Land Rover Range Rover Body Repair Rover Manual
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PANEL REPAIRS 3 REPAIR UPPER A POST PANEL AND REPAIR PANEL 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 both airbag modules. See SUPPLEMENTARY RESTRAINT SYSTEM, Repair. 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 windscreen.See CHASSIS AND BODY, Repair. 11.Remove headlamp.See Workshop Manual - ELECTRICAL. 12.Remove bonnet.See CHASSIS AND BODY, Repair. 13.Remove wheel arch liner - front.See CHASSIS AND BODY, Repair. 14.Remove front door assembly.See CHASSIS AND BODY, Repair. 15.Remove A post trim.See CHASSIS AND BODY, Repair. 16.Remove fascia assembly.See CHASSIS AND BODY, Repair. 17.Remove front wing.Refit NOTE: In this operation, the A post panel and repair panel are replaced in combination with the lower A post and reinforcement. It is also necessary to remove the front sidemember for access. 18.Prepare and clean panel joint faces. Punch or drill holes in new panels for plug welding as shown. WARNING: Remove ALL traces of adhesive from outer face of A post reinforcement before plug welding. Cut upper A post and repair panel to form seam welded joints with existing panels. 19.Reverse removal procedure. 20.Remove stands and lower vehicle.
77PANEL REPAIRS NEW RANGE ROVER 4 REPAIR LOWER A POST AND REINFORCEMENT 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 both airbag modules. See SUPPLEMENTARY RESTRAINT SYSTEM, Repair. 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 windscreen.See CHASSIS AND BODY, Repair. 11.Remove headlamp.See Workshop Manual - ELECTRICAL. 12.Remove bonnet.See CHASSIS AND BODY, Repair. 13.Remove wheel arch liner - front.See CHASSIS AND BODY, Repair. 14.Remove front door assembly.See CHASSIS AND BODY, Repair. 15.Remove A post trim.See CHASSIS AND BODY, Repair. 16.Remove fascia assembly.See CHASSIS AND BODY, Repair. 17.Remove front wing.Refit NOTE: In this operation, the lower A post and reinforcement are replaced in combination with the upper A post and repair panel. It is also necessary to remove the front sidemember for access. 18.Prepare and clean panel joint faces. Punch or drill holes in new panels for plug welding as shown. WARNING: Remove ALL traces of structural adhesive from dash reinforcement end flange before plug welding. Cut A post reinforcement to form a seam welded butt joint with existing panel. 19.Reverse removal procedure. 20.Remove stands and lower vehicle.
PANEL REPAIRS 5 REPAIR BC POST REPAIR PANEL Remove 1.Disconnect battery earth lead. 2.Raise side of vehicle. WARNING: Support on safety stands. 3.Disconnect all ECUs. 4.Disconnect airbags and sensor system. 5.Remove both airbag modules. See SUPPLEMENTARY RESTRAINT SYSTEM, Repair. See SUPPLEMENTARY RESTRAINT SYSTEM, Repair. 6.Disconnect alternator. 7.Remove front seat. See CHASSIS AND BODY, Repair. 8.Remove seat belt - front.See CHASSIS AND BODY, Repair. 9.Remove front seat belt adjustable mounting. See CHASSIS AND BODY, Repair. 10.Remove B post trim.See CHASSIS AND BODY, Repair. 11.Remove rear door assembly.See CHASSIS AND BODY, Repair. Refit 12.Prepare and clean panel joint faces. Punch or drill holes in new BC post repair panel for plug welding as shown. Cut panel to form seam welded butt joints with existing panel. 13.Reverse removal procedure. 14.Remove stands and lower vehicle.
77PANEL REPAIRS NEW RANGE ROVER 6 REPAIR BC POST REINFORCEMENT Remove 1.Disconnect battery earth lead. 2.Raise side of vehicle. WARNING: Support on safety stands. 3.Disconnect all ECUs. 4.Disconnect airbags and sensor system. 5.Disconnect alternator. 6.Remove front seat. See CHASSIS AND BODY, Repair. 7.Remove seat belt - front.See CHASSIS AND BODY, Repair. 8.Remove front seat belt adjustable mounting. See CHASSIS AND BODY, Repair. 9.Remove B post trim.See CHASSIS AND BODY, Repair. 10.Remove rear door assembly.See CHASSIS AND BODY, Repair. Refit NOTE: In this operation, the B post reinforcement and B post repair panel are replaced in combination. 11.Prepare and clean panel joint faces. Punch or drill holes in new panel for plug welding as shown. Cut new panel to form seam welded butt joint with existing panel. 12.Reverse removal procedure. 13.Remove stands and lower vehicle.
PANEL REPAIRS 7 REPAIR BC POST INNER PANELS Remove 1.Disconnect battery earth lead. 2.Raise side of vehicle. WARNING: Support on safety stands. 3.Disconnect all ECUs. 4.Disconnect airbags and sensor system. 5.Disconnect alternator. 6.Remove front seat. See CHASSIS AND BODY, Repair. 7.Remove seat belt - front.See CHASSIS AND BODY, Repair. 8.Remove front seat belt adjustable mounting. See CHASSIS AND BODY, Repair. 9.Remove B post trim.See CHASSIS AND BODY, Repair. 10.Remove rear door assembly.See CHASSIS AND BODY, Repair. Refit NOTE: In this operation, the inner panels are replaced in combination with a B post reinforcement and repair panel. 11.Prepare and clean panel joint faces. Punch or drill holes in new BC post inner panels for plug welding as shown. 12.Reverse removal procedure. 13.Remove stands and lower vehicle.
77PANEL REPAIRS NEW RANGE ROVER 8 REPAIR ROOF ASSEMBLY Remove 1.Disconnect battery earth lead. 2.Disconnect all ECUs. 3.Disconnect airbags and sensor system. 4.Disconnect alternator. 5.Remove headlining - sliding roof. See CHASSIS AND BODY, Repair. 6.Remove sliding roof - electric.See CHASSIS AND BODY, Repair. 7.Remove windscreen.See CHASSIS AND BODY, Repair. 8.Remove front door assembly.See CHASSIS AND BODY, Repair. 9.Remove rear door assembly.See CHASSIS AND BODY, Repair. 10.Remove tailgate - upper.See CHASSIS AND BODY, Repair. 11.Remove seat belt - front.See CHASSIS AND BODY, Repair. 12.Remove front seat belt adjustable mounting. See CHASSIS AND BODY, Repair. 13.Remove A, B, D and E post trims.See CHASSIS AND BODY, Repair. 14.Remove sunroof drain tube - front.See CHASSIS AND BODY, Repair. 15.Remove sunroof drain tube - rear.See CHASSIS AND BODY, Repair. Refit 16.Prepare and clean panel joint faces. Punch or drill holes in new roof assembly for plug welding as shown. WARNING: Remove ALL traces of adhesive from joints to cant rail front and rear corners before plug welding. 17.Reverse removal procedure.
PANEL REPAIRS 9 REPAIR OUTER REAR QUARTER PANEL Remove 1.Disconnect battery earth lead. 2.Raise rear of vehicle. WARNING: Support on safety stands. 3.Disconnect all ECUs. 4.Disconnect airbags and sensor system. 5.Disconnect alternator. 6.Remove tailgate - lower. See CHASSIS AND BODY, Repair. 7.Remove parcel tray support.See CHASSIS AND BODY, Repair. 8.Remove parcel tray support trim.See CHASSIS AND BODY, Repair. 9.Remove E post - exterior trim.See CHASSIS AND BODY, Repair. 10.Remove D and E post trims.See CHASSIS AND BODY, Repair. 11.Remove wheel arch liner - rear.See CHASSIS AND BODY, Repair. 12.Remove rear quarter light.See CHASSIS AND BODY, Repair. 13.Remove quarter panel rubbing strips.See CHASSIS AND BODY, Repair. 14.Remove rear bumper valance.See CHASSIS AND BODY, Repair. 15.Remove rear seat belt - left hand or right hand. See CHASSIS AND BODY, Repair. See CHASSIS AND BODY, Repair. 16.Remove sunroof drain tube - rear.See CHASSIS AND BODY, Repair. Refit 17.Prepare and clean panel joint faces. Punch or drill holes in new panel for plug welding as shown. Apply structural adhesive at joint to outer wheelarch. See Corrosion protection. WARNING: Remove ALL traces of adhesive from joint to lower panel before plug welding. 18.Reverse removal procedure. 19.Remove stands and lower vehicle.
77PANEL REPAIRS NEW RANGE ROVER 10 REPAIR INNER REAR QUARTER PANEL Remove 1.Disconnect battery earth lead. 2.Raise rear of vehicle. WARNING: Support on safety stands. 3.Disconnect all ECUs. 4.Disconnect airbags and sensor system. 5.Disconnect alternator. 6.Remove tailgate - lower. See CHASSIS AND BODY, Repair. 7.Remove tailgate - upper.See CHASSIS AND BODY, Repair. 8.Remove parcel tray support and trim.See CHASSIS AND BODY, Repair. 9.Remove E post - exterior trim.See CHASSIS AND BODY, Repair. 10.Remove D and E post trims.See CHASSIS AND BODY, Repair. 11.Remove wheel arch liner - rear.See CHASSIS AND BODY, Repair. 12.Remove rear quarterlight.See CHASSIS AND BODY, Repair. 13.Remove appropriate rubbing strip.See CHASSIS AND BODY, Repair. 14.Remove rear bumper valance.See CHASSIS AND BODY, Repair. 15.Remove rear seat belt - left hand or right hand. See CHASSIS AND BODY, Repair. See CHASSIS AND BODY, Repair. 16.Remove sunroof drain tube - rear.See CHASSIS AND BODY, Repair. Refit NOTE: In this operation, the inner rear quarter panel, outer quarter and rear quarter repair panel are replaced in combination . 17.Prepare and clean panel joint faces. Apply structural adhesive at joint to floor at lower edge of wheelarch. See Corrosion protection. Plug weld at joints to floor using holes left by spot weld cutter. Cut inner rear quarter to form seam welded butt joints with existing panel. WARNING: Remove ALL traces of adhesive from joint to floor inside vehicle before plug welding. 18.Reverse removal procedure. 19.Remove stands and lower vehicle.
PANEL REPAIRS 11 REPAIR REAR QUARTER REPAIR PANEL Remove 1.Disconnect battery earth lead. 2.Raise rear of vehicle. WARNING: Support on safety stands. 3.Disconnect all ECUs. 4.Disconnect airbags and sensor system. 5.Disconnect alternator. 6.Remove tailgate - lower. See CHASSIS AND BODY, Repair. 7.Remove tailgate - upper.See CHASSIS AND BODY, Repair. 8.Remove parcel tray support and trim.See CHASSIS AND BODY, Repair. 9.Remove E post - exterior trim.See CHASSIS AND BODY, Repair. 10.Remove D and E post trims.See CHASSIS AND BODY, Repair. 11.Remove wheel arch liner - rear.See CHASSIS AND BODY, Repair. 12.Remove rear quarterlight.See CHASSIS AND BODY, Repair. 13.Remove rear quarter rubbing strip.See CHASSIS AND BODY, Repair. 14.Remove rear bumper valance.See CHASSIS AND BODY, Repair. 15.Remove rear seat belt - left hand or right hand. See CHASSIS AND BODY, Repair. 16.Remove sunroof drain tube - rear.See CHASSIS AND BODY, Repair. Refit NOTE: In this operation, the rear quarter repair panel, outer quarter and rear quarter repair panel are replaced in combination. 17.Cut new rear quarter repair panel to form MIG welded butt joints with existing panels. CAUTION: Do NOT cut into the inner quarter during this operation. 18.Reverse removal procedure. 19.Remove stands and lower vehicle.
77PANEL REPAIRS NEW RANGE ROVER 12 REPAIR LOAD FLOOR SIDE Remove 1.Disconnect battery earth lead. 2.Raise rear of vehicle. WARNING: Support on safety stands. 3.Disconnect all ECUs. 4.Disconnect airbags and sensor system. 5.Disconnect alternator. 6.Remove tailgate - lower. See CHASSIS AND BODY, Repair. 7.Remove rear bumper valance.See CHASSIS AND BODY, Repair. Refit 8.Prepare and clean panel mating faces. Punch or drill holes in new rear floor panel for plug welding as shown. Plug weld also to spare wheel well edges using holes left by spot weld cutter. 9.Reverse removal procedure. 10.Remove stands and lower vehicle.REAR CROSSMEMBER PANEL Remove 1.Disconnect battery earth lead. 2.Raise rear of vehicle. WARNING: Support on safety stands. 3.Disconnect all ECUs. 4.Disconnect airbags and sensor system. 5.Disconnect alternator. 6.Remove tailgate - lower. See CHASSIS AND BODY, Repair. 7.Remove rear bumper valance.See CHASSIS AND BODY, Repair. Refit 8.Prepare and clean panel joint faces. Punch or drill holes in new rear crossmember panel for plug welding as shown. 9.Reverse removal procedure. 10.Remove stands and lower vehicle.