Land Rover Range Rover Body Repair Rover Manual

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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 is recommended that
test coupons of the same metal gauges
and materials are produced to carry out
peel tests to ensure that welding
equipment being used can produce a
satisfactory joint. Plug welds must be used
if a satisfactory spot weld cannot be
produced.
·The electrode arms on hand-held spot
welding guns must not exceed 300mm in
length.
·Single-sided spot welding is not
acceptable.
·Brazing and gas welding are not
acceptable EXCEPT where they have been
specified in production.
·Where 3 metal thicknesses or more are to
be welded together it is imperative to use
MIG plug welds to ensure joint strength.
·MIG plug welds must be used in repair
joints where there is no access for a
resistance spot welder. To replace each
production spot weld a hole must be drilled
and/or punched, and a MIG weld then
made in its place. The number of plug
welds must match exactly the number of
spot welds which have been removed.
·Where holes are left in an existing panel
after removal of the spot welds, a single
MIG plug weld will be made in each hole as
appropriate.·The replacement welds in the welding
diagrams are denoted by the following
symbols:
A. Single thickness plug welds
B. Multiple thickness plug welds
C. MIG seam weld
Seat Belt Anchorages
Seat belt anchorages are safety critical. When making
repairs in these areas it is essential to follow design
specifications. Note that High Strength Low Alloy
(HSLA) steel may be used for seat belt anchorages.
Where possible, the original production assembly
should be used, complete with its seat belt
anchorages, or the cut line should be so arranged that
the original seatbelt anchorage is not disturbed.
All welds within 250mm (9.9in.) of seat belt
anchorages must be carefully checked for weld
quality, including spacing of spot welds.
WARNING: Body parts incorporating seat
belt anchorages MUST be renewed
completely if damaged beyond repair, as
the welds in these areas are safety critical and
cannot be disturbed. 
						

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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 fitted to an air
drill, or alternatively a hand held wire brush.
NOTE: In wheelarch areas it may be
necessary to soften underbody coating
using a hot air gun, prior to exposing spot
welds.
2.Cut out welds using a cobalt drill.
3.Alternatively use a clamp-type spot weld
remover. 
						

							PANEL REPAIRS
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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 the
risk of toxic fumes caused by generated
heat. CARE MUST BE TAKEN TO AVOID
EXCESSIVE HEAT BUILD UP WHICH MAY BE
CAUSED BY THIS EQUIPMENT.
7.As an alternative a disc sander may be used.
Straighten existing joint edges using shaping
block and hammer. 
						

							77PANEL REPAIRS NEW RANGE ROVER
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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 finish. This must include inner
as well as outer faces.
11.Apply suitable weld-through primer to panel joint
surfaces to be welded, using brush or aerosol
can. 
						

							PANEL REPAIRS
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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 for resistance spot welding and
shape electrode tips using a tip trimmer.
NOTE: To maintain efficiency, the tips will
require regular cleaning with emery cloth.
CAUTION: Use electrode arms not
exceeding 300mm (11.8in.) in length.
14.Fit resistance spot welding arms and test
equipment for satisfactory operation, using test
coupons. Where monitoring equipment is not
available, verify weld strength by checking that
metal around the weld puddle pulls apart under
tension during pulling. 
						

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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. 
						

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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 repair operations itemise body
trim components which must be removed for access
during each repair.See Repairs section.
Because of the unpredictable nature of accident
damage, the items listed make no allowance for any
difficulties which may be found in removal and only
apply to an undamaged vehicle. No allowance is
made for any difficulties which may be found during
panel removal. Damaged body trim items must be
renewed as necessary following body repairs. 
						

							PANEL REPAIRS
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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 Workshop Manual -
ELECTRICAL.
11.Remove bonnet.See CHASSIS AND BODY,
Repair.
12.Remove bonnet strut.See CHASSIS AND
BODY, Repair.
13.Remove bonnet lock RH or LH.See CHASSIS
AND BODY, Repair.
14.Remove wheel arch liner - front.See CHASSIS
AND BODY, Repair.
15.Remove front door assembly.See CHASSIS
AND BODY, Repair.
16.Remove A post trim.See CHASSIS AND
BODY, Repair.
17.Remove fascia.See CHASSIS AND BODY,
Repair.
18.Remove front wing.
19.Remove engine.
See Workshop Manual -
ENGINE.
20.Remove gearbox.See Workshop Manual -
GEARBOX.
Refit
NOTE: In this operation the valance and
wheelarch is fitted in combination with a
front sidemember.
21.Prepare and clean panel joint faces. Punch or
drill holes in new valance and wheelarch for plug
welding as shown.
22.Reverse removal procedure.
23.Remove stands and lower vehicle. 
						

							77PANEL REPAIRS NEW RANGE ROVER
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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 headlamp.See Workshop Manual -
ELECTRICAL
11.Remove bonnet.See CHASSIS AND BODY,
Repair.
12.Remove bonnet strut.See CHASSIS AND
BODY, Repair.
13.Remove bonnet lock RH or LH.See CHASSIS
AND BODY, Repair.
14.Remove wheel arch liner - Front.See CHASSIS
AND BODY, Repair.
15.Remove front door assembly.See CHASSIS
AND BODY, Repair.
16.Remove A post trim.See CHASSIS AND
BODY, Repair.
17.Remove front wing.Refit
18.Prepare and clean panel joint faces. Punch or
drill holes in new front sidemember for plug
welding as shown.
WARNING: Remove ALL traces of
adhesive from valance upper edge before
plug welding.
19.Reverse removal procedure.
20.Remove stands and lower vehicle.