Range Rover Body Repair Manual — part 39
CHASSIS AND BODY
81
REPAIR
25. Apply a continuous bead of sealer to backlight
as shown.
26. Original glass:Apply 3mm bead of sealer to
channels of side finishers and fit to backlight.
27. Fit suction lifters to glass.
28. With assistance, fit glass and centralize to
previously made tape markings. Set glass to
correct depth.
29. Connect screen heater.
30. Remove reference and protective tapes.
31. Position lower finisher and secure to clips.
32. Fit interior trim to tailgate,
See this section.
CAUTION: A curing time of 6 hours is
recommended. During this time, leave the
windows open and DO NOT slam the
doors.
REAR QUARTER LIGHT
Service repair no - 76.81.20
NOTE: The following equipment is
required:
Masking tape.
Sharp knife.
Cutting wire and handles, or a reciprocatig
blade, powered cutting knife*.
Suction Lifters.
Windscreen repair kit.
Sealer applicator gun.
*A reciprocating blade cutting tool, such as ’FEIN
Special Cutter’ is recommended for this operation. A
flat blade, with an effective length of at least 25mm
and a ’U’ shaped blade of at least 30mm is required.
NOTE: New rear quarter glass is supplied
with exterior trim fitted.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
Remove
1. Remove parcel tray support,
See this section.
2. Remove both ’E’ post trims,
See this section.
3. Remove relevant ’B’ post upper trim,
See this
section.
4. Remove relevant side interior lamp assembly,
See ELECTRICAL, Repair.
5. Remove relevant grab handle,
See this
section.
6. Remove relevant exterior ’E’ post finisher,
See
this section.
76
CHASSIS AND BODY
NEW RANGE ROVER
82
REPAIR
7. Remove 2 trim studs securing headlining to ’E’
posts.
8. Release headlining from tailgate seal. Lower
headlining as necessary during glass removal to
provide access to sealant along top edge of
glass.
9. Disconnect aerial amplifier plugs.
10. R.H. glass only:Disconnect alarm receiver plug.
11. Protect surrounding area of body using masking
tape.
Removal Using Reciprocating Blade Tool
12. Lift flip seal to reveal trim fixings.
13. Remove 2 screws securing exterior trim to ’D’
post.
14. Cut through P.U. adhesive from inside of glass
along lower and side edges.
CHASSIS AND BODY
83
REPAIR
CAUTION: Manoeuvre knife blade around 3
parcel tray support clips. Ensure aerial
amplifier and alarm reciever plugs do not
become damaged.
15. Attach suction lifters to glass. With assistance,
cut through sealant along top of edge glass.
16. Remove rear quarter glass.
Removal Using Cutting Wire Handles
17. Protect surrounding area of body using masking
tape.
18. Lift flip seal to reveal trim fixings.
19. Remove 2 screws securing exterior trim to ’D’
post.
20. Carefully cut through adhesive bead between
glass and trim using a sharp knife.
NOTE: A reciprocating blade cutting tool,
such as ’FEIN Special Cutter’ will ease the
removal of the trim. Use a cranked blade
with an effective length of not more than 22mm.
21. Remove and discard quarter light trim.
NOTE: Rear quarter lights are supplied
with finisher fitted. Finisher is not
available separately.
22. Using a sharp knife, cut through P.U. sealer at
forward edge of quarter glass.
23. Insert cutting wire through knife cut and fit
handles, as shown, with approximatley 200mm
of wire between handles.
24. With assistance, wedge tube of handles ’A’
between glass and body, ahead of the cutting
position, and carefully cut the sealer using a
continuous pull on handle ’B’ from the outside.
Cut side and top edges first. Attach suction lifters
as last sealant is cut.
NOTE: When cutting along lower edge,
manoeuvre wire between glass edge and
parcel tray support clips to reduce strain
on wire.
CAUTION: Ensure aerial amplifier and
alarm receiver plugs do not become
damaged.
25. Remove rear quarter glass.
76
CHASSIS AND BODY
NEW RANGE ROVER
84
REPAIR
Refit
26. Carefully cut old sealer from body flange to
obtain a smooth surface, approximatley 2mm
thick.
CAUTION: Do not cut down to painted
surface.
27. Position new quarter glass on felt covered
surface.
28. Apply cleaning solvent to sealing surface of
glass and body flange.
CAUTION: Do not touch cleaned or primed
areas with fingers.
29. Stick 4 self adhesive spacers on the inside edge
of glass at corners.
30. Shake primer tins for at least 30 seconds. Apply
body primer to sealing surface of body flange
using supplied applicator.
31. Apply glass primer to sealing surface of glass.
CAUTION: Use a separate applicator for
each primer.
32. Remove lid from sealer cartridge, remove
crystals, pierce membrane and fit pre-cut nozzle.
Fit cartridge to applicator gun.
NOTE: The profile of the nozzle must be
modified slightly to produce the required
bead section.
33. Apply a continuous bead of sealer to rear quarter
glass as shown.
34. Fit suction lifters to glass.
35. With assistance, fit glass and align to body. Seat
glass to spacer rubbers.
36. Remove protective tape.
37. Secure exterior trim to ’D’ post with screws.
38. Connect aerial amplifier plug.
39. R.H. glass only:Connect alarm receiver plug.
40. Position headlining and engage beneath tailgate
flip seal.
41. Secure headlining to ’E’ posts with trim studs.
42. Fit exterior ’E’ post finisher,
See this section.
43. Fit grab handle,
See this section.
44. Fit side interior lamp assembly,
See
ELECTRICAL, Repair.
45. Fit ’B’ post upper trim,
See this section.
46. Fit ’E’ post trims,
See this section.
47. Fit parcel tray support,
See this section.
CAUTION: A curing time of 6 hours is
recommended. During this time, leave the
windows open and DO NOT slam the
doors.
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