Range Rover Body Repair Manual — part 48
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.
77
PANEL 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.
77
PANEL 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.
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