.
4.Connect alternator. 
5.Connect battery earth lead.
Valance outer extension
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator. 
3.Remove front wing. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Wing - front.
4. RH side: Remove ECU housing. 
5. LH side: Remove windscreen washer 
reservoir.
6.Remove harness from valance outer extension 
panel.
7.Remove bumper fixing.
8. LH side: Remove bonnet release cable.
9. LH side: Remove radiator expansion tank. 
Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. 
Refit
1. LH side: Fit radiator expansion tank. 
2. LH side: Fit bonnet release cable.
3.Fit harness to valance outer extension panel.
4.Fit bumper fixing.
5. LH side: Fit windscreen washer reservoir.
6. RH side: Fit ECU housing. 
7.Fit front wing. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Wing - front.
8.Connect alternator. 
9.Connect battery earth lead. 
						

							PANEL REPAIRS
REPAIRS -27
Valance inner closing panel
This panel is changed in conjunction with the valance 
outer.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator. 
3.Remove valance outer. 
 
 +  , , Valance outer.
Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. 
Refit
1.Fit valance outer. 
 
 +  , , Valance outer.
2.Connect alternator. 
3.Connect battery earth lead.
Valance inner assembly
The valance inner assembly is changed in 
conjunction with the valance outer extension, 
valance outer and the valance inner closing panel.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator. 
3.Remove valance outer. 
 
 +  , , Valance outer.
4.Remove underbelly panel. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Undertray - front.
5.Remove front bumper assembly. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
6.Remove front armature. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
7.Remove radiator. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
8. LH side: Remove radiator expansion tank. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
9.Recover refrigerant from A/C system.
 
 +  AIR CONDITIONING, REFRIGERANT 
RECOVERY, RECYCLING AND 
RECHARGING, Refrigerant recovery - 
recycling and recharge.
NOTE: Receiver drier need only be changed 
under the following circumstances. There is dirt 
in the refrigerant circuit ( e.g. compressor 
seizure ). The system is leaking and refrigerant 
has been lost to atmosphere.  Refrigerant 
circuit has been open more than 24 hours due 
to repair.
10.Remove A/C pipes from sidemember. 
11. RH side: Remove gearbox fluid cooler. 
 
 +  AUTOMATIC TRANSMISSION - GM 
5L40-E, REPAIRS, Gearbox fluid cooler.
12. Diesel models: Release and remove 
intercooler pipes.
13. Diesel models: Remove FBH.
14. Diesel models: Remove FBH fuel pump.
15.Remove air intake plenum. 
 
 +  HEATING AND VENTILATION, 
REPAIRS, Plenum - air intake.
16.Remove windscreen lower finisher. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Lower finisher - windscreen.
17.Remove brake servo. 
 
 +  BRAKES, REPAIRS, Servo 
assembly. 
						

							PANEL REPAIRS
-28 REPAIRS
18.Remove plenum chamber drain tube.
19.Remove throttle pedal.
20.Remove front wing. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Wing - front.
21.Remove front wheel arch liner. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Liner - front wheel arch.
22.Remove PAS pipes to access panel.
23. LH side: Remove windscreen washer 
reservoir.
24. Remove alternator. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Alternator - Td6.
25.Remove ABS modulator. 
 
 +  BRAKES, REPAIRS, ABS Modulator 
unit.
26.Remove fuel pipes from sidemember.
27. LH side: Remove fuel filter. 
 
 +  FUEL DELIVERY SYSTEM - Td6, 
REPAIRS, Filter.
28. LH side: Remove battery carrier. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Carrier - battery.
29. Remove air spring assembly. 
 
 +  FRONT SUSPENSION, REPAIRS, Air 
spring assembly.
30. RH side: Remove air suspension reservoir. 
 
 +  FRONT SUSPENSION, REPAIRS, Air 
reservoir.
31. Remove fuel and brake pipes. 
32.Disconnect wiring harnesses and position 
aside. 
33.Remove insulation from dash lower.
34.Remove heatshield from tunnel.
35.Remove steering column assembly. 
 
 +  STEERING, REPAIRS, Column 
assembly - inner & outer.
36.Remove fascia carrier. 
 
 +  INTERIOR FITTINGS, REPAIRS, 
Fascia - carrier.
37.Release front carpet to access welds.Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. 
Refit
1.Fit insulation pads to dash lower.
2.Position front carpet.
3.Fit fascia carrier. 
 
 +  INTERIOR FITTINGS, REPAIRS, 
Fascia - carrier.
4.Fit steering column assembly.
5.Fit heatshield to tunnel.
6.Fit and secure wiring harnesses and position 
aside. 
7.Fit fuel and brake pipes. 
8.Fit air spring assembly. 
 
 +  FRONT SUSPENSION, REPAIRS, Air 
spring assembly.
9. RH side: Fit air suspension reservoir. 
 
 +  FRONT SUSPENSION, REPAIRS, Air 
reservoir.
10. LH side: Fit fuel filter. 
 
 +  FUEL DELIVERY SYSTEM - Td6, 
REPAIRS, Filter.
11. LH side: Fit battery carrier. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Carrier - battery.
12.Fit fuel pipes to sidemember.
13.Fit ABS modulator. 
 
 +  BRAKES, REPAIRS, ABS Modulator 
unit.
14.Fit brake servo. 
 
 +  BRAKES, REPAIRS, Servo 
assembly.
15.Fit alternator. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Alternator - Td6. 
						

							PANEL REPAIRS
REPAIRS -29
16.Fit front wheel arch liner. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Liner - front wheel arch.
17.Fit front wing. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Wing - front.
18.Fit PAS pipes.
19.Fit throttle pedal.
20.Fit plenum chamber drain tube.
21.Fit windscreen lower finisher. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Lower finisher - windscreen.
22. Diesel models: Fit FBH.
23. Diesel models: Fit FBH fuel pump.
24. Diesel models: Position and connect 
intercooler pipes.
25. RH side: Fit gearbox fluid cooler.
26.Fit A/C pipes to sidemember.
27.Recharge A/C system.
 
 +  AIR CONDITIONING, REFRIGERANT 
RECOVERY, RECYCLING AND 
RECHARGING, Refrigerant recovery - 
recycling and recharge.
28. LH side: Fit radiator expansion tank. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
29.Fit air intake plenum. 
 
 +  HEATING AND VENTILATION, 
REPAIRS, Plenum - air intake.
30. LH side: Fit windscreen washer reservoir.
31.Fit radiator. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
32.Fit front armature.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
33.Fit front bumper assembly. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
34.Fit underbelly panel. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Undertray - front.
35.Connect alternator. 
36.Connect battery earth lead.
Valance inner reinforcement
The procedure to remove the valance inner 
reinforcement is the same as the side member 
assembly.
Remove
1.Remove front sidemember assembly. 
 
 +  , , Front sidemember assembly.
Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. 
Refit
1.Fit front sidemember assembly. 
 
 +  , , Front sidemember assembly. 
						

							PANEL REPAIRS
-30 REPAIRS
Valance inner assembly - front section
The valance outer extension is also removed in this 
procedure.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator. 
3.Remove valance outer extension. 
 
 +  , , Valance outer extension.
4.Remove wiring harness from valance inner 
panel.
Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. 
Refit
1.Connect wiring harness to valance inner panel.
2.Fit valance outer extension. 
 
 +  , , Valance outer extension.
3.Connect alternator. 
4.Connect battery earth lead.
Body side panel - A post
In this procedure, the A post body side panel is 
replaced.
NOTE: The A post body side panel is supplied as an 
assembly and includes the A post reinforcement. 
Therefore, prior to refitting the A post body side 
panel, the two panels will have to be separated.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator. 
3.Remove valance outer. 
 
 +  , , Valance outer.
4.Remove battery carrier, if required. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Carrier - battery.
5.Remove brake servo, if required. 
 
 +  BRAKES, REPAIRS, Servo 
assembly.
6.Remove air intake plenum. 
 
 +  HEATING AND VENTILATION, 
REPAIRS, Plenum - air intake.
7.Remove windscreen lower finisher. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Lower finisher - windscreen.
8.Remove front seat. 
 
 +  SEATS, REPAIRS, Front seat.
9.Remove front head airbag. 
 
 +  RESTRAINT SYSTEMS, REPAIRS, 
Airbag module - head - front.
10.Remove front and rear door aperture seals.
11.Remove front door check strap.
12.Remove sill finisher. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Extension - spoiler - front bumper.
13.Release front carpet
14.Release wiring harness from A post and 
position aside.
15.Remove interior lamp.
16.Release and remove dash insulation pads. 
						

							PANEL REPAIRS
REPAIRS -31
Repair
1.Before removing the A post panel, observe the 
following precautions.
CAUTION: When cutting the A post upper 
section do not cut through the 
reinforcement panel as a rubber drain tube 
is located behind it. The approximate 
position of the drain tube is shown in the 
illustration.
NOTE: Arrows A and B shown in the 
illustration, indicate the approximate position of 
the drain tube fixings.
2.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. 
Refit
1.Refit dash insulation pads.
2.Secure front carpet.
3.Fit interior lamp.
4.Fit and secure wiring harness to A post.
5.Fit front door check strap.
6.Fit sill finisher. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Extension - spoiler - front bumper.
7.Fit front and rear door aperture seals.
8.Fit front head airbag. 
 
 +  RESTRAINT SYSTEMS, REPAIRS, 
Airbag module - head - front.
9.Fit front seat. 
 
 +  SEATS, REPAIRS, Front seat.
10.Fit battery carrier. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Carrier - battery.
M77 2234A - A
A
A
AA
B
B
B 
						

							PANEL REPAIRS
-32 REPAIRS
11.Fit brake servo. 
 
 +  BRAKES, REPAIRS, Servo 
assembly.
12.Fit air intake plenum. 
 
 +  HEATING AND VENTILATION, 
REPAIRS, Plenum - air intake.
13.Fit windscreen lower finisher. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Lower finisher - windscreen.
14.Fit valance outer. 
 
 +  , , Valance outer.
15.Connect alternator. 
16.Connect battery earth lead.
A post reinforcement
The procedure to change the A post reinforcement 
is the same as the A post body side panel. 
NOTE: The A post reinforcement is supplied as an 
assembly and includes the A post body side panel. 
Prior to refitting the A post reinforcement it is 
necessary to separate it from the A post body side 
panel. This allows all welding operations on the A 
post reinforcement to be carried out.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator. 
3.Remove A post body side panel. 
 
 +  , , Body side panel - A post. 
						

							PANEL REPAIRS
REPAIRS -33
Repair
1.Before removing the A post reinforcement, 
observe the following precautions.
CAUTION: When cutting the A post upper 
section, extreme caution must be taken as a 
rubber drain tube is located behind it. The 
approximate position of the drain tube is 
shown in the illustration.
NOTE: Arrows A and B shown in the 
illustration, indicate the approximate position of 
the drain tube fixings.
2.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. 
CAUTION: Before welding the top of the A 
post reinforcement, tack weld a small plate 
over the drain tube to protect it from 
excessive heat.
Refit
1.Fit A post body side panel. 
 
 +  , , Body side panel - A post.
2.Connect alternator. 
3.Connect battery earth lead.
M77 2234A - A
A
A
AA
B
B
B