Land Rover Range Rover Body Repair Rover Manual

							CHASSIS AND BODY
67
REPAIR Refit
13.With assistance, position tailgate to hinges. Align
marks. Secure with bolts. Tighten to
25 Nm. (18
lbf.ft)
14.With assistance, connect gas struts to tailgate.
15.Remove protective tape from roof panel.
16.Attach draw string to washer tube. Pull tube
along roof into position at E post. Remove draw
string.
17.Connect tube to non-return valve.
18.Feed 3 tailgate harness multiplugs through roof
panel. Connect to body harness.
19.Secure tailgate harness protective sleeve to roof
panel.
20.Reposition headlining at E posts. Secure with
studs.
21.Fit load space access panel. Secure with turn
buckles.
22.Fit both E post finishers.
Adjust
23.Check alignment of lower tailgate.
See this
section.
24.Align tailgate to aperture by adjusting position of
hinges on tailgate or body.
25.Align tailgate to adjacent body panels by
adjusting position of hinges on body.
NOTE: To prevent wind noise, ensure top
edge of tailgate does not stand proud of
roof panel.TAILGATE - LOWER
Service repair no - 76.28.30
Remove
1.Remove parcel tray support trim from RH side of
luggage area.
See this section.
2.Disconnect tailgate harness multiplug from body
harness. Release grommet from lower of E
post. Pull harness from body.
3.Fit protection under tailgate.
4.Mark outline of hinges to body to aid
reassembly.
5.Remove bolt securing each check strap to body.
Collect spacer and fibre sealing washer. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
68
REPAIR 6.With assistance, remove bolts securing tailgate
hinges to body. Remove tailgate complete with
hinges.
Refit
7.With assistance, position tailgate to body.
Secure with bolts. Tighten to
25 Nm. (18 lbf.ft)
8.Position support stays with spacer and sealing
washer next to body. Tighten to
22 Nm. (16
lbf.ft)
9.Remove protection.
10.Feed tailgate harness into E post. Connect
multiplug to body harness.
11.Fit harness grommet to E post.
12.Fit parcel tray support trim.
See this section.
Adjust
13.Align tailgate to aperture by adjusting position of
hinges on tailgate or body.
14.Align tailgate to adjacent body panels by
adjusting position of hinge to tailgate.
15.When tailgate alignment is correct, adjust height
and inboard/outboard position of each striker.
Tighten striker bolts. Check for correct latching.
16.Slacken bolts, re-adjust striker positions as
necessary. Tighten to
8 Nm. (6 lbf.ft)
TAILGATE STRIKER
Service repair no - 76.37.26
Remove
1.Remove 2 bolts securing striker. Remove striker.
Refit
2.Position striker. Secure with bolts
3.Close tailgate. Check alignment.
4.If necessary, open tailgate, slacken bolts, realign
striker. Re-tighten bolts. 
						

							CHASSIS AND BODY
69
REPAIR TAILGATE LATCH
Service repair no - 76.37.17
Remove
1.Release studs securing tailgate board. Remove
board.
2.Release clips securing operating rods to tailgate
centre latch. Release rods.
3.Disconnect latch multiplug.
4.Remove 2 bolts securing latch to tailgate.
Remove latch.
Refit
5.Reverse removal procedure.TAILGATE LATCH - OUTER
Service repair no - 76.37.73
Remove
1.Release studs securing tailgate board. Remove
board.
2.Release clip securing outer latch rod. Disconnect
rod from centre latch. 
						

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70
REPAIR 3.Remove 2 bolts securing outer latch to tailgate.
Remove latch and rod.
4.Rotate release rod 90Ê to remove from outer
latch.
Refit
5.Reverse removal procedure.UPPER TAILGATE - INTERIOR TRIM
Service repair no - 76.34.13
Remove
Lower trim assembly
1.Release load space lamp from trim panel,
disconnect 2 Lucar terminals and remove lamp.
2.Remove 6 screws securing trim panel to side
trims and tailgate.
3.Release 4 studs securing trim panel to tailgate.
4.Disconnect high level stop lamp multiplug, if
fitted.
5.Remove lower trim assembly.
Upper trim
6.Remove 6 screws securing trim panel to tailgate. 
						

							CHASSIS AND BODY
71
REPAIR 7.Remove trim panel and collect 2 foam pads.
Side trims
8.Release 3 studs securing each side trim.
9.Remove 2 side trims.
Refit
10.Reverse removal procedure.TAILGATE STRUT
Service repair no - 76.40.33
Remove
1.Secure tailgate in open position using suitable
support.
2.Release clips securing strut to ball joints.
Remove strut.
Refit
3.Reverse removal procedure. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
72
REPAIR WHEEL ARCH LINER - FRONT
Service repair no - 76.10.48
Remove
1.Raise the vehicle.
WARNING: Support on safety stands.
2.Remove relevant road wheel.
3.Remove 3 screws securing mud flap. Remove
mud flap.
4.Remove 8 studs securing wheel arch liner.
Refit
5.Position liner and secure with trim studs.
6.Fit mud flap and secure with screws.
7.Refit road wheel. Secure with nuts. Tighten to
108 Nm. (80 lbf.ft)
8.Remove safety stands. Lower vehicle.WHEEL ARCH LINER - REAR
Service repair no - 76.10.49
Remove
1.Raise the vehicle.
WARNING: Support on safety stands.
2.Remove relevant road wheel.
3.Remove screws from wheel arch liner fixings.
Remove fixings.
4.Remove liner.
Refit
5.Position liner. Fit liner fixings. Secure with
screws.
6.Refit road wheel. Secure with nuts. Tighten to
108 Nm. (80 lbf.ft)
7.Remove safety stands. Lower vehicle. 
						

							CHASSIS AND BODY
73
REPAIR WINDSCREEN
Service repair no - 76.81.01
NOTE: The following equipment is
required:
masking tape;
sharp knife;
reciprocating blade, powered cutting knife*, or
cutting wire and handles;
suction lifters;
windscreen repair kit;
sealer applicator gun.
* A reciprocating blade cutting tool, such as FEIN
Special Cutter, is recommended for this operation. A
flat blade, with an effective length of at least 25mm
and a U shaped blade of at least 30mm is required.
CAUTION: Extreme care is necessary to
ensure that paintwork and trim does not
become damaged during the removal
process.
Particular care should be taken when using
cutting wire and handles to avoid damage to seal
along leading edge of fascia.
WARNING: Wear protective gloves when
handling glass, solvents and primers.Remove
1.Remove interior mirror.
See this section.
2.Remove plenum panels.See HEATING AND
VENTILATION, Repair.
3.Insert a thin plastic strip, such as a credit card,
between windcreen upper finisher and roof
panel.
4.Disengage 8 clips securing upper finisher by
sliding clips towards left hand side of vehicle.
5.Remove upper screen finisher. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
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REPAIR
6.If fitted, disconnect heating element multiplugs.
Disconnect heating element earth wire. Tape
heater connections onto windscreen to prevent
fouling during removal procedure.
7.Mask around windscreen aperture to protect
paintwork.
8.Fit protective cover over fascia and bonnet.
Removal Using Reciprocating Blade Tool
9.Cut through P.U. adhesive along sides of screen
using flat blade.
10.Using a U shaped blade, cut through adhesive
bead along upper and lower edges of screen.
CAUTION: Access to adhesive around
lower screen supports is restricted.
Manoeuvre blade to cut as much sealant
from around screen supports as possible.11.Attach suction lifters to glass. With assistance,
cut through remaining sealant around screen
supports using a sharp knife.
12.With assistance, remove windscreen glass.
Removal Using Cutting Wire and Handles.
13.Remove both A post finishers.
See this
section.
14.Remove both sun visors.See this section.
15.Remove map/courtesy lamp assembly.See
ELECTRICAL, Repair. 
						

							CHASSIS AND BODY
75
REPAIR
16.Mask along leading edge of headlining.
17.Using a sharp knife, cut through P.U. sealer at
side of screen, towards lower corner.
18.Insert cutting wire through knife cut and fit
handles, as shown, with approximately 200 mm
(8 in) of wire between handles.
19.With assistance, wedge tube of handle A
between glass and body, ahead of the cutting
position, and carefully cut the sealer using a
continuous pull on handle B from the outside.
Cut side and top edges first. Attach suction lifters
and restrain glass as last of sealant is cut.
NOTE: When cutting along lower edge,
manoeuvre wire between glass edge and
screen supports to reduce strain on wire.
20.Attach suction lifters to glass. With assistance,
remove windscreen.Refit
21.carefully cut old sealer from body flange to
obtain a smooth surface, approximately 2 mm
(1/16 in) thick.
CAUTION: Do not cut down to painted
surface.
22.Inspect supports, renew if damaged.
23.Position screen on felt covered surface.
24.If original screen is to be refitted, cut old sealer
from glass to obtain a smooth surface,
approximately 2 mm (1/16 in) thick. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
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REPAIR
CAUTION: Do not cut down to surface of
glass.
25.Position and centralise new windscreen to body.
Apply tape reference marks to aid final fitment.
Remove screen and position to work surface.
26.Apply cleaning solvent to sealing surface of
glass and body flange.
CAUTION: Do not touch cleaned or primed
areas with fingers.
27.Position 5 screen spacer blocks on inside edge
of glass, over cut-out marks in obscuration band.
28.If necessary, peel off backing strip and stick
foam glazing dam along inside surface of glass,
approximately 13 mm (1/2 in) from top edge.29.Shake primer tins for at least 30 seconds. Apply
body primer to sealing surface of body flange
using supplied applicator.
30.Apply glass primer to sealing surface of glass.
CAUTION: Use a separate applicator for
each primer.
31.Remove lid from sealer cartridge, remove
crystals, pierce membrane and fit pre-cut nozzle.
Fit cartridge to applicator gun.
NOTE: The profile of the nozzle must be
modified slightly to produce the required
bead section.