Land Rover Range Rover Body Repair Rover Manual

							CHASSIS AND BODY
77
REPAIR
32.Apply a continuous bead of sealer to windscreen
as shown.
33.Fit suction lifters to glass.
34.With assistance, position glass centrally, using
previously made tape markings and lower onto
supports. Seat glass to spacer blocks.
CAUTION: Do not apply heavy pressure to
the sides of the screen. Lightly press
screen from centre outwards until edges
are to required gap. Pushing screen edges into
position can bend screen and lead to cracking in
service.
35.Remove protection from fascia and bonnet.
36.Remove masking tape.
37.If fitted, connect heating element multiplugs and
earth wire.
38.Remove clips from upper screen finisher.
39.Fit clips to body studs. Position upper screen
finisher and engage to clips.40.Fit plenum panels.
See HEATING AND
VENTILATION, Repair.
41.Fit interior mirror.See this section.
If Cutting Wire and Handles Used
42.Remove masking from leading edge of
headlining.
43.Fit map/courtesy lamp assembly.
See
ELECTRICAL, Repair.
44.Fit sun visors.See this section.
45.Fit A post finishers.See this section.
CAUTION: A curing time of 6 hours is
recommended. During this time, leave the
windows open and DO NOT slam the
doors. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
78
REPAIR WINDSCREEN LOWER FINISHER
Service repair no - 76.43.41
Remove
1.Remove both windscreen side finishers.
See
this section.
2.Remove both windscreen wiper arms.See
WIPERS AND WASHERS, Repair.
3.Release 10 clips securing windscreen lower
finisher.
4.Remove windscreen lower finisher.
Refit
5.Reverse removal procedure.WINDSCREEN SIDE FINISHER
Service repair no - 76.43.39
Remove
1.Lift side finisher seal to reveal fixings.
2.Remove 4 screws securing side finisher.
3.Remove side finisher.
Refit
4.Position side finisher. Secure side with screws. 
						

							CHASSIS AND BODY
79
REPAIR BACKLIGHT GLASS
Service repair no - 76.81.10
NOTE: The following equipment is
required:
masking tape.
Sharp knife.
Cutting wire and handles, or a reciprocating
blade, powered cutting knife*.
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 are required.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
Remove
1.Remove interior trim from tailgate,
See this
section.
2.Release backlight lower finisher from 7 clips.
3.Remove backlight lower finisher.
4.Remove backlight side finishers.
NOTE: Side finishers are secured to
backlight with P.U. sealer. New backlight
glasses are supplied with side finishers
fitted. Side finishers are available separatley if
original glass is to be refitted.
5.Remove rubber finisher from upper edge of
backlight glass.6.Protect tailgate panel with masking tape.
7.Disconnect two Lucar terminals from screen
heater element.
Removal Using Reciprocating Blade Tool
8.Cut through P.U. adhesive along sides of screen
using flat blade.
9.Using a U shaped blade, cut through adhesive
bead along upper and lower edges of glass.
CAUTION: Access around lower clips is
restricted. Manoeuvre blade to cut through
as much adhesive as possible.
10.Attach suction lifters to glass. With assistance,
cut through remaining sealant around lower
clips.
11.With assistance, remove backlight glass. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
80
REPAIR Removal Using Cutting Wire Handles
12.Using a sharp knife, cut through P.U. sealer at
side of backlight.
13.Insert cutting wire through knife cut and fit
handles, as shown, with approximatley 200mm
of wire between handles.
14.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
finisher clips to reduce strain on wire.
15.With assistance, remove backlight glass.
Refit
16.Carefully cut old sealer from body flange to
obtain a smooth surface, approximately 2mm
thick.
CAUTION: Do not cut down to painted
surface.
17.Renew broken finisher clips as necessary.
Position finisher clips centrally on tailgate studs.
NOTE: Clips control height and seating of
lower glass edge.18.Position and centralize new backlight to tailgate.
Apply tape reference mark to aid final fitment.
19.Position new backlight on felt covered surface.
20.Fit and centralize rubber finisher to top of glass.
NOTE: Finisher controls seating depth of
glass top edge.
21.Apply cleaning solvent to sealing surface of
glass and body flange.
CAUTION: Do not touch cleaned or primed
areas with fingers.
22.Shake primer tins for at least 30 seconds. Apply
body primer to sealing surface of body flange
using supplied applicator.
23.Apply glass primer to sealing surface of glass.
CAUTION: Use a separate applicator for
each primer.
24.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. 
						

							CHASSIS AND BODY
81
REPAIR 25.Apply a continuous bead of sealer to backlight
as shown.
26. Original glass:Apply 3mm bead of sealer to
channels of side finishers and fit to backlight.
27.Fit suction lifters to glass.
28.With assistance, fit glass and centralize to
previously made tape markings. Set glass to
correct depth.
29.Connect screen heater.
30.Remove reference and protective tapes.
31.Position lower finisher and secure to clips.
32.Fit interior trim to tailgate,
See this section.
CAUTION: A curing time of 6 hours is
recommended. During this time, leave the
windows open and DO NOT slam the
doors.REAR QUARTER LIGHT
Service repair no - 76.81.20
NOTE: The following equipment is
required:
Masking tape.
Sharp knife.
Cutting wire and handles, or a reciprocatig
blade, powered cutting knife*.
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.
NOTE: New rear quarter glass is supplied
with exterior trim fitted.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
Remove
1.Remove parcel tray support,
See this section.
2.Remove both E post trims,See this section.
3.Remove relevant B post upper trim,See this
section.
4.Remove relevant side interior lamp assembly,
See ELECTRICAL, Repair.
5.Remove relevant grab handle,See this
section.
6.Remove relevant exterior E post finisher,See
this section. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
82
REPAIR 7.Remove 2 trim studs securing headlining to E
posts.
8.Release headlining from tailgate seal. Lower
headlining as necessary during glass removal to
provide access to sealant along top edge of
glass.
9.Disconnect aerial amplifier plugs.
10. R.H. glass only:Disconnect alarm receiver plug.
11.Protect surrounding area of body using masking
tape.Removal Using Reciprocating Blade Tool
12.Lift flip seal to reveal trim fixings.
13.Remove 2 screws securing exterior trim to D
post.
14.Cut through P.U. adhesive from inside of glass
along lower and side edges. 
						

							CHASSIS AND BODY
83
REPAIR
CAUTION: Manoeuvre knife blade around 3
parcel tray support clips. Ensure aerial
amplifier and alarm reciever plugs do not
become damaged.
15.Attach suction lifters to glass. With assistance,
cut through sealant along top of edge glass.
16.Remove rear quarter glass.
Removal Using Cutting Wire Handles
17.Protect surrounding area of body using masking
tape.
18.Lift flip seal to reveal trim fixings.
19.Remove 2 screws securing exterior trim to D
post.
20.Carefully cut through adhesive bead between
glass and trim using a sharp knife.
NOTE: A reciprocating blade cutting tool,
such as FEIN Special Cutter will ease the
removal of the trim. Use a cranked blade
with an effective length of not more than 22mm.
21.Remove and discard quarter light trim.
NOTE: Rear quarter lights are supplied
with finisher fitted. Finisher is not
available separately.
22.Using a sharp knife, cut through P.U. sealer at
forward edge of quarter glass.23.Insert cutting wire through knife cut and fit
handles, as shown, with approximatley 200mm
of wire between handles.
24.With assistance, wedge tube of handles 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
as last sealant is cut.
NOTE: When cutting along lower edge,
manoeuvre wire between glass edge and
parcel tray support clips to reduce strain
on wire.
CAUTION: Ensure aerial amplifier and
alarm receiver plugs do not become
damaged.
25.Remove rear quarter glass. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
84
REPAIR Refit
26.Carefully cut old sealer from body flange to
obtain a smooth surface, approximatley 2mm
thick.
CAUTION: Do not cut down to painted
surface.
27.Position new quarter glass on felt covered
surface.
28.Apply cleaning solvent to sealing surface of
glass and body flange.
CAUTION: Do not touch cleaned or primed
areas with fingers.
29.Stick 4 self adhesive spacers on the inside edge
of glass at corners.
30.Shake primer tins for at least 30 seconds. Apply
body primer to sealing surface of body flange
using supplied applicator.
31.Apply glass primer to sealing surface of glass.
CAUTION: Use a separate applicator for
each primer.
32.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.33.Apply a continuous bead of sealer to rear quarter
glass as shown.34.Fit suction lifters to glass.
35.With assistance, fit glass and align to body. Seat
glass to spacer rubbers.
36.Remove protective tape.
37.Secure exterior trim to D post with screws.
38.Connect aerial amplifier plug.
39. R.H. glass only:Connect alarm receiver plug.
40.Position headlining and engage beneath tailgate
flip seal.
41.Secure headlining to E posts with trim studs.
42.Fit exterior E post finisher,
See this section.
43.Fit grab handle,See this section.
44.Fit side interior lamp assembly,See
ELECTRICAL, Repair.
45.Fit B post upper trim,See this section.
46.Fit E post trims,See this section.
47.Fit parcel tray support,See this section.
CAUTION: A curing time of 6 hours is
recommended. During this time, leave the
windows open and DO NOT slam the
doors. 
						

							PANEL REPAIRS
1
SEALING AND CORROSION PROTECTION CORROSION PROTECTION
Factory Treatments
The New Range Rover is treated with the following
anti-corrosion materials in production:
·A PVC-based underbody sealer material
which is sprayed onto the underfloor, wheel
arches and undersill areas.
·An application of cavity wax which is
sprayed into enclosed cavities, box
sections and lower inner door panels.
·A final coating of underbody wax to cover
the complete underfloor including
components but excluding brake discs.
·A coat of protective lacquer or wax applied
to the engine bay area.
In addition to the above measures, all steel parts are
zinc-coated both sides, and front wings, door and
tailgate skins are manufactured from aluminium.
The information given on the following pages is
intended as a guide and shows the areas to be
treated with cavity wax, as well as the access holes
used during manufacture.See GENERAL
INFORMATION DATA, Sealing and corrosion
protection section.
Underbody Wax
A coat of underbody wax is applied to the entire
underbody inboard of the sill vertical flanges, and
covers all moving and flexible components EXCEPT
for wheels and tyres, brakes and exhaust. The wax is
applied over paints and underbody sealers.
The underbody wax must be reinstated following all
repairs affecting floor panels.
CAUTION: Old underbody wax must be
completely removed from a zone
extending at least 200mm (7.9in.) beyond
the area where new underbody sealer is to be
applied.Underbody Sealer
Underfloor areas and outer sill panels are treated with
a Plastisol PVC underbody sealer. This material is not
suitable for re-treatment.
When repairing areas of underbody sealer, strip the
factory-applied material back to a suitable break point,
ensuring that a clean metal surface is exposed and
that the edge of the existing material adheres soundly
to the panel.
Blanking plugs and grommets in the floor pan (except
those used for wax injection) MUST be fitted before
underbody sealer application. Heat-fusible plugs
which have been disturbed should either be refitted
with the aid of a hot air blower or replaced with rubber
grommets.
NOTE: Application of new underbody
sealer must be carried out between primer
and surfacer paint operations. Areas
where seam sealer is used should be re-treated as
necessary before application of underbody sealer.
CAUTION: Ensure that suspension units,
wheels, tyres, power unit, driveshafts,
exhaust and brakes (including all
mounting points) are shielded prior to application
of fresh underbody sealer.
Engine Bay Wax
Reinstate protective engine bay wax disturbed during
repairs using the approved material. 
						

							77PANEL REPAIRS NEW RANGE ROVER
2
SEALING AND CORROSION PROTECTION Stone Chip Resistant Paint/Primer
Re-treat all areas protected with factory-applied
anti-chip primer with suitable approved material in
repair.
Inspections during Maintenance Servicing
It is a requirement of the Land Rover Corrosion
Warranty that the vehicle body is checked for
corrosion by an authorised Land Rover dealer at least
once a year, to ensure that the factory-applied
protection remains effective.
Service Job Sheets include the following operations to
check bodywork for corrosion:
·With the vehicle on a lift, carry out visual
check of underbody sealer for damage.
·With the vehicle lowered, inspect exterior
paintwork for damage and body panels for
corrosion.
NOTE: Wash the vehicle and ensure that it
is free from deposits prior to inspection. It
is part of the owners responsibility to
ensure that the vehicle is kept free of
accumulations of mud which could accelerate the
onset of corrosion. The Dealer MUST wash the
vehicle prior to inspection of bodywork if the
customer has offered it in a dirty condition, and
pay special attention to areas where access is
difficult.
NOTE: The checks described above are
intended to be visual only. It is not
intended that the operator should remove
trim panels, finishers, rubbing strips or sound
deadening materials when checking the vehicle
for corrosion and paint damage.
With the vehicle on a lift, and using an inspection or
spot lamp, visually check for the following:
·Corrosion damage and damaged
paintwork, condition of underbody sealer
on front and rear lower panels, sills and
wheel arches.
·Damage to underbody sealer on main floor
and chassis members. Corrosion in areas
adjacent to suspension mountings and fuel
tank fixings.
NOTE: The presence of small blisters in
PVC underbody sealer is acceptable,
providing they do not expose bare metal.
Special attention must be paid to signs of damage
caused to panels or corrosion material by incorrect
jack positioning.
It is essential to follow the correct jacking and lifting
procedures.See GENERAL INFORMATION DATA,
Information section.
With the vehicle lowered, visually check for evidence
of damage and corrosion on all painted areas, in
particular the following:
·Front edge of bonnet.
·Visible flanges in engine compartment and
boot.
·Lower body and door panels.
Where bodywork damage or evidence of corrosion is
found during inspection, rectify this as soon as is
practicable, both to minimise the extent of the damage
and to ensure the long term effectiveness of the
factory-applied corrosion protection treatment. Where
the cost of rectification work is the owners
responsibility, the Dealer must advise the owner and
endorse the relevant documentation accordingly.
Where corrosion has become evident and is
emanating from beneath a removable component
(e.g. trim panel, window glass, seat etc.), remove the
component as required to permit effective rectification.