Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual

							PANEL REPAIRS
-14 PROCEDURES
5.Separate spot welded joints and remove panel 
remnants using hammer, bolster, chisel and 
pincers.
Prepare old surfaces
1.Clean all panel joint edges to a bright smooth 
finish, using a belt-type sander.
NOTE: Prior to sanding, remove remaining 
sealant using a hot air gun to minimise the risk 
of toxic fumes caused by generated heat.
Caution: Care must be taken to avoid 
excessive heat build up when using this 
equipment.2.Straighten existing panel joint edges using a 
shaping block and hammer.
CAUTION: Never use the same tools for 
working with steel or aluminium. All tools 
used for working with steel must be kept 
separate from those used on aluminium.
Prepare new surfaces
1.Mark out bulk of new panel and trim to size, 
leaving approximately 50 mm (1.968 ins) 
overlap with existing panel. Offer up new panel/
section, align with associated panels (e.g. new 
body side panel aligned with door and trunklid). 
Clamp into position. 
						

							PANEL REPAIRS
PROCEDURES -15
2.Cut new and existing panels as necessary to 
form butt, joggle or brace joint as required. 
Remove all clamps and metal remnants.
3.Prepare new panel joint edges for welding by 
sanding to a bright finish. This must include 
inner as well as outer faces.
4.Apply suitable weld-through primer, to panel 
joint surfaces to be welded, using brush or 
aerosol can.5.Apply adhesive sealant to panel joint surfaces.
Offer up and align
1.Offer up new panel and align with associated 
panels. Clamp into position using welding 
clamps or Mole grips. Where a joggle or brace 
joint is being adopted, make a set in the original 
panel joint edge or insert a brace behind the 
joint.
NOTE: In cases where access for welding 
clamps is difficult, it may be necessary to use 
tack welds.
Welding
1.Select arms for resistance spot welding and 
shape electrode tips using a tip trimmer. Tips 
should be dressed so the diameter is equal to 
twice the thickness of the metal to be welded 
plus 3.0 mm (0.118 ins).
 CAUTION: Use arms not exceeding 300 mm 
(11.811ins) in length.
NOTE: To maintain weld efficiency, the tips will 
require regular cleaning and dressing.  
						

							PANEL REPAIRS
-16 PROCEDURES
2.Fit resistance spot welding arms and test 
equipment for satisfactory operation, using test 
coupons. Where monitoring equipment is not 
available, verify weld strength by checking that  
metal around the weld puddle pulls apart under 
tension during pulling.
3.Use a resistance spot welder where access 
permits. Try to  ensure weld quality by using a 
welding monitor where possible. 4.MIG tack weld butt joints and re-check 
alignment and panel  contours where 
n e c e s s a r y .  E n s u r e  t h a t  a  g a p  i s  m a i n t a i n e d  t o        
minimise welding distortion, by inserting a 
hacksaw blade as an approximate guide.
5.Dress MIG tack welds using a sander with 36 
grit disc, or a belt-type sander where access is 
limited. 
						

							PANEL REPAIRS
PROCEDURES -17
6.MIG seam weld butt joints. When MIG welding 
long joints, a large amount of heat is generated 
which can cause the panels to distort. To avoid 
heat distortion, divide the welds into small 
sections as shown on the illustration. The large 
arrows signifies the direction of welding.
7.Always use MIG plug welds where excessive 
metal thickness or limited access make 
resistance spot welding impractical. Make plug 
welds either by using holes left by the spot weld 
cutter, or through holes punched and drilled for 
the purpose, approximately 8 mm (0.134 ins) 
diameter.8.Dress all welds using either a sander with 36 
grit disc, or a  belt-type sander and/or wire 
brush. When dressing welds ensure an area as 
small as possible is removed to protect the zinc 
coating.
9.Carry out any further necessary sealing 
operations. 
 
 +  , , Factory treatments. 
						

							PANEL REPAIRS
-18 PROCEDURES 
						

							PANEL REPAIRS
REPAIRS -19
REPAIRS
Front bulkhead assembly 
In this procedure, the headlamp mounting panels 
and the bonnet locking platform are removed. 
Remove
1.Disconnect battery earth lead.
CAUTION: After switching off the ignition, 
wait 2 minutes before disconnecting the 
battery. Failure to wait two minutes will 
damage the navigation computer.
2.Remove both headlamp assemblies.
 
 +  LIGHTING, REPAIRS, Headlamp 
assembly.
3.Remove front bumper.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
4.Release 4 cable ties securing washer hose to 
armature and move hose aside.
5.Disconnect the headlamp, headlamp wash/
wiper and horn multiplugs from the bonnet 
locking platform assembly.
6.Remove 2 screws securing armature extension 
and remove extension from armature.
7.Remove scrivets securing radiator intake ducts 
to bumper support brackets.
8.Remove 3 bolts securing LH bumper support 
bracket. Repeat for RH bracket and remove.
9. Diesel models: Remove 2 bolts securing fuel 
cooler intake duct to bonnet locking platform.
10.Move duct aside.
11.Remove radiator assembly retaining bolts from 
bonnet locking platform.
12.Remove 4 bolts securing bonnet locking 
platform to inner wings.
13.Cut and discard cable tie securing radiator 
expansion pipe to bonnet locking platform.
14. LH side only: Remove bolt securing washer 
bottle to headlamp mounting panel.
15.Remove 4 bolts securing lower outer edge of 
the bonnet locking platform assembly to inner 
wings.
16.With assistance carefully release and remove 
the bonnet locking platform assembly.
Refit
1.With assistance position the bonnet locking 
platform assembly to body.
2.Fit and finger tighten bolts securing bonnet 
locking platform assembly to body, align and 
tighten M8 bolts to 25 Nm (18 lbf.ft), tighten the 
M6 bolts to 10 Nm (7 lbf.ft).
3.Position radiator assembly to bonnet locking 
platform and secure with bolts.4.Position armature to body fit nuts and bolts, 
tighten bolts to 10 Nm (7 lbf.ft), tighten nuts to 
45 Nm (33 lbf.ft).
5.Fit bolt securing washer bottle to the headlamp 
mounting bracket and tighten to 3 Nm (2.2 
lbf.ft).
6.Secure harness with cable ties.
7.Fit and secure bumper support brackets, 
tighten bolts to 3 Nm (2.2 lbf.ft), fit scrivets.
8.Connect multiplugs.
9.Fit armature extension and tighten bolts to 10 
Nm (7 lbf.ft).
10.Position washer hose to armature and secure 
with new cable ties.
11. Diesel models:  Position fuel cooler intake 
duct to bonnet locking platform, fit and tighten 
bolts to 3 Nm (2.2 lbf.ft)
12.Position radiator expansion hose and cable tie 
to bonnet locking platform.
13.Fit front bumper.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
14.Fit both headlamp assemblies.
 
 +  LIGHTING, REPAIRS, Headlamp 
assembly.
15.Connect the battery earth lead.
CAUTION: After re-connecting the battery, 
the steering wheel must be turned to full LH 
and RH lock (with engine running). This 
allows the DSC system to re-learn the 
steering wheel position. Failure to do so will 
result in a variety of instrument warning 
lights been illuminated. 
						

							PANEL REPAIRS
-20 REPAIRS
Bonnet locking platform
The bonnet locking platform is bolted in position, 
there are no welds to hold it in place.
Remove
1.Remove both headlamp assemblies. 
 
 +  LIGHTING, REPAIRS, Headlamp 
assembly.
2.Remove LH and RH bonnet locks.
3. Diesel models: Remove fuel cooler air duct.
4.Remove 3 screws securing grille to bonnet 
locking platform.
5.Remove bolts securing bonnet locking platform 
and remove platform.
Refit
1.Position bonnet locking platform, align to 
correct position, fit and tighten bolts.
2.Fit grille and secure with screws.
3. Diesel models: Fit fuel cooler air duct.
4.Fit LH and RH bonnet locks.
5.Fit both headlamp assemblies. 
 
 +  LIGHTING, REPAIRS, Headlamp 
assembly.
Headlamp mounting panel
The headlamp mounting panels are bolted in 
position, there are no welds to hold them in place.
Remove
1.Remove both headlamp assemblies. 
 
 +  LIGHTING, REPAIRS, Headlamp 
assembly.
2.Remove LH and RH bonnet locks.
3. Diesel models: Remove fuel cooler air duct.
4.Remove 3 screws securing grille to bonnet 
locking platform.
5.Remove bolts securing bonnet locking platform 
and remove platform.
6. LH side: Remove horn. 
7. LH side: Remove air intake hose. 
8. RH side: Remove front bumper RH support 
bracket.
9. RH side: Remove windscreen washer 
reservoir. 
 
 +  WIPERS AND WASHERS, REPAIRS, 
Reservoir - combined windscreen/
headlamp washer.
10. RH side: Remove PAS fluid cooler. 
 
 +  STEERING, REPAIRS, Oil cooler - 
power steering - Td6.
Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. 
Refit
1. RH side: Fit PAS fluid cooler. 
 
 +  STEERING, REPAIRS, Oil cooler - 
power steering - Td6.
2. RH side: Fit windscreen washer reservoir. 
 
 +  WIPERS AND WASHERS, REPAIRS, 
Reservoir - combined windscreen/
headlamp washer.
3. RH side: Fit front bumper RH support bracket.
4. LH side: Fit horn. 
5. LH side: Fit air intake hose. 
6.Fit and tighten bolts securing bonnet locking 
platform.
7.Fit 3 screws securing grille to bonnet locking 
platform.
8. Diesel models: Fit fuel cooler air duct.
9.Fit LH and RH bonnet locks.
10.Fit both headlamp assemblies. 
 
 +  LIGHTING, REPAIRS, Headlamp 
assembly. 
						

							PANEL REPAIRS
REPAIRS -21
Radiator protection bar
Remove
1.Disconnect battery earth lead.
2.Remove headlamp mounting panel.
 
 +  , , Headlamp mounting panel.
3.Remove RH headlamp mounting panel.
4.Remove nut securing PAS hose mounting to 
radiator protection bar and move hose aside.
5.Remove 2 bolts securing radiator protection bar 
to front sub-frame and with assistance remove 
from vehicle.
NOTE: Do not carry out further dismantling if 
component is removed for access only.
6. V8 models only: Remove scrivet and release 
clip securing front axle cooling duct to radiator 
protection bar and remove duct.
7.Remove 5 scrivets securing intercooler baffle to 
radiator protection bar. Remove baffle.
Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. 
Refit
1.Fit baffle and secure with scrivets.
2.With assistance position radiator protection 
bar, fit bolts and tighten to 105 Nm (77 lbf.ft). 
3.Fit PAS hose mounting and tighten nut to 10 
Nm (7 lbf.ft).
4.Fit RH headlamp mounting panel.
5.Fit headlamp mounting panel.
 
 +  , , Headlamp mounting panel.
6.Connect the battery earth lead.
Front sidemember end panel
In this procedure, only the sidemember end panel is 
replaced.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator. 
3.Remove underbelly panel. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Undertray - front.
4.Remove front bumper assembly. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
5.Remove front armature. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
6.Remove radiator. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
7. LH side: Remove radiator expansion tank. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
8. RH side: Remove gearbox fluid cooler. 
 
 +  AUTOMATIC TRANSMISSION - GM 
5L40-E, REPAIRS, Gearbox fluid cooler.
9. Diesel models: Release and remove 
intercooler pipes.
10. LH side: Remove windscreen washer 
reservoir. 
 
 +  WIPERS AND WASHERS, REPAIRS, 
Reservoir - combined windscreen/
headlamp washer.
Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown.  
						

							PANEL REPAIRS
-22 REPAIRS
Refit
1. LH side: Fit windscreen washer reservoir. 
 
 +  WIPERS AND WASHERS, REPAIRS, 
Reservoir - combined windscreen/
headlamp washer.
2. Diesel models: Fit and connect intercooler 
pipes.
3. RH side: Fit gearbox fluid cooler. 
 
 +  AUTOMATIC TRANSMISSION - GM 
5L40-E, REPAIRS, Gearbox fluid cooler.
4. LH side: Fit radiator expansion tank. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
5.Fit radiator. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
6.Fit front armature. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
7.Fit front bumper assembly. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
8.Fit underbelly panel. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Undertray - front.
9.Connect alternator. 
10.Connect battery earth lead.
Front sidemember (front section) 
In this procedure, the front section of the front 
sidemember inner panel, front sidemember outer 
panel and the front sidemember reinforcement panel 
are replaced. 
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator. 
3.Remove underbelly panel. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Undertray - front.
4.Remove front bumper assembly. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
5.Remove front armature. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
6.Remove radiator. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
7. LH side: Remove radiator expansion tank. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
8.Recover refrigerant from A/C system.
 
 +  AIR CONDITIONING, REFRIGERANT 
RECOVERY, RECYCLING AND 
RECHARGING, Refrigerant recovery - 
recycling and recharge.
NOTE: Receiver drier need only be changed 
under the following circumstances. There is dirt 
in the refrigerant circuit ( e.g. compressor 
seizure ). The system is leaking and refrigerant 
has been lost to atmosphere.  Refrigerant 
circuit has been open more than 24 hours due 
to repair.
9.Remove A/C pipes from sidemember. 
10. RH side: Remove gearbox fluid cooler. 
 
 +  AUTOMATIC TRANSMISSION - GM 
5L40-E, REPAIRS, Gearbox fluid cooler.
11. Diesel models: Release and remove 
intercooler pipes.
12. LH side: Remove windscreen washer 
reservoir. 
 
 +  WIPERS AND WASHERS, REPAIRS, 
Reservoir - combined windscreen/
headlamp washer.
13. LH side: Remove alternator. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Alternator - Td6.
14.Remove front wheel arch liner. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Liner - front wheel arch.
15.Remove PAS pipes to access panel. 
						

							PANEL REPAIRS
REPAIRS -23
Repair
1.Remove existing panel(s), prepare panel joint 
faces and install new panel(s) in accordance 
with Panel Replacement Procedure. Punch or 
drill holes in new panel for plug welding as 
shown. 
Refit
1.Fit PAS pipes.
2.Fit front wheel arch liner. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Liner - front wheel arch.
3. LH side: Fit alternator. 
 
 +  CHARGING AND STARTING, 
REPAIRS, Alternator - Td6.
4. LH side: Fit windscreen washer reservoir. 
 
 +  WIPERS AND WASHERS, REPAIRS, 
Reservoir - combined windscreen/
headlamp washer.
5. Diesel models: Fit and connect intercooler 
pipes.
6.Fit A/C pipes to sidemember. 
7. RH side: Fit gearbox fluid cooler. 
 
 +  AUTOMATIC TRANSMISSION - GM 
5L40-E, REPAIRS, Gearbox fluid cooler.8. LH side: Fit radiator expansion tank. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
9.Fit radiator. 
 
 +  COOLING SYSTEM - Td6, REPAIR, 
Radiator.
10.Fit front armature. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
11.Fit front bumper assembly. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Bumper - assembly - front.
12.Recharge A/C system.
 
 +  AIR CONDITIONING, REFRIGERANT 
RECOVERY, RECYCLING AND 
RECHARGING, Refrigerant recovery - 
recycling and recharge.
13.Bleed PAS system. 
 
 +  STEERING, ADJUSTMENTS, Power 
assisted steering (PAS) system - bleed.
14.Fit underbelly panel. 
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Undertray - front.
15.Connect alternator. 
16.Connect battery earth lead.