Land Rover Range Rover Body Repair Rover Manual
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PANEL REPAIRS 13 SEALING AND CORROSION PROTECTION 22. Structural adhesive 23. Semi-structural adhesive/anti-flutter material 24. Seam sealer light 25. Seam sealer light, structural adhesive 26. Seam sealer light27. Seam sealer 28. Seam sealer 29. Seam sealer heavy 30. Seam sealer light 31. Seam sealer light All areas symmetrically opposite to those shown are also treated. See GENERAL INFORMATION DATA, Information section.
77PANEL REPAIRS NEW RANGE ROVER 14 SEALING AND CORROSION PROTECTION 34. Seam sealer light 35. Seam sealer light 36. Seam sealer light 37. Seam sealer light All areas symmetrically opposite to those shown are also treated. See GENERAL INFORMATION DATA, Information section.
PANEL REPAIRS 15 SEALING AND CORROSION PROTECTION 32. Brushable sealer 33. Seam sealer light 38. Seam sealer light39. Seam sealer light 40. Seam sealer light 41. Seam sealer light All areas symmetrically opposite to those shown are also treated. See GENERAL INFORMATION DATA, Information section.
PANEL REPAIRS 1 PANELS PAINT Replacement Panels Service panels are supplied with a cathodic primer coating as part of the panel protection, and in compliance with the vehicles Corrosion Warranty where applicable.DO NOT remove this primer before paint refinishing. In the event of localised surface damage or imperfections, ensure that the minimum of primer is removed during rectification work for effective repair. Rectify damage by panel beating or straightening. To remove corrosion or paint runs on outer surfaces, abrade primer coat in the affected area as necessary using the following procedure: 1. Clean the panel using a solvent wipe. 2. Treat exposed areas of metal with an etch phosphate process. 3. Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer, or an integrated etch primer/filler. Bolted Panels Before fitting bolt-on panels, ensure that all mating and adjacent surfaces on the vehicle and replacement panel are free from damage and distortion. Rectify if necessary as described in this section, and apply preformed strip sealer where specified.Welded Panels 1. Remove primer from the immediate vicinity of new and existing panel flanges, cleaning to bright metal finish. 2. On joints to be spot welded, apply weld-through zinc rich primer to joint faces of both flanges. Make spot welds while primer is still wet or according to the manufacturers instructions. 3. Dress accessible weld seams. 4. Clean panel using solvent wipe. 5. Treat bare metal with an etch phosphate process. 6. Re-treat repaired areas. NOTE: It is not satisfactory to use weld-through, zinc rich primers in conjunction with arc or MIG welding. Sectioned Panels When replacing part or sectioned panels, the basic procedure is the same as for welded panels described above, with the following variations: 1. Remove primer from both new and existing joint faces, cleaning to a bright metal finish. 2. Where an overlap joint with the existing panel is to be spot welded, apply weld-through, zinc rich primer to both joint faces and spot weld while the primer is still wet or according to the manufacturers instructions. 3. MIG weld butt joints where applicable. 4. Clean the panel with a solvent wipe. 5. Treat bare metal areas using an etch phosphate process. 6. Re-prime affected areas as necessary as for rectifying transit damage.See this section. 7. Treat the inner faces of lap or butt joints with a suitable cavity wax.See Sealing and corrosion protection.
77PANEL REPAIRS NEW RANGE ROVER 2 PANELS Clinch Panels (eg Doorskins etc.) 1. Abrade primer on new and existing panel joint faces, and clean using a solvent wipe. 2. Apply metal-to-metal adhesive where applicable. 3. Where joints are to be spot welded, apply suitable weld-through, zinc rich primer to weld areas. 4. Where joints are to be MIG, arc or gas welded, apply zinc rich primer in adjacent areasbut leave the welded area untreated. 5. To retain the panel whilst clinching the flanges, tack spot weld or plug weld as appropriate. 6. Clean the panel with a solvent wipe. 7. Treat bare metal areas with a suitable etch phosphate process. 8. Re-prime affected areas as necessary as for rectifying transit damage.See this section. NOTE: Replacement doors, bonnets and tailgates must be treated with a suitable seam sealer on clinched seams, following the primer coat. Paint Refinishing 1. Seal all accessible exterior and interior seams with an approved seam sealer. Certain joints such as sill lower flange seams must be left unsealed. 2. Apply a suitable anti-chip primer where specified. 3. Apply a two-pack paint refinishing system. 4. Repair any damage to underbody sealers either at this stage or before paint operations.Paint Repairs Before carrying out paintwork repairs, the vehicle must be thoroughly cleaned using either a steam cleaner or high-pressure washer. Wash locally repaired areas using a mild water-mixable detergent and wipe them clean with solvent, immediately prior to paint application. Abrade damaged paintwork where bare metal has been exposed until the metal is clean and extends beyond the area of immediate damage. Treat the bare metal with an etch phosphate to remove all traces of rust and provide a key for new paint coats. Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer or an integrated etch primer/filler, and follow with a two-pack paint system. Those surfaces not receiving paint must be treated with a cavity wax following paint operations. A. Two-pack top coat B. Two-pack primer filler and etch primer C. Etch phosphate
PANEL REPAIRS 3 PANELS SERVICE CONDITION OF PANELS Bodyshell Assembly Bodyshells, which are also supplied with sunroof aperture (not shown), are serviced less front wings, bonnet,door assemblies and upper/lower tailgates. Headlamp and Grille Panel Headlamp/grille panels are serviced as a complete assembly including a bolt-on bonnet lock platform.Front Wing Front wings are serviced as separate bolt-on aluminium panels. Bonnet Bonnets are serviced less hinges which are available separately.
77PANEL REPAIRS NEW RANGE ROVER 4 PANELS Valance and Wheelarch Valance and wheelarch panels are serviced as a separate part and are fitted to the bulkhead. Front Sidemember Front sidemembers are fitted to the A post and valance/wheelarch. A Post Lower The A post lower is fitted to the bulkhead, inner sill and A post reinforcement.A Post Panels A posts are serviced as separate A post repair panel (1), upper A post (2) and A post reinforcement (3). B Post Panels B posts are serviced as separate BC post reinforcement (1) and inner BC post panels (2, 3).
PANEL REPAIRS 5 PANELS Door Assemblies and Outer Door Panels Door assemblies comprise an aluminium outer panel fitted to a steel frame.BC Post Repair Panel BC posts are serviced as a complete panel including the sill. Roof Assembly Roof assemblies are serviced complete with inner frames.
77PANEL REPAIRS NEW RANGE ROVER 6 PANELS Outer Rear Quarter Panel Outer rear quarters are serviced as a separate panel. Lower Panel Lower panels are serviced as an assembly including the tailgate lock reinforcement.Upper Tailgate Assembly Upper tailgates are serviced less hinges, which are available separately. Lower Tailgate Assembly Lower tailgate assemblies comprise an aluminium outer panel fitted to a steel frame and are serviced less hinges, which are available separately. Lower tailgate outer panels are also serviced as separate items.
PANEL REPAIRS 7 PANELS Inner Rear Quarter Panel Inner rear quarters are serviced as an assembly with associated reinforcements and brackets. Rear Crossmember Panel The rear crossmember is serviced as a separate panel.Load Floor Side Load floor sides are serviced as a separate panel. Rear Crossmember Extension The rear crossmember extension is serviced separately.