Land Rover Range Rover Body Repair Rover Manual

							CHASSIS AND BODY
17
REPAIR 28.Disconnect multiplug from SRS control module,
route harness into fascia to prevent fouling as
fascia is removed.
29.Remove both front wheel arch liners.
See this
section.
30.Remove 2 scrivet fasteners securing air cleaner
baffle beneath LH wheel arch. Remove baffle.
31.Disconnect both SRS crash sensor multiplugs.
32.Remove 4 bolts securing battery tray and 2 bolts
securing air cleaner to valance. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
18
REPAIR 33.Raise air cleaner and battery tray for access to
crash sensor harness clips.
34.Release clips securing each crash sensor
harness to valance. Release harness grommets
and feed both harnesses through valance into
wheel arches.
35.Release 3 clips securing each crash sensor
harness to underside of wheel arches.
36.Release harness grommets, feed harnesses
through bulkhead and route into fascia to
prevent fouling as fascia is removed.
37. Vehicles with air conditioning only:Discharge
air conditioning system.
See AIR
CONDITIONING, Adjustment.
38.Remove bolt securing pipe clamp to
Thermostatic Expansion Valve (TXV).
39.Release pipes from TXV and remove O rings.
Seal pipes and ports of TXV.
40. All models:Remove 4 tube bolts securing
fascia to scuttle panel. 
						

							CHASSIS AND BODY
19
REPAIR 41.Remove nuts and washers securing fascia to
base of A posts.
42.Remove bolt securing fascia to pedal box.
43.Using assistance, carefully manoeuvre the
fascia through the drivers door aperture. Place
fascia on a soft covered work surface, supported
on suitable wooden blocks.
44.Remove rubber seals from air intake ducts.
45.Collect rear heater duct connecting tubes.
Refit
46.Fit intake seals to blower motor ducts. Tape
rubbers inside blower ducts to aid fitment.
NOTE: Tape the rubbers at this stage, as
they are almost impossible to locate after
dash fitment.
47.Fit guide pins LRT-76-001 to outer fascia studs.
48.With assistance, manoeuvre fascia into position
through drivers front door aperture. Locate
guide pins.
NOTE: Assistance from a third person may
be necessary when guiding heater pipes
through bulkead.
49.Loosely fit 1 tube bolt, fascia to scuttle.50.Fit bolt securing fascia to pedal box. Tighten to
25 Nm. (18 lbf.ft)
51.Fit nuts and washers at base of A posts. Tighten
to
25 Nm. (18 lbf.ft)
52.Remove guide pins.
53.Fit remaining tube bolts. Tighten to
25 Nm. (18
lbf.ft)
54.Fit rear heater duct connecting pipes.
55.Remove tape from intake seals.
56.Engage lips of sealing rubbers around scuttle
apertures.
57.Fit pollen filter housings, tighten bolts.
58.Fit scuttle side panel to passenger side of
vehicle, tighten bolts.
59.Connect heated screen multiplug, fit to side
panel clip.
60.Connect hoses to heater pipes. Tighten clips.
61. Air conditioning vehicles:Remove seals from
air conditioning pipes and TXV ports.
62.Lubricate new O rings with clean compressor oil,
fit to pipes.
63.Locate pipes in TXV ports, position clamp and fit
clamp bolt.
64.Engage evaporator drain tubes over pipes in
transmission tunnel.
65. Vehicles with SRS only:Route SRS crash
sensor harnesses through bulkhead into wheel
arches, locate harness grommets.
66.Secure harness clips beneath wheel arches,
route harnesses through valances into engine
bay, locate harness grommets.
67.Raise battery tray and air cleaner for access.
Route crash sensor harnesses, secure harness
clips, connect multiplugs to crash sensors.
68.Tighten battery tray and air cleaner bolts.
69.Connect multiplug to SRS control module.
70.Connect SRS harness multiplug to main
harness.
71.Fit air cleaner baffle beneath LH wheel arch,
secure with scrivet fasteners.
72.Fit wheel arch liners.
See this section.
73. All models:Route harness along sill, connect
multiplugs to BeCM.
74.Connect multiplugs at base of A posts and
secure plugs to brackets.
75.Fit earth wires to stud, tighten captive nut.
76.Connect vacuum hose and multiplugs to brake
and clutch pedal switches.
77.Position closing panel beneath passenger side
of fascia. Secure dianostic plug, connect footwell
lamp. Align closing panel, secure with scrivet
fasteners.
78.Fit carpet retainer, engage sprag clips.
79.Fit seat base trim panel, secure trim studs,
tighten screw.
80.Fit fuse cover to seat base trim.
81.Fit both A post lower trim panels, secure sprag
clips. Engage door aperture seals. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
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REPAIR 82. LHD automatic vehicles only:Fit foot rest,
secure with bolts.
83.Fit radio.
See ELECTRICAL, Repair.
84.Fit wiper motor and linkage.See WIPERS AND
WASHERS, Repair.
85.Fit steering column.See STEERING, Repair.
86.Fit centre console.See this section.
87.Refill cooling system.See COOLING SYSTEM,
Repair.
88. Vehicles with SRS only:Fit battery.See
ELECTRICAL, Repair.
89.Reconnect battery negative lead.
90.Evacuate and recharge air conditioning.
See
AIR CONDITIONING, Adjustment.
FASCIA ASSEMBLY - VEHICLES WITH SINGLE
POINT SENSED SRS
Service repair no - 76.46.23/99
WARNING: Refer to SRS safety
precautions before commencing repair.
WARNING: The fascia assembly houses
the heater distribution unit, blower
assemblies and air conditioning
evaporator and is therefore heavy. Assistance is
essential during removal and refit procedures.
CAUTION: When removed from the
vehicle, the fascia should be placed on a
work surface with a soft covering and
supported on suitable wooden blocks.
Remove
1.Remove key from starter switch and wait 10
minutes for SRS back up power circuit to
discharge.
2.Disconnect both battery terminals, earth lead
first.
3.Drain cooling system.
See COOLING SYSTEM,
Repair.
4.Release 2 clips securing heater hoses to heater
matrix and disconnect hoses.
5.Cap both heater matrix pipes to prevent coolant
spillage inside vehicle during fascia removal.
6.Recover refrigerant from air conditioning system.
See AIR CONDITIONING, Adjustment. 
						

							CHASSIS AND BODY
21
REPAIR
7.Remove bolt securing pipe clamp to thermostatic
expansion valve (TXV) and release pipes.
8.Remove and discard O ring seals from air
conditioning pipes.
9.Immediately cap both air conditioning pipes and
TXV ports to prevent moisture entering the air
conditioning system.
10.Remove wiper motor and linkage.
See WIPERS
AND WASHERS, Repair.
11.Disconnect passenger side heated screen
multiplug.
12.Release heated screen multiplug from scuttle
side panel and position aside.
13.Remove 6 bolts securing scuttle side panel to
scuttle and remove panel.
14.Remove pollen filter from both heater intake
housings.
15.Remove 8 screws securing each heater intake
housing to scuttle and remove intake housings.
Release sealing rubbers from scuttle panel
aperture.
16.Remove centre console.
See this section.
17.Remove transmission tunnel insulation pad. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
22
REPAIR
18.Release latching mechanism and disconnect
multiplug from airbag diagnostic and control unit
(DCU).
19.Release SRS harness from transmission tunnel
and position to fascia to avoid snagging.
20.Remove 6 nuts securing gear lever gaiter ring to
transmission tunnel and release gaiter.
21.Remove 2 bolts securing gear lever to gearbox
remote and remove gear lever.
22.Disconnect high/low switch multiplug.
23.Remove 4 bolts securing fascia centre bracket to
fascia and transmission tunnel.
24.Remove fascia centre bracket.
25.Remove radio.
See ELECTRICAL, Repair.
26.Remove steering column.See STEERING,
Repair. 
						

							CHASSIS AND BODY
23
REPAIR
27.Remove 3 scrivets securing lower fascia closing
panel to passengers side of fascia.
28.Release closing panel and release diagnostic
connector from panel.
29.Release door aperture seal adjacent to A post
lower trim panels.
30.Remove screw securing each A post lower trim
panel to A post.
31.Release A post lower trim panels from sprag
clip and remove panels.
32.Remove fuse box cover from drivers seat base
trim.33.Remove screw and 3 trim studs securing seat
base trim to body and remove seat base trim.
34.Release 4 sprag clips securing drivers side
carpet retainer to body and remove carpet
retainer.
35.Disconnect 3 multiplugs from Body Electrical
Control Module (BeCM).
36.Position carpet aside and disconnect multiplug
from rear of BeCM. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
24
REPAIR
37.Remove captive nut securing earth wires to
drivers side lower A post and release 3
additional earth wires.
38.Disconnect 3 multiplugs at base of drivers side
A post.
39.Release harness from drivers side carpet and
position to fascia to avoid snagging.
40.Disconnect multiplugs from clutch and 2 brake
pedal switches.
41.Disconnect vacuum hose from clutch and brake
pedal switches.
42.Disconnect 2 multiplugs at base of passengers
side A post.
43.Remove 2 nuts securing fascia to A post and
transmission tunnel bracket, passengers side
44.Remove 2 nuts securing fascia to A post and
transmission tunnel bracket, drivers side. 
						

							CHASSIS AND BODY
25
REPAIR
45.Remove 4 tube bolts securing fascia assembly
to scuttle panel.
46.Disconnect 2 evaporator drain hoses from
evaporator.
47.Using assistance, carefully manoeuvre fascia
assembly through the drivers door aperture.
Position the fascia on a work surface with a soft
covering and support on suitable wooden blocks.
48.Collect 2 ducts connecting rear heating pipes to
fascia assembly.
Refit
49.Tape intake duct seals inside blower duct to aid
fitment.
50.Fit guide pins LRT-76-001 to outer fascia studs.
51.With assistance, manoeuvre fascia assembly
through drivers door aperture and locate guide
pins to scuttle panel.
NOTE: Assistance from a third person may
be required to guide heater pipes through
bulkhead.
52.Fit one tube bolt securing fascia to scuttle panel
but do not tighten.53.Fit nuts securing fascia to lower A posts and
tighten to
25 Nm. (18 lbf.ft)
54.Fit nuts securing fascia to transmission tunnel
brackets and tighten to
25 Nm. (18 lbf.ft)
55.Remove LRT-76-001.
56.Fit remaining tube bolts securing fascia to scuttle
panel and tighten to
25 Nm. (18 lbf.ft)
57.Fit fascia centre bracket, fit bolts and tighten to
25 Nm. (18 lbf.ft)
58.Connect evaporator drain hoses to evaporator.
59.Fit ducts connecting rear heating pipes to fascia
assembly.
60.Fit gearlever to gearbox remote, fit bolts and
tighten to
25 Nm. (18 lbf.ft)
61.Fit gear lever gaiter and ring to transmission
tunnel and secure with nuts.
62.Connect high/low switch multiplug.
63.Position SRS harness to transmission tunnel.
64.Connect multiplug to airbag DCU. Ensure
connector latching mechanism is correctly
engaged.
65.Fit transmission tunnel insulation pad to
transmission tunnel and position multiplugs
through pad.
66.Fit radio.
See ELECTRICAL, Repair.
67.Connect multiplugs at base of passengers side
A post.
68.Fit passengers side A post lower trim panel
and secure with screw.
69.Engage door aperture seal to door aperture.
70.Position fascia lower closing panel and engage
diagnostic connector to panel.
71.Position closing panel to fascia and secure with
scrivets.
72.Connect vacuum hose to clutch and brake pedal
switches.
73.Connect multiplugs to clutch and brake pedal
switches.
74.Position harness to drivers side carpet.
75.Connect multiplugs to BeCM.
76.Connect multiplugs at base to drivers side A
post.
77.Position earth wires to A post stud, fit and
secure captive nut.
78.Fit drivers side carpet retainer and engage to
clips.
79.Fit seat base trim and secure with trim studs and
screw.
80.Fit seat base fuse box cover.
81.Fit drivers side lower A post trim and secure
with screw.
82.Fit steering column.
See STEERING, Repair.
83.Fit radio.See ELECTRICAL, Repair.
84.Fit centre console.See this section.
85.Remove tape from heater intake ducts.
86.Engage heater intake seals to scuttle apertures.
87.Fit heater intake housings and secure with
screws.
88.Fit pollen filters to intake housings. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
26
REPAIR 89.Fit wiper motor and linkage.
See WIPERS AND
WASHERS, Repair.
90.Fit scuttle side panel to scuttle and secure with
bolts.
91.Connect heated screen multiplug and engage
multiplug to scuttle side panel bracket.
92.Remove caps from heater matrix pipes.
93.Engage heater matrix grommet to bulkhead
aperture.
94.Connect heater hoses to heater matrix and
secure with clips.
95.Remove caps from air conditioning pipes and
TXV.
96.Lubricate NEW O ring seals with clean
compressor oil and fit to air conditioning pipes.
97.Connect air conditioning pipes to TXV, position
clamp and fit bolt.
98.Tighten clamp bolt to
6 Nm. (4 lbf.ft)
99.Charge air conditioning system.See AIR
CONDITIONING, Adjustment.
100.Fill coolant system.See COOLING SYSTEM,
Repair.
101.Connect both battery terminals, earth lead last.FASCIA CLOSING PANEL
Service repair no - 76.46.27
Remove
1.Remove closing panel screw covers and screws.
2.Lower closing panel.
3.Disconnect air tube from closing panel, remove
panel.
Refit
4.Reverse removal procedure.