Land Rover Range Rover Body Repair Rover Manual

							CHASSIS AND BODY
7
REPAIR CHASSIS CROSS MEMBER
Remove
1.Disconnect battery negative lead.
2.Raise vehicle on four post lift.
3.Support transmission with a suitable stand.
4.Remove and discard 6 nuts securing
transmission mount to crossmember. Remove
snubber bar.
5.Remove 3 of 4 nuts and bolts securing each side
of crossmember to chassis.
6.With assistance, remove remaining bolt securing
crossmember. Remove crossmember.Refit
7.With assistance, position crossmember to
chassis. Secure with nuts and bolts. Tighten to
45 Nm. (33 lbf.ft)
8.Fit snubber bar. Secure transmission mount to
crossmember with new flange nuts. Tighten to
45 Nm. (33 lbf.ft)
9.Remove support from transmission.
10.Lower vehicle.
11.Reconnect battery negative lead. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
8
REPAIR ENGINE ACOUSTIC COVER
Service repair no - 76.11.06
Remove
1.Raise front of vehicle.
WARNING: Support on safety stands.
2.Release 4 threaded fasteners securing engine
acoustic cover to chassis brackets.
3.Release acoustic cover from brackets and
manoeuvre past steering gear.
Refit
4.Fit acoustic cover to brackets and secure with
threaded fasteners.GEARBOX LOWER ACOUSTIC COVER
Service repair no - 76.11.13
Remove
1.Raise front of vehicle.
WARNING: Support on safety stands.
2.Release 6 threaded fasteners securing lower
acoustic cover to side acoustic covers.
3.Remove lower acoustic cover.
Refit
4.Fit acoustic cover to side acoustic covers.
5.Tighten threaded fasteners securing lower cover
to side covers.
6.Remove stand(s) and lower vehicle. 
						

							CHASSIS AND BODY
9
REPAIR GEARBOX ACOUSTIC COVER - RH
Service repair no - 76.11.14
Remove
1.Raise front of vehicle.
WARNING: Support on safety stands.
2.Remove gearbox lower acoustic cover.
See this
section.
3.Remove bolt securing RH acoustic cover to
crossmember.
4.Remove bolt securing RH acoustic cover to
chassis member.
5.Remove gearbox RH acoustic cover.
Refit
6.Fit acoustic cover to chassis and secure with
bolts.
7.Fit gearbox lower acoustic cover.
See this
section.
GEARBOX ACOUSTIC COVER - LH
Service repair no - 76.11.15
Remove
1.Raise front of vehicle.
WARNING: Support on safety stands.
2.Remove gearbox lower acoustic cover.
See this
section.
3.Remove bolt securing LH acoustic cover to
crossmember.
4.Remove bolt securing LH acoustic cover to
chassis member.
5.Remove gearbox LH acoustic cover.
Refit
6.Fit acoustic cover to chassis and secure with
bolts.
7.Fit gearbox lower acoustic cover.
See this
section. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
10
REPAIR FRONT BUMPER VALANCE
Service repair no - 76.22.72
Remove
1.Raise the vehicle.
WARNING: Support on safety stands.
2.Remove battery cover for access to RH fog
lamp.
3.Disconnect fog lamp multiplugs and breather
hoses.
4.Release 2 clips securing bumper ends to
mounting brackets.
CAUTION: Loosen bolts securing bumper
end mounting brackets to chassis frame to
avoid damage to sealing rubber during
bumper remove and refit. 
						

							CHASSIS AND BODY
11
REPAIR 5.Remove 2 bumper bolt access plugs from
bumper valance. Remove bolts.
6.With assistance remove bumper assembly.Do
not carry out further dismantling if
component is removed for access only.
7.Remove 8 studs and 6 clips securing extensions
spoiler. Remove extension.
8.Remove 8 screws securing fog lamps. Remove
lamps.
9.Remove 8 bolts securing bumper end brackets
to bumper. Remove brackets.
WARNING: If front bumper is damaged due
to impact, the impact cans must be
inspected. There must be no visible
deformation. The overall length must be 188.25
mm ñ 0.5 mm. Replace the impact cans if
necessary.
Refit
10.Fit end brackets and secure with bolts. Fit fog
lamps and secure with screws.
11.Fit extension and secure with clips and studs.
12.With assistance fit bumper assembly, tighten
bolts to
70Nm. (52 lbf.ft)
13.Fit bolt access plugs.
14.Align end brackets, tighten bolts and secure
bumper end clips.
15.Connect fog lamp multiplugs and breather
hoses, fit battery cover.
16.Remove safety stands. Lower vehicle. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
12
REPAIR EXTENSION SPOILER FRONT BUMPER
Service repair no - 76.22.78
Remove
1.Raise the vehicle.
WARNING: Support on safety stands.
2.Remove 8 studs and 6 clips securing spoiler to
front bumper.
3.Remove spoiler halves.
Refit
4.Fit spoiler halves to bumper. Secure with clips
and studs.
5.Remove safety stands. Lower vehicle.REAR BUMPER VALANCE
Service repair no - 76.22.74
Remove
1.Raise the vehicle.
WARNING: Support on safety stands.
2.Remove rear road wheels.
3.Remove 3 screws securing each mud flap.
Remove mud flaps.
4.Remove 2 screws securing each wheel arch
liner extension panel to rear bumper/chassis.
5.Remove 2 wheel arch liner extension panels.
6.Release 2 clips securing bumper ends to
mounting brackets. 
						

							CHASSIS AND BODY
13
REPAIR 7.Disconnect 3 towing harness multiplugs.
8.Remove 2 mounting bolt covers.
9.Remove 2 bolts securing bumper to chassis.
10.With assistance, release bumper ends from
brackets. Remove bumper.
Refit
11.With assistance, position bumper. Engage nylon
end supports to brackets.
12.If necessary, slacken bolts securing end support
brackets. Align bumper to body. Tighten to
29
Nm. (22 lbf.ft)
13.Fit bumper mounting bolts. Tighten to70 Nm.
(52 lbf.ft)
14.Fit bolt covers.
15.Secure bumper end clips.
16.Connect towing harness multiplugs.
17.Position wheel arch liner extensions. Secure with
screws.
18.Position mud flaps. Secure with screws.
19.Fit road wheels. Tighten to
108 Nm. (80 lbf.ft)
20.Remove safety stands. Lower vehicle.FASCIA ASSEMBLY
Service repair no - 76.46.23/99
WARNING: The fascia assembly houses
the heater distribution unit, blower
assemblies and air conditioning
evaporator. Assistance is essential during
removal and refit procedures.
CAUTION: When removed from the
vehicle, the fascia should be placed on a
soft covered work surface, supported on
suitable wooden blocks.
Remove
1. Vehicles with SRS only:Remove battery.
See
ELECTRICAL, Repair.
2. Vehicles without SRS:Disconnect battery
negative lead.
3.Drain cooling system.
See COOLING SYSTEM,
Repair.
4.Loosen hose clips, disconnect hoses from
heater pipes.
5.Remove centre console.See this section.
6.Remove steering column.See STEERING,
Repair.
7.Remove wiper motor and linkage.See WIPERS
AND WASHERS, Repair.
8.Disconnect passenger side heated front screen
multiplug. Release multiplug from clip. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
14
REPAIR
9.Remove 6 bolts, remove remaining scuttle side
panel.
10.Remove heater intake pollen filters.
11.Remove 8 screws securing each pollen filter
housing. Remove both housings.
12.Remove radio.See ELECTRICAL, Repair.
13.Release door aperture seal adjacent to A post
lower trim panels.
14. Drivers side - LHD automatic vehicles only:
Remove 3 bolts securing foot rest through A
post lower trim, remove foot rest.
15.Remove screw securing each A post lower trim
panel, release from single sprag clip, remove
both trim panels. 
						

							CHASSIS AND BODY
15
REPAIR 16.Remove fuse cover from drivers seat base trim.
17.Remove screw and 2 trim studs, remove seat
base trim.
18.Release 4 sprag clips, remove drivers side
carpet retainer.19.Remove 2 scrivet fasteners securing lower
closing panel to passenger side of fascia.
20.Release closing panel, disconnect footwell lamp,
release diagnostic multiplug. Remove closing
panel.
21.Remove 4 bolts, remove fascia centre bracket. 
						

							76CHASSIS AND BODY NEW RANGE ROVER
16
REPAIR 22.Disconnect 4 multiplugs from Body Electrical
Control Module (BeCM)
23.Remove captive nut, remove earth wires from
stud at base of drivers side A post.
24.Disconnect multiplugs at base of each A post.25.Release BeCM harness from sill, route into
fascia to prevent fouling as fascia is removed.
26.Disconnect multiplugs and release vacuum hose
from brake and clutch switches.
27. Models with SRS only:Disconnect SRS
multiplug from main harness.