Range Rover Classic. Manual — part 162
CHASSIS AND BODY
71
REPAIR
CHASSIS
Diagram reference
millimetres
SECTION W - W
31
Frame datum line DD
32
155,91
. . . . . . . . . . . . . . . . . . . . . . . ...
±
1,27
33
990,6
. . . . . . . . . . . . . . . . . . . . . . . . .
±
0,50
34
825,5
. . . . . . . . . . . . . . . . . . . . . . . . .
±
2,54
SECTION X - X
35
Frame datum line DD
36
488,95
. . . . . . . . . . . . . . . . . . . . . . . ...
±
2,54
37
309,83
. . . . . . . . . . . . . . . . . . . . . . . ...
±
1,00
SECTION Y - Y
38
Frame datum line DD
39
1320,8
. . . . . . . . . . . . . . . . . . . . . . . ...
±
0,50
40
80,39
. . . . . . . . . . . . . . . . . . . . . . . . .
±
1,27
SECTION Z - Z
41
Frame datum line DD
42
80,39
. . . . . . . . . . . . . . . . . . . . . . . . .
±
1,27
43
660,4
. . . . . . . . . . . . . . . . . . . . . . . . .
±
0,25
44
9,53
. . . . . . . . . . . . . . . . . . . . . . . . ...
±
2,54
76
CHASSIS AND BODY
72
REPAIR
ADD: 09/95
WINDSCREEN GLASS
Service repair no - 76.81.01
Information
The following equipment is required:
Cutting wire and handles
Windscreen repair kit
See WIPERS AND WASHERS,
Repair, Wiper arms - windscreen
Sealant applicator gun
Suction cup lifters
The following materials are included in the windscreen
repair kit:
Glass cleaning solvent - ’Betawipe’ Glass activator
(yellow cap)
Cotton buds.
Glass primer - ’Betaprime’(green cap)
Body primer - ’Betaprime’ paint/plastic primer (red
cap)
Betaseal Adhesive sealant
NOTE: The adhesive sealant cures in 6 to 8
hours
CAUTION: Once existing sealant is cut, the
exposed surfaces oxidises in
approximately 90 minutes. The refit
procedure must be completed within this time
span to prevent the sealant oxidising, to effect a
satisfactory joint.
CAUTION: If the windscreen aperture body
flange shows signs of corrosion it must be
treated with anti corrosion primer and
repainted. Newly painted areas must then be left
for 8 hours or more before applying adhesive
sealant.
NOTE: The multiplugs for heated
windscreen are located under the
decker[cowl] panel, release decker[cowl]
panel to gain access.
Remove
1. Remove windscreen wiper arms.
See WIPERS
AND WASHERS, Repair, Wiper Arms -
Windscreen.
2. Remove rear view mirror and stickers from
glass.
3. Remove ’A’ post finishers.
4. Fit protective cover over dash panel and apply
masking tape to protect ’A’ posts.
5. Ease one end of bottom finisher away from
glass, pull to disengage finisher flange and
remove.
6. Lift lip of LH ’A’ post finisher and release sealing
strip along its length, pull to disengage finisher
flange from glass and remove.
CHASSIS AND BODY
73
REPAIR
ADD: 09/95
7. Remove RH ’A’ post finisher.
8. Remove header finisher.
9. Apply masking tape to protect paint finish around
glass.
10. Prepare cutting wire in handle ’A’. Bend end of
wire to handle and tape over end.
11. Force cutting wire through sealer from inside and
100mm from a top corner. Use a needle if
necessary to make a pilot hole.
12. Attach handle ’B’. Allow 200mm of wire between
handles, tape over end of wire.
13. With an assistant on the inside: Wedge the
tube of the handle ’A’ between glass and body
flange 100mm ahead of hole in sealer.
14. From the outside: Carefully cut sealer from
flange using a straight pull away from the glass.
Continue in 100mm steps around the glass, use
a sawing action at the corners.
CAUTION: Along the bottom edge, great
care must be taken to cut up to the 2
supports, positions indicated on the
obscuration band (See item 18).
15. Remove handle ’B’, withdraw the cutting wire
and insert it through the sealer between the
supports. Refit handle ’B’.
16. Cut through sealer between the supports.
If heated front screen: Cut through the 2 wires
each side of the supports. Tape cut wires and
panels to prevent damage to bodywork when
screen is removed.
17. Attach suction cups to glass and lift glass from
body flange, cut sealer free around supports as
necessary.
WARNING: If glass has splintered: Protect
eyes and operate demister blower at
maximum speed to remove any glass from
ducts. Use a vacuum cleaner to remove glass
particles from inside the vehicle.
Refit
18. Check condition of supports, renew if necessary.
Locating studs must be at right angle to flange.
NOTE: The supports were fitted to early
vehicles and now replaced with nylon
sheaths.
19. Carefully cut back old sealant around body
flange to obtain a smooth surface 2mm thick. DO
NOT cut down to flange.
20. If refitting original glass: It must be free from
chips or cracks. Cut back old sealant around
glass to obtain a smooth surface 2mm thick. DO
NOT cut down to glass surface.
76
CHASSIS AND BODY
74
REPAIR
ADD: 09/95
CAUTION: Lay glass on felt covered
supports, do not stand on edge. Any
chipping of glass edge may develop into
cracks.
21. Align header finisher on top edge of glass, push
flange fully onto glass and use a wooden block
and mallet to ensure fit.
22. Carefully align each side finisher on edge of
glass, push flange fully onto glass and use a
wooden block and mallet to ensure fit.
23. Using a cotton bud, apply glass cleaning solvent
(yellow cap) to inside face of glass, 20mm strip
around inside of finishers and 30mm wide along
bottom edge. Immediately wipe off solvent with a
clean cloth.
CAUTION: Do not touch cleaned or primed
surfaces with fingers.
24. Ensure body flanges and surfaces covered by
the finishers are clean
25. Shake the primer container for at least 30
seconds.
26. Using a cotton bud, apply Glass Primer (green
cap) to inside face of glass, 20mm strip around
inside of finishers and 30mm wide along bottom
edge. This must be touch dry before applying
adhesive.
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