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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 -34 REPAIRS Body side panel - sill section In this procedure the sill section of the body side panel is changed. Remove 1.Disconnect battery earth lead. 2.Disconnect alternator. 3.Remove rear road wheel. 4.Remove front and rear doors. 5.Remove SRS side crash sensor. + RESTRAINT SYSTEMS, REPAIRS, Crash sensor - side. 6.Remove front seat belt. 7.Remove front and rear door tread plates. 8.Remove front and rear door aperture seals. 9.Remove sill finisher. + EXTERIOR FITTINGS, REPAIRS, Extension - spoiler - front bumper. 10.Remove front seat. 11.Remove rear seat cushion. 12.Release carpet from door apertures and position aside. 13. RH side: Remove air reservoir. + FRONT SUSPENSION, REPAIRS, Air reservoir. 14.Remove exhaust assembly. + MANIFOLD AND EXHAUST SYSTEM - Td6, REPAIR, Exhaust system and mountings. 15.Remove fuel tank shield. 16.Release wiring harnesses from sill area and position aside.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.Secure harness to sill. 2.Position carpet to inner sill. 3.Fit fuel tank shield. 4.Fit exhaust assembly. + MANIFOLD AND EXHAUST SYSTEM - Td6, REPAIR, Exhaust system and mountings. 5. RH side: Fit air reservoir. + FRONT SUSPENSION, REPAIRS, Air reservoir. 6.Fit front seat. 7.Fit rear seat cushion. 8.Fit front and rear door aperture seals. 9.Fit front and rear door tread plates. 10.Fit sill finisher. + EXTERIOR FITTINGS, REPAIRS, Extension - spoiler - front bumper. 11.Fit front seat belt.
PANEL REPAIRS REPAIRS -35 12.Fit SRS side crash sensor. + RESTRAINT SYSTEMS, REPAIRS, Crash sensor - side. 13.Fit front and rear doors. 14.Fit rear road wheel. 15.Connect alternator. 16.Connect battery earth lead.Body side panel - sill and B/C post section In this procedure the sill and B/C post section of the body side panel is changed. Remove 1.Disconnect battery earth lead. 2.Disconnect alternator. 3.Remove all components that are removed on the sill section of the body side panel. + , , Body side panel - sill section. 4.Remove headlining. + INTERIOR FITTINGS, REPAIRS, Headlining. 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.
PANEL REPAIRS -36 REPAIRS Refit 1.Fit headlining. + INTERIOR FITTINGS, REPAIRS, Headlining. 2.Fit all components that are removed on the sill section of the body side panel. + , , Body side panel - sill section. 3.Connect alternator. 4.Connect battery earth lead. B/C post reinforcement In this procedure the sill and B/C post section of the body side panel is changed. Remove 1.Disconnect battery earth lead. 2.Disconnect alternator. 3.Remove all components that are removed on the sill and B/C post section of the body side panel. + , , Body side panel - sill and B/C post section. 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. If the front sill reinforcement is not being replaced, then the B/C post reinforcement must be cut in the area identified by the saw tooth line on the above illustration. M77 2239
PANEL REPAIRS REPAIRS -37 Refit 1.Fit all components that are removed on the sill and B/C post section of the body side panel. + , , Body side panel - sill section. 2.Connect alternator. 3.Connect battery earth lead. Sill reinforcement In this procedure the sill and B/C post section of the body side panel is changed. Remove 1.Disconnect battery earth lead. 2.Disconnect alternator. 3.Remove all components that are removed on the sill section of the body side panel. + , , Body side panel - sill section. 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. If the B/C post reinforcement is not being replaced then the sill reinforcement must be cut in the area identified by arrow A. Refit 1.Fit all components that are removed on the sill and B/C post section of the body side panel. + , , Body side panel - sill section. 2.Connect alternator. 3.Connect battery earth lead. M77 2226 A
PANEL REPAIRS -38 REPAIRS Body side panel - rear section In this procedure, the rear outer body side panel is replaced in conjunction with the complete rear quarter. Remove 1.Disconnect battery earth lead. 2.Disconnect alternator. 3.Remove rear road wheel. 4.Remove rear door. 5.Remove rear door and tail door aperture seals. 6.Remove rear door and tail door strikers. 7.Remove sill finisher. + EXTERIOR FITTINGS, REPAIRS, Extension - spoiler - front bumper. 8.Remove rear bumper armature. + EXTERIOR FITTINGS, REPAIRS, Bumper armature - rear. 9.Remove rear wheel arch liner. 10.Remove exhaust assembly. + MANIFOLD AND EXHAUST SYSTEM - Td6, REPAIR, Exhaust system and mountings. 11.Remove E post external finisher. + EXTERIOR FITTINGS, REPAIRS, Finisher - E post. 12.Remove rear quarter light glass. + SCREENS, REPAIRS, Glass - quarter light - rear. 13.Remove tail lamp assembly. + LIGHTING, REPAIRS, Lamp assembly - tail. 14. RH side: Drain fuel tank. + FUEL DELIVERY SYSTEM - Td6, ADJUSTMENTS, Tank - drain. 15. RH side: Remove fuel filler neck. 16. RH side: Remove fuel flap and fuel flap release mechanism. 17.Remove air suspension cross link valve. + REAR SUSPENSION, REPAIRS, Valve assembly - cross link. 18.Remove rear seat belt. 19.Remove E post internal finisher. + INTERIOR FITTINGS, REPAIRS, Trim finisher - E post. 20.Remove lower rear quarter trim casing. + INTERIOR FITTINGS, REPAIRS, Trim casing - rear quarter - lower. 21.Remove all navigation and in car entertainment components from rear quarter area. + NAVIGATION AND IN CAR ENTERTAINMENT, REPAIRS, Power amplifier. 22.Release rear carpet and position aside. 23.Remove luggage compartment carpet.24.Remove insulation from rear quarter area. 25.Release vehicle harness from D post and rear quarter area. Repair 1.Before removing the A post reinforcement, observe the following caution. CAUTION: When cutting out the body side panel, 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. M77 2235 B - B BB BB C B
PANEL REPAIRS REPAIRS -39 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.Fit insulation to rear quarter area. 2.Position vehicle harness to D post and rear quarter area. 3.Fit luggage compartment carpet. 4.Fit all navigation and in car entertainment components to rear quarter area. + NAVIGATION AND IN CAR ENTERTAINMENT, REPAIRS, Power amplifier. 5.Fit lower rear quarter trim casing. + INTERIOR FITTINGS, REPAIRS, Trim casing - rear quarter - lower. 6.Fit and secure rear carpet. 7.Fit E post internal finisher. + INTERIOR FITTINGS, REPAIRS, Trim finisher - E post. 8.Fit air suspension cross link valve. + REAR SUSPENSION, REPAIRS, Valve assembly - cross link.9.Fit rear wheel arch liner. 10.Fit rear seat belt. 11.Fit E post external finisher. + EXTERIOR FITTINGS, REPAIRS, Finisher - E post. 12.Fit rear quarter light glass. + SCREENS, REPAIRS, Glass - quarter light - rear. 13.Fit tail lamp assembly. + LIGHTING, REPAIRS, Lamp assembly - tail. 14. RH side: Fit fuel filler neck. 15. RH side: Fit fuel flap and fuel flap release mechanism. 16.Fit sill finisher. + EXTERIOR FITTINGS, REPAIRS, Extension - spoiler - front bumper. 17.Fit exhaust assembly. + MANIFOLD AND EXHAUST SYSTEM - Td6, REPAIR, Exhaust system and mountings. 18.Fit rear bumper armature. + EXTERIOR FITTINGS, REPAIRS, Bumper armature - rear. 19.Fit rear door and tail door strikers. 20.Fit rear door and tail door aperture seals. 21.Fit rear door. 22.Fit rear road wheel. 23. RH side: Refill fuel tank. + FUEL DELIVERY SYSTEM - Td6, ADJUSTMENTS, Tank - drain. 24.Connect alternator. 25.Connect battery earth lead.
PANEL REPAIRS -40 REPAIRS Rear wheel arch reinforcement - upper In this procedure, the rear wheel arch upper reinforcement is replaced in conjunction with the rear section of the body side panel. The upper rear wheel arch reinforcement must be removed before the wheel arch assembly can be removed. Remove 1.Disconnect battery earth lead. 2.Disconnect alternator. 3.Remove rear section of the body side panel. + , , Body side panel - rear section. 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 rear section of the body side panel. + , , Body side panel - rear section. 2.Connect alternator. 3.Connect battery earth lead. D post reinforcement In this procedure, the rear outer body side panel and the rear body side reinforcement assembly is replaced in conjunction with the inner E post assembly. Remove 1.Disconnect battery earth lead. 2.Disconnect alternator. 3.Remove rear section of the body side panel. + , , Body side panel - rear section. 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 rear section of the body side panel. + , , Body side panel - rear section. 2.Connect alternator. 3.Connect battery earth lead.
PANEL REPAIRS REPAIRS -41 Body side - rear extension In this procedure, the body side rear extension in conjunction with the inner body side rear panel. Remove 1.Disconnect battery earth lead. 2.Disconnect alternator. 3.Remove rear section of the body side panel. + , , Body side panel - rear section. 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 rear section of the body side panel. + , , Body side panel - rear section. 2.Connect alternator. 3.Connect battery earth lead. Tail lamp mounting panel The tail lamp mounting panel may be changed with the body side rear section or the body rear outer panel. The drain channel may also be changed in this procedure. Remove 1.Disconnect battery earth lead. 2.Disconnect alternator. 3.Remove rear section of the body side panel. + , , Body side panel - rear section. 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.
PANEL REPAIRS -42 REPAIRS Refit 1.Fit rear section of the body side panel. + , , Body side panel - rear section. 2.Connect alternator. 3.Connect battery earth lead. Body rear - outer panel Remove 1.Disconnect battery earth lead. 2.Disconnect alternator. 3.Remove tail door lower. 4.Remove tail door aperture seal. 5.Remove rear bumper armature. + EXTERIOR FITTINGS, REPAIRS, Bumper armature - rear. 6.Remove tow bar. 7.Remove exhaust assembly. + MANIFOLD AND EXHAUST SYSTEM - Td6, REPAIR, Exhaust system and mountings. 8.Remove both tail lamp assemblies. + LIGHTING, REPAIRS, Lamp assembly - tail. 9.Remove air supply unit. + FRONT SUSPENSION, REPAIRS, Air supply unit. 10.Remove LH and RH rear quarter lower trim casings. 11.Remove luggage space carpet. 12.Release vehicle harness from rear body lower closing and position aside. 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.
PANEL REPAIRS REPAIRS -43 Refit 1.Secure vehicle harness to rear body lower closing. 2.Fit luggage space carpet. 3.Fit LH and RH rear quarter lower trim casings. 4.Fit air supply unit. + FRONT SUSPENSION, REPAIRS, Air supply unit. 5.Fit both tail lamp assemblies. + LIGHTING, REPAIRS, Lamp assembly - tail. 6.Fit tail door lower. 7.Fit tail door aperture seal. 8.Fit rear bumper armature. + EXTERIOR FITTINGS, REPAIRS, Bumper armature - rear. 9.Fit tow bar. 10.Fit exhaust assembly. + MANIFOLD AND EXHAUST SYSTEM - Td6, REPAIR, Exhaust system and mountings. 11.Connect alternator. 12.Connect battery earth lead. Body rear assembly The procedure to remove the body rear lower assembly is the same as the body rear outer panel. Remove 1.Disconnect battery earth lead. 2.Disconnect alternator. 3.Remove body rear outer panel. + , , Body rear - outer 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.Fit body rear outer panel. + , , Body rear - outer panel. 2.Connect alternator. 3.Connect battery earth lead.