Land Rover Range Rover Body Repair Rover Manual

77PANEL REPAIRS NEW RANGE ROVER
8
PANELS Rear Quarter Repair Panel
The rear quarter which is fitted between the outer
panel and inner quarter is serviced as a separate
repair panel.
Spare Wheel Closing Panel
The spare wheel closing panel is serviced separately
and fits at the upper front of the spare wheel well. 

PANEL REPAIRS
1
PROCEDURES GENERAL WELDING PRECAUTIONS
For ease of reference the diagrams on the following
pages show only the type of weld used in repair where
this varies from that used in production.
When carrying out welding operations the following
criteria must be observed:
·Where 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
30mm (1.2in.) apart.
·When spot welding, it...

77PANEL REPAIRS NEW RANGE ROVER
2
PROCEDURES PANEL REPLACEMENT PROCEDURE
General
This information is designed to explain the basic panel
removal and replacement method. This standard
method may vary slightly from one vehicle to another.
The main criterion in removal and replacement of
body panels is that Land Rovers 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 impregnated wire brush...

PANEL REPAIRS
3
PROCEDURES
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.
5.Separate spot welded joints and remove panel
remnants using hammer, bolster chisel and
pincers.Prepare Old Surfaces
6.Clean all panel joint edges to a bright smooth
finish, using a belt-type sander.
NOTE: Prior to sanding, remove remaining
sealant using a hot air gun to minimise...

77PANEL REPAIRS NEW RANGE ROVER
4
PROCEDURES Prepare New Surfaces
8.Mark out bulk of new panel and trim to size,
leaving approximately 50mm (1.9in.) overlap
with existing panel. Offer up new panel/section,
align with associated panels (e.g. new rear
quarter aligned with door and tailgate). Clamp
into position.
9.Cut new and existing panels as necessary to
form butt, joggle or brace joint as required.
Remove all clamps and metal remnants.
10.Prepare new panel joint edges for welding by
sanding to a bright...

PANEL REPAIRS
5
PROCEDURES
12.Apply adhesive sealant to panel joint surfaces.
See GENERAL SPECIFICATION DATA,
Information section.
Offer Up and Align
Offer up new panel and align with associated panels.
Clamp into position using welding clamps or Mole
grips. Where a joggle or brace joint is being adopted,
make a set in the original panel joint edge or insert a
brace behind the joint.
NOTE: In cases where access for welding
clamps is difficult, it may be necessary to
use tack welds.Welding
13.Select arms...

77PANEL REPAIRS NEW RANGE ROVER
6
PROCEDURES
15.Use a resistance spot welder where access
permits. Try to ensure weld quality by using a
weld monitor where possible.
16.MIG tack weld butt joints and re-check alignment
and panel contours where necessary. Ensure
that a gap is maintained to minimise welding
distortion, by inserting a hacksaw blade as an
approximate guide.
17.Dress MIG tack welds using a sander with 36 grit
disc, or a belt-type sander where access is
limited. 

PANEL REPAIRS
7
PROCEDURES
18.MIG seam weld butt joints.
19.Always use MIG plug welds where excessive
metal thickness or lack of access make
resistance spot welding impractical. Make plug
welds either by using holes left by the spot weld
cutter, or through holes punched or drilled for the
purpose.
20.Dress all welds using a sander with 36 grit disc,
or a belt-type sander and/or impregnated wire
brush.
NOTE: Brazing operations, if required,
must be carried out at this point.
Body Trim
The following panel...

PANEL REPAIRS
1
REPAIR VALANCE AND WHEELARCH
Remove
1.Disconnect battery earth lead.
2.Raise front of vehicle.
WARNING: Support on safety stands.
3.Disconnect all ECUs.
4.Disconnect airbags and sensor system.
5.Remove airbag modules.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair.
6.Disconnect alternator.
7.Remove front bumper valance.
See CHASSIS
AND BODY, Repair.
8.Remove extension spoiler front bumper.See
CHASSIS AND BODY, Repair.
9.Remove front grille.See CHASSIS AND BODY,
Repair.
10.Remove headlamp.See...

77PANEL REPAIRS NEW RANGE ROVER
2
REPAIR FRONT SIDEMEMBER
Remove
1.Disconnect battery earth lead.
2.Raise front of vehicle.
WARNING: Support on safety stands.
3.Disconnect all ECUs.
4.Disconnect airbags and sensor system.
5.Remove airbag module.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair.
6.Disconnect alternator.
7.Remove front bumper valance.
See CHASSIS
AND BODY, Repair.
8.Remove extension spoiler front bumper.See
CHASSIS AND BODY, Repair.
9.Remove front grille.See CHASSIS AND BODY,
Repair.
10.Remove...